Medical Industry

Automotive Industry

MSI Case Study 1 (Medical Industry)

Medical instrument now lasts longer due to reduction in hardness

MSI recommended the change after performing a variety of state-of-the-art tests.

The Background:
A medical implements company manufactured parts used for back surgery. Given the critical nature of the application, the parts needed to be strong enough to withstand the loads applied during surgery and tough enough to last through multiple surgical uses.

The Business Problem:
Customers began complaining that the spring portion of the implement was failing prematurely. Any slight scratch or notch in the spring created high stress regions and resulted in reduced life of the part. The company was at risk of losing an important customer base. They had the opportunity to appear responsive and improve “good-will” by fixing the problem. They not only needed a metallurgy lab to analyze the part, but they needed someone to look beyond the part – to how it was manufactured and how surgeons used the part. They turned to Metallurgical Solutions, Inc. (MSI), in Middletown, Ohio.

The Solution:
MSI received the part and began the failure analysis process by asking a battery of questions to determine the historical application of the part. Through this discovery process, MSI learned how the part was manufactured and how the surgeons used the part. After looking at the fracture surface, determining mode of failure, and identifying the fracture initiation site using a scanning electron microscope (SEM), MSI conducted microstructure evaluation and hardness tests and determined that the hardness was too severe for the application. With MSI’s recommendation, the company changed the hardness specifications which proved to be the solution. The surgeons are satisfied and the life of the part has been dramatically extended.

MSI Case Study 2 (Automotive Industry)

Plant avoided a shut down by getting repaired part analyzed

MSI analyzed the part and had the plant up and running in 30 minutes

The Background:
An automotive manufacturer discovered they had a defective but repairable casting, which was promptly sent out for repair. The company knew that if their part did not come back in time, they were at risk of shutting down production.

The Business Problem:
When the part was repaired and returned, the plant manager needed a quick analysis to determine if the part was free from defects. Time was critical. Normally, it would take days, and maybe weeks to get certified analysis complete. They didn’t have time to waste. The Quality Engineer called Brian Joyce at Metallurgical Solutions, Inc. Because Brian had responded quickly in the past, he thought MSI might be able to help.

The Solution:
True to their reputation for concern for the customer, MSI reacted immediately. With an on-site visit that afternoon, the team from MSI took a section of the weld and evaluated it under a microscope to determine the weld repair was successful. Within 30 minutes the part was in production. MSI then prepared a letter certifying as of this date, there are no defects. It’s that kind of responsiveness and concern for the customer’s business that sets MSI apart from other metallurgical labs.