The Design Engineer studies product blueprints, manufacturing processes, and/or customer specifications to conceptualize the machine design required to produce the product.  Using knowledge of machines, machining, and manufacturing processes, the Engineer creates drawings for accurate interpretation of the design by toolmakers and oversees the auxiliary layout and detailing activities.

QUALIFICATIONS:

1. Bachelor’s degree in mechanical design, engineering or related area OR at least two years mechanical design experience with an Associates degree in mechanical design or engineering.
2. Thorough knowledge of machine tools and assembly of automated machinery.
3. Application of mechanics, hydraulics, pneumatics, and manufacturing processes.
4. Understanding of costs and production times to manufacture machinery.
5. Experience in computer aided design.
6. Applied math skills using geometry, trigonometry, and standard tool engineering data to develop machine configuration.

The Machinist sets up and operates conventional, special purpose, and numerical (NC) machines and machining centers to fabricate metallic and nonmetallic parts, and fits and assembles machined parts into complete units, applying knowledge of machine shop theory and procedures, shop mathematics, maintainability of materials, and layout techniques.

QUALIFICATIONS:

1. Between 4 and 10 years of trade school, vocational education, work experience, and/or apprenticeship.
2. Ability to perform math calculations using trigonometry.
3. Familiarity with geometric dimensioning and tolerancing.

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DTE recognizes that time to market is a critical factor for the successful introduction of Pharmaceutical products. The packaging operation in manufacturing is often one of the obstacles to fast product introduction especially if standard equipment cannot be utilized. DTE has provided customized pharmaceutical packaging lines which enabled our customers to get their products to market ahead of their planned product introduction timeframe.

System Overview

DTE can provide customized packaging lines which consist of standard thermoforming and cartoning equipment in combination with our custom material handling and vision inspection systems. For the packaging of an oral drug delivery device, DTE provided a packaging line consisting of a robot for populating blisters, a thermoformer, vision inspection systems, a robot for blister transfer and a cartoner. The system was shipped 8 weeks ahead of schedule and the user exceeded production schedules within 3 weeks of installation. A second system was provided in the following year and it was operational 3 days after user site installation.

System Highlights

• Custom part feeding equipment
• Custom gantry robot for product feeding
• Vision inspection system for lot and date code
• Standard horizontal blister forming machine
• Vision inspection system for product quality
• Multi color printing system
• Blister accumulation system
• Blister inversion, rotation and nesting
• Standard automatic cartoner
• Automatic instruction leaflet insertion
• Automatic weight checking
• Metal detection feature
• Optional case packing & palletizing
• Allen Bradley Controllogix Platform

System Values and Benefits

• High Output-Up to 300 parts per minute
• Product changeover in less than 15 minutes
• Tamper proof carton packaging
• Bar code verification Product inspection
• Uptime greater than 98%

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Copyright 2011 Detroit Tool & Engineering

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Detroit Tool & Engineering was a single source for the tooling, special forming and welding equipment for this Oven project. This is only one of many projects where DTE has combined the tooling and the special machines to give the customer a one stop shop. DTE can control the total schedule of the project, providing fit up parts to the machine group as required, part development utilizing tooling and machines with no shipping of part between two suppliers.

System Overview

• Single source for total project control
• Tooling group supplied parts for the equipment development and run off
• Tooling group utilizes Dynaform software for drawn part die design
• Machine design utilizing information from tooling

System Highlights

• Tooling package included twenty dies for the one project plus eight additional for other parts.
• One special machine to final piercing of different hole pattern, One to form a reverse curl complete in the opening and one to spot weld all parts together including two additional parts.

System Values and Benefits

• Mid-freq. welding with servo controlled locations
• Tooling design for automated press line including part transfer with auto die change
• Matching shut height for all tooling
• Matching clamping locations for all tools
• Cell configuration layout for lean manufacturing

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Copyright 2011 Detroit Tool & Engineering

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This project represents the first phase of several projects in which DTE worked with our customer to take multiple sizes of different parts of construction equipment and give them the ability to weld the parts together on a single fixture. This project paved the way for additional orders from our customer for new fixtures or modifications to current fixtures when models change or new models have been added to the program. Our constant communication through our project team members and quality that surpassed our customers’ expectation has benefited DTE by giving us the opportunity to expand the work we do for this customer into other areas of the manual weld, machining, and robotic weld departments.

