Handheld Medical Device Redesign Cuts Costs 60%, Adds Wireless Features

Product development case study of a handheld medical device

The Back Story

A handheld medical device launched to praise from the Wall Street Journal, ABC News, and other influential press. But in addition to facing high manufacturing costs, the medical devices company also began to receive complaints about product performance and reliability.

The Strategy

The company selected Boston Engineering to update product design and packaging for an enhanced user experience, and to reengineer the product for added performance. As part of the redesign process, Boston Engineering reduced the number of product components to accelerate assembly time and developed a design control process to help improve production quality.
Boston Engineering also selected a global manufacturer and oversaw pilot production to ensure production quality and speed met contracted service levels.

The Impact

Project results included:

  • Reduced production costs by 60%
  • Accelerated production time by 20%
  • Increased the product’s battery life by 100%
  • Installed a near field communication (NFC) tag to track disposable tip usage
  • Improved product reliability significantly

The product redesign enabled the medical devices company to increase profit margins and to boost customer satisfaction. In addition to managing product growth, the company is also evaluating additional applications for its patented technology.