The Challenge: Beyond Component Shortages
For our clients in the USA and Europe, the primary bottleneck wasn’t just the lack of chips; it was the rigidity of legacy automation systems. Traditional blister packing lines were over-engineered with redundant sensors that became failure points when replacement parts were backordered for months.
The Azomak Shift: Strategic Simplification
Our engineering team implemented a Strategic Shift focused on two core pillars:
- Modular Resilience: We redesigned our rotary filling and blister packing systems (specifically for size 0 and 00 capsules) using a modular architecture. This allowed for faster troubleshooting and the ability to bypass non-critical sensor arrays without compromising safety or FDA cGMP compliance.
- Precision Calibration: While we simplified the mechanics, we doubled down on the accuracy. In 2022, we achieved a sustained 0.1mm tolerance standard across our high-speed labeling lines, ensuring that even under maximum throughput, the rejection rate remained below 0.05%.
Impact on Global Operations
This pivot was successfully piloted in a high-volume facility in San Diego, California. By focusing on “Resilience and Precision,” the client saw a 28% increase in uptime despite the ongoing global logistics crisis.
Today, this shift remains the backbone of Azomak’s philosophy: Automation should be as robust as the steel it’s built from, yet as precise as the medicine it protects.