System Overview

• The overall program consists of twelve different weld fixtures.
• Each fixture can accommodate an average of three or four different models.
• Part tolerances on some fixtures range as low as .020″.
• Overall fixture sizes range from approximately 3 feet long to approximately 20 feet long.
• Efficient storage of change out parts was a requirement in order to maintain a space saving solution.

System Highlights

• Solutions to control deformation caused by the weld process are implemented on each fixture.
• Individually controlled hydraulic valves assist with movement on larger weld fixtures or with parts that cannot be moved manually.
• Coordinated change out parts with locators which were utilized to ensure correct positioning for each different model.
• Movement of different parts on a fixture to accommodate a different size model is achieved with slides that lock into place with plunger style locators.
• Custom designed racks provide efficient storage of change out parts in close proximity to each fixture.

System Values and Benefits

• Combining multiple models on a single weld fixture reduces the overall required floor space.
• Precision locating eliminates the need for manual measurement of parts throughout the weld process.
• Coordinated change out parts allow for quick change between models.

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Copyright 2011 Detroit Tool & Engineering

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Ever increasing transmission rates for data forced all telecommunications equipment manufacturers to constantly upgrade and redesign their products to adapt to the market needs. This manufacturer of high speed data ports teamed up with the Bodine technical group while the product was still somewhat fluid, allowing them to take advantage of the “Design For Assembly” expertise that was available. The new connector needed to be assembled at high speed, and with great precision. Contact wire forming and positioning within the housing was absolutely critical to the functionality of the product. This made the Bodine Chassis the ideal platform.

System Overview

The system would be made up of three modules: On the PCB (printed circuit board) Module, (8)IDCs (insulation displacement contacts) are processed and inserted into zero clearance holes in the PCB. Additionally (2) sets of precision formed wire lead frames are pressed into the PCB. The Solder Module uses a thermal carrier puck on a conveyor system to send subassemblies through the solder reflow oven. The Final Module allows the soldered PCB to be assembled into its plastic housing. Labeling, ultrasonic welding, final wire form die cutting, and functional electric testing all follow with good assemblies being laser marked.

System Highlights

• System Operating Speed :50 ppm
• Gross Production Rate : 3000 assemblies/hour
• High Precision Placements Prevent Wire Damage
• Vision Verification of All Critical Placements and Dimensions
• Components are Fed from Coil Stock, Die Cut and Transferred.
• Protective Puck Pallets used in Solder Process.

System Values and Benefits

• Standard platform ensures proven performance results.
• 100% vision verification of critical features.
• Quick change mounting for Die sets to allow for minimal downtime to facilitate die maintenance.

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Copyright 2011 Detroit Tool & Engineering

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Detroit Tool and Engineering designs and builds continuous motion machines for a variety of applications. The most common applications are the closing of plastic molded caps and the assembly of two piece caps. Continuous motion design is also applied to other applications such as: Pharmaceutical Product assembly at 250parts per minute; Confectionary Product packaging at 200 PPM; and others.

System Overview

The Model 938 Cap Closing Machine is a rotary, continuous motion machine which closes hinged plastic caps from the open position. This design achieves cycle speeds up to 400 parts per minute, depending on cap size and shape.

The Model 937 Two-Piece Cap Assembly Machine is a mechanically synchronized rotary machine to assemble two piece caps. Cycle speeds of up to 450 parts per minute can be achieved depending on cap size and shape.

System Highlights

• Speeds up to 450 parts per minute
• Cam controlled continuous motion using from 6 to 24 spindles depending on product configuration
• Mechanical Overload protection safeguards the machine
• Detection and subsequent rejection of missing or not fully closed lids
• Variable speed D.C. motor to adjust speed to match associated process machines
• Automatic machine stop after a predetermined number of rejects is reached

System Values and Benefits

• Low Maintenance Cam controlled design
• Mechanical Overload protection for safety
• Reliable detection and removal of missing lids or not fully closed lids
• Resettable product counter with diverter gate for box packaging options

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Copyright 2011 Detroit Tool & Engineering

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A large medical product design firm has determined that it will introduce a new “safety” Catheter to the marketplace. This is in response to legislation and a market recognition of the need for medical products which do not threaten the health care provider with undo risk of infection. The Catheter’s design incorporates a protective sheath and a retractable needle (Cannula), insuring that the individual introducing the Catheter into the patient’s vein, does not accidentally get stuck by an infected device. The risk of HID, Hepatitis C, etc. have created the need for such medical product redesign. The safety features result in a more complex assembly process with more components than a standard traditional Catheter.

