Making the Invisible Visible: Real-Time Data for MedTech Assembly

You’ve validated your device. Now you need to scale. But how do you prove quality at 300+ parts per minute without expanding your footprint or slowing down production? As MedTech device manufacturers scale from low- to high-volume production, it’s no longer just about building a device that works; it’s about building millions of them flawlessly. Regulators increasingly expect more than just end-of-line inspection. They want proof that every device was built right in real time, during the process, not after the fact. But traditional quality assurance methods, pre- and post-assembly inspection stations, are no longer enough. They add footprint, cost, and complexity on top of what is, in essence, a black box assembly process, and in a world where floor space is at a premium and throughput is increasing, these legacy approaches are quickly becoming unsustainable.

This is where the collaboration between ATS and Kistler becomes transformative.

Symphoni™, ATS’s high-speed, flexible assembly platform, was built for this moment. With its patented digital synchronous motion technology, Symphoni™ can assemble MedTech devices at over 300 parts per minute without compromising validated processes. But speed alone isn’t enough. That’s why ATS has integrated Kistler’s advanced process monitoring systems directly into the platform. For manufacturers, making previously invisible process data accessible and understandable with real-time data is becoming essential to stay ahead of both regulators and competitors.

From Assumptions to Assurance

With Kistler’s real-time force and displacement monitoring, Symphoni™ doesn’t just assemble, it verifies. The entire assembly process is measured and analyzed as it happens to enable:

• Inline force/distance evaluation with precision accuracy, reducing false positives / negatives and eliminating the need for separate inspection stations
• Inertia Compensation, a patent-pending Kistler innovation that neutralizes the effects of inertia on force measurement at high speeds
• Real-time waveform analysis to detect failure modes and ensure consistent quality
• Collected data can be sent to different data bases for process improvement and quick ramp-up of new lines

This is not inspection as an afterthought. It’s quality built into the process and it changes everything.

Why It Matters to You

For MedTech manufacturers, these capabilities translate into measurable operational advantages:

• Regulatory confidence: Full traceability and audit-ready data aligned with FDA 21 CFR Part 11 and MDR
• Smaller machine footprints: Fewer inspection stations, more efficient layouts
• Higher yield, lower downtime: Thanks to in-situ calibration and long-lasting piezoelectric sensors that are essentially maintenance free

These aren’t just technical wins, they’re business wins. Faster validation. Lower cost, better quality. Greater agility in scaling production.

Strategic Fit for the Future

ATS’s deep roots in life sciences automation, combined with Kistler’s proven sensing technology, create a powerful foundation for growth. Inline process monitoring is a strategic differentiator that supports:

• Lean, scalable automation: Symphoni’s modular design and Kistler’s embedded sensing reduce waste and increase throughput
• Compliance by design: Kistler’s secure data management and audit trail capabilities complement Symphoni’s own, and support even the most demanding regulatory environments
• Customer-centric innovation: We’re solving real-world challenges with integrated, intelligent solutions

Looking Ahead

As sensing technologies evolve and regulatory expectations continue to rise, the ability to monitor, analyze, and optimize every step of the assembly process will become a competitive necessity. As technology matures, so will the opportunities from injectables to diagnostics to next-gen wearables. As automation and sensing converge, manufacturers who embed quality into every motion will lead the next wave of MedTech innovation. This isn’t just about better machines; it’s about enabling what’s next in MedTech.

Curious how this could apply to your next program? Let’s talk.

For details on patents covering Symphoni™, visit https://symphonitech.com/patents/.

ATS LSS Business Development Contact
Leslie Toews
Business Development Manager
Tel: + 1 519 222 3250
Email: ltoews@atsautomation.com
 
About ATS Life Sciences Systems

ATS Life Sciences Systems (ATS LSS) is a trusted automation partner to lead MedTech and pharmaceutical manufacturers, providing custom automated manufacturing solutions from concept through delivery and lifecycle support. With deep expertise in assembly, material handling, conveyance, vision inspection, testing, and IIoT-enabled software, ATS LSS helps customers solve complex manufacturing challenges, especially in highly regulated environments.

ATS LSS is part of ATS Corporation and a proud member of the ATS Life Sciences Group, with eight manufacturing facilities across four countries, over 1 million square feet of production space, and a team of 1,300+ employees dedicated to delivering reliable, compliant automated manufacturing solutions at scale.

For more information about ATS Life Sciences Systems please visit atslifesciences.com or contact lifesciences@atsautomation.com


About the Kistler Group

Kistler is the global market leader for dynamic pressure, force, torque and acceleration measurement technology. Cutting-edge technologies provide the basis for Kistler’s modular solutions. Customers in industry and scientific research benefit from Kistler’s experience as a development partner, enabling them to optimize their products and processes so as to secure sustainable competitive edge. Unique sensor technology from this Swiss corporation helps to shape future innovations not only in automotive development and industrial automation but also in many newly emerging sectors. Drawing on our extensive application expertise, and always with an absolute commitment to quality, Kistler plays a key part in the ongoing development of the latest megatrends. The focus is on issues such as electrified drive technology, autonomous driving, emission reduction and Industry 4.0. Some 2,000 employees at more than 60 facilities across the globe are dedicated to the development of new solutions, and they offer application-specific services at the local level. Ever since it was founded in 1959, the Kistler Group has grown hand-in-hand with its customers and in 2024, it posted sales of mCHF 448. About 9 percent of this figure is reinvested in research and technology – with the aim of delivering innovative solutions for every customer. For more information about Kistler, please visit https://www.kistler.com/INT/en