Automotive

Calvary has a long history within the Automotive industry. Our experience expands over a wide range of technology applications including, but not limited to semi-automated lean cells, robotic work cells, asynchronous and synchronous assembly systems, flexible platform technology , web handling and functional test and inspection systems. We are experienced in numerous control systems and data analysis software platforms. We have integrated a large number of third party equipment and systems into our final solutions and have taking turnkey responsibility for the result. We have learned how to deal with cost and delivery constraints through innovative solutions and close collaboration with our customers.
Calvary is very familiar with our customer expectations, such as statistical quality metrics (Cpk, gauge R&R, capability studies), robust tooling design, poka-yoke verification methods, lean manufacturing practices and just-in-time production. We have integrated all core technologies such as feeding, part placement, assembly methodologies, joining technologies, dispensing, inspection, testing, and packaging solutions.

Calvary has provided solutions in many specialized applications, such as but not limited to:

  • Emission Control Products
  • Sensors and Actuators
  • Electronics and Associated Assemblies
  • Safety Products
  • Control Modules
  • Engine Management Components
  • Fuel Delivery Systems
  • Braking Systems
  • Steering Systems
  • Thermal Management Products

Consumer Products

Calvary’s work in the Consumer Products industry has spanned over several years with installations in several countries. Our experience includes multiple technologies to optimize processes for high volume or high mix production. In addition we have provided solutions to accommodate flexible volumes by designing solutions that are modular and scalable. We are sensitive to the ongoing development and product design iterations, as well as delicate handling to avoid cosmetic damage to products that will be exposed to end users.

We are experienced with many different control platforms and are familiar with integration to ERP and MES systems, as well as plant floor supervisory networks. Our controls experience can provide a variety of batch and part level data collection for analysis and record keeping.

We have integrated a number of technologies frequently used in consumer products, such as flexible part feeding, container filling, coating, adhesive applications, screwdriving and welding technologies, electronic, leak and functional testing, cosmetic and qualitative vision inspection, laser marking, printing and decorating processes, as well as primary and secondary packaging.

Calvary has provided solutions in many specialized applications, such as but not limited to:

  • Consumer Electronics
  • Optical and Electronic Connectors
  • Household Goods
  • Sporting Goods
  • Office Products
  • Toiletries

Electronics

Calvary has delivered numerous world-class systems performing Electronics Assembly for the industries foremost manufacturing companies. Our experience includes integration of PCB manufacturing equipment, soldering/welding, functional testing, part marking and traceability, calibration, coating and sealing systems along with many others technologies and applications used throughout the world today. We are familiar with requirements such as board stress reduction, part recovery/reintroduction, environment control, ESD practices and SMEMA interfacing.

Calvary has provided solutions in many specialized applications, such as:

  • Electronic Actuators
  • Sensors
  • Actuators
  • Control Modules
  • Meters
  • Computer Peripherals
  • PDA and Smartphone Components 
  • Energy Storage Devices
  • Integration of Standard Electronic Assembly and Test Equipment

Energy

Calvary has delivered systems into the Energy Generation and Storage Industry for many years. We have designed numerous systems for the PV Industry both in traditional polycrystalline products as well as thin film based solar products. These systems have been based around various material handling methodologies including web, asynchronous conveyors, synchronous transfer dials or chassis as well as robotic modules. We are experienced in a variety aspects regarding the production and handling of solar cells and modules.

In addition, we have built systems for battery assembly, fuel cell, technology and hybrid electric vehicle componentry.

Calvary has provided solutions in many specialized applications, such as but not limited to:

  • Fuel Cell Manufacturing and Test
  • Solar Panel Assembly and Test
  • Wafer, Web and Glass Handling
  • Energy Storage
  • Batteries
  • Energy Transmission
  • Nuclear
  • Hybrid Electric Vehicles

Healthcare

Calvary has delivered numerous systems into the Healthcare Industry for a large number of global, world-class medical device, diagnostic and pharmaceutical companies.

We have designed systems for a wide variety of assemblies including sharps products for infusion and extraction, tubing and valves, glass products, syringes, various components as well as medical electronic devices. These assembly and test systems incorporate many different technologies including feeding, placement and assembly, joining, curing, inspection, testing and packaging. This automation is based on technology configurations such as lean cells, robotic platforms, asynchronous and synchronous transfer systems, along with web-based and highly flexible conveyance systems.

We are familiar with clean room equipment design, cGMP, IQ/OQ validation requirements and the associated documentation, as well as 21CFR part 11 compliance. Calvary will work with you to define the division of scope between your operations and our solution in order to meet regulatory requirements and your general practices. This will ensure you receive a predictable solution that will meet or exceed your requirements.

Calvary has provided solutions in many specialized applications, such as but not limited to:

  • Sharps and syringes 
  • Catheters
  • Infusion Products
  • Diagnostic Products
  • Medical Electronic Devices
  • Glass Products
  • Non-woven and film-based products
  • Tube Sets
  • Valving Components and Assemblies
  • Machine Tending Applications
  • Material Handling Systems
  • Testing and Inspection Systems
  • Primary and Secondary Packaging

Prototyping & Development

Our close relationships with technology leaders coupled with our years of experience on more than a 1000 applications have resulted in a deep understanding of product and process development activities. We have integrated these skills into our offering and formalized our systems and processes through our in-house Technology Labs. Here, we are able to perform a number of early development tasks to better understand project requirements and mitigate risks. We have dedicated areas for Vision Application Development and Testing; Rapid Prototyping, New Technology Evaluation, as well as a comprehensive Robot Lab which includes multiple robot brands and configurations for live testing and development. In addition, we typically leverage partnerships with suppliers and companies that have enabling or disruptive technologies whereby we can have access to equipment and instrumentation for research and development. In addition, we used these labs to develop and test our series of robotic platforms that are a key part of our offering when meeting your production and manufacturing challenges.

Calvary invests a large amount of its profits back into direct research and development activities. This ensures and maintains our leading position in the marketplace as well as aligns performance expectations with our customer's needs. This allows us to provide the most innovative, cost effective and risk managed solutions possible.

We are flexible to offer different levels of engagement, whether it is development prior to equipment sourcing, part of a vendor evaluation, an independent project or part of a system solution, we can offer but are not limited to the following:

  • Theoretical Analysis
  • Proof-of-Concept Testing
  • Feasibility Studies
  • Risk Assessments
  • Cycle Time and Capability Verification
  • Prototype Tooling
  • Simulations
  • 3D Printing
  • Testing
  • Report Generation
  • Functional Specification Development

It is proven that performing these early project tasks will improve the overall project result. The cost of change increases over the lifetime of a project while the degree of influence decreases over the same period.

We look forward to put these capabilities to work for you.