System Overview

The entire product was assembled on one Bodine indexing carousel assembly module. Bodine was selected because the customer knew of Bodine’s experience with Catheters and the related assembly processes. The assembly module was 9 bays in length, providing 54 possible operating stations, 42 of which were actually used in this case. The product consisted of 9 components and (2) different gages of Cannula had to be handled. Operating at 30 cycles per minute, the system had a gross production rate of 1800 assemblies per hour. The system was operated in a class 10,000 clean room. Extensive use of sophisticated vision systems assured Needle grind quality and ultimate Cannula radial orientation.

System Highlights

Assembly process highlights included:

• Auto cannulas loading, adjustable to two different gages (see photo)
• Automatic feeding of all components
• Extra space on machine to accommodate future product variations
• UV curing of Loctite adhesive (used to glue Cannula to Hub) PLC based control system with remotely monitored HMI and Webnet remote reporting system
• Lubeless clean room tooling
• Full verification of all assembly processes and critical dimensions
• Automated bagging of finished product prior to final sterilization process.

System Values and Benefits

• Clean room operation
• Fully automated assembly process…no human contact during assembly
• High production volumes…gross production rate of 14,400 assemblies per 8 hour shift!

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Copyright 2011 Detroit Tool & Engineering

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This project represents the partnering of DTE’s machine building experience with the customer’s current processes. The customer had neither the in-house expertise nor manpower to move up to the next level of automation that was requested by their customer. A plan was put together by DTE and with ongoing communication this system was developed to more than double the prescription output and tripled the available cassettes while maintaining the integrity of the patient specific medical needs. The project was so successful over 15 machines were built, tested, and installed in locations throughout the United States in 24 months.

System Overview

• System consists of two sections, medication picking/dispensing and packaging/labeling.
• Medications are stored in cassettes that are placed onto two carrousels.
• Cassettes are picked simultaneously with two computer controlled x-y slides and placed onto eight dispensing x-y slides.
• Completed medication loads are transferred to a packaging dial at the end of the machine.
• An eight station cam driven dial is used to move between card/blister, medication placement, folding and sealing stations.
• Pick and place unit removes the completed card for labeling and stacking.

System Value and Benefits

• Designed for single or expanded models.
• Higher output.
• Barcode conformation from beginning to end of prescription filling.
• Modular design to allow installation into all types of locations.

System Highlights

• 304 Different cassettes available.
• On the fly cassette swaps.
• Barcode verification from cassette load to stacking of the prescription ensures accurate and safe dispensing.
• Primary and secondary carrousels allow smaller or expanded machine depending on customer’s requirements.

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Copyright 2011 Detroit Tool & Engineering

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DTE has supplied a variety of automated assembly systems enabling major manufacturers of pharmaceutical products to reduce labor, enhance quality and get their products to market quicker. In this project, the customer had issues with being able to successfully dispense the proper quantity of glue within the desired cycle time without spillage onto the product. DTE designed and developed a prototype gluing system to prove a successful glue dispensing mechanism. After extensive prototype testing, the production system was built and installed 2 months ahead of schedule. Product rates were at least 10- 11 times faster than the existing production equipment. The customer was elated about the ease of installation and the innovative DTE design which allowed fast cleaning during product dose changes. Several duplicate systems were provided in the following years as the product enjoyed periods of rapid growth.

System Overview

This system is for the high speed assembly, inspection, printing and labeling of a specialty oral consumption drug delivery product. The highly reliable system consists of a high speed assembly machine, vision inspection stations and a labeling machine. The components are supplied to the assembly machine by feeder bowls with hoppers. One component is placed in a fixture and its orientation is checked. Next, the part is indexed to another station for the glue dispensing and mating with another component. The part is then ink jet printed and inspected for quality. The part is then sent to a custom labeling station for the final operation. The labeler applies one of six different labels which confirm the product dosage and this is verified by a vision inspection station. The output is fed directly to a custom DTE built final packaging line.

System Highlights

• Clean Room Type Stainless Steel Construction
• Product damage inspection system
• High reliability part feeding
• Glue dispense and detection systems
• Quality inspection with variable quantity audit
• Compact equipment footprint
• Enclosed system for cleanliness and safety
• Speeds up to 250 ppm

System Value and Benefits

• Minimized product damage
• Minimum floor space required
• Changeover in less than 15 minutes
• Ease of cleaning design considerations
• Ink jet printing for 6 different product dosages
• Clean and safe working area for employees
• Low cost unit assembly

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Copyright 2011 Detroit Tool & Engineering