How a Medical Device Manufacturer Simplified Multi-Lumen Catheter Testing and Eliminated Production Bottlenecks
Learn how a medical device manufacturer solved complex testing inefficiencies and improved production throughput by integrating multiple test methods into one controlled process
“By integrating multiple testing methods into a single system, we transformed catheter testing from a complex bottleneck into a fast, controlled, and scalable operation.”
About the company and their role in medical device manufacturing
The company operates in the medical device industry, producing multi-lumen catheters used for applications such as drug delivery, hemodialysis, and critical care treatments.
Their production environment requires high precision, strict compliance, and consistent quality to meet regulatory standards and ensure patient safety.
Why multi-lumen catheter testing created inefficiencies and production bottlenecks
Testing multi-lumen catheters is complex and highly regulated.
The main challenges were clear:
Each lumen needed to be tested individually for leaks
Leakage between lumens had to be detected
Blockages and occlusions needed to be verified
Compliance with organizations such as the FDA was required
This created several issues:
Long and complicated testing cycles
Multiple instruments required for different tests
High dependency on manual setup
Increased risk of errors and inconsistent results
What should have been a controlled quality step became a production bottleneck.
How fragmented testing setups increased complexity without solving the root problem
To address testing requirements, the manufacturer developed a custom setup using multiple instruments and software systems.
While this approach was functional, it introduced new challenges:
Systems became difficult to operate and maintain
Scaling required additional equipment and floor space
Data collection and compliance tracking were fragmented
Testing performance depended heavily on operator handling
The problem was partially addressed, but not solved in a scalable or efficient way.
How Optimus Instruments analyzed the process and implemented the right integrated testing solution
To improve the process, the company partnered with Optimus Instruments.
The goal was to simplify testing, reduce complexity, and improve production throughput.
Optimus analyzed the existing setup and identified the need for a fully integrated testing approach. Based on this analysis, a solution built around the Sprint mD was selected and implemented.
Key elements of the solution included:
Multi-channel sequential testing for up to four lumens
Integrated leak and occlusion testing in one system
Automated detection of inter-lumen leakage
Programmable test sequences for flexible operation
Centralized data logging for compliance and traceability
The system replaced multiple separate instruments with one streamlined and controlled solution.
How process integration simplified testing and improved reliability
By replacing a fragmented setup with an integrated system, the process changed significantly.
Each lumen is tested automatically in sequence
Inter-lumen leaks are detected during testing
Occlusion testing is performed within the same system
Manual setup and handling are minimized
This resulted in a stable, repeatable, and controlled testing process.
What results were achieved after implementing the optimized testing process
After implementation, the company achieved clear improvements:
Testing time per product was reduced
Production throughput increased
System complexity decreased significantly
Fewer instruments were required
Compliance and data tracking improved
Most importantly:
Testing was no longer a bottleneck, but a scalable and efficient part of the production process.
Why integrating testing processes improves efficiency and scalability
This case highlights an important insight.
Using multiple separate systems may seem like a flexible solution, but often increases complexity and reduces control.
By integrating testing into one system, the company was able to:
Reduce operational complexity
Improve consistency and reliability
Scale production more easily
Maintain compliance more effectively
Final thoughts on improving production performance through better process control
Improving production is not always about adding more equipment.
In many cases, it comes down to understanding the process and implementing the right solution to control it effectively.
Looking to reduce complexity and improve efficiency in your testing or critical process steps
If you are dealing with complex testing requirements or process inefficiencies, Optimus Instruments helps you analyze your application and implement the right solutions to improve performance.
Book a call to explore how you can achieve similar results.