ComfortFit Labs: Digital Transformation with FactoryFour
Customer Company Size
Mid-size Company
Region
- America
Country
- United States
Product
- FactoryFour platform
Tech Stack
- 3D scanning
- Digital workflow
Implementation Scale
- Enterprise-wide Deployment
Impact Metrics
- Productivity Improvements
- Customer Satisfaction
Technology Category
- Platform as a Service (PaaS) - Application Development Platforms
Applicable Industries
- Healthcare & Hospitals
Applicable Functions
- Discrete Manufacturing
Use Cases
- Digital Twin
- Mass Customization
Services
- Software Design & Engineering Services
About The Customer
ComfortFit Labs is a New Jersey-based packaging manufacturer that designs and manufactures custom orthotics. Their manufacturing process involves more than 50 production personnel that produce more than 80,000 products per year. Each orthotic is made per customer and combines several different types of materials and techniques. The company was facing challenges with their traditional order processing workflow, which was tedious and prone to human error. The process involved significant manual labor and long turnaround times, with customers sending plaster casts of their patients’ limbs along with paper order forms.
The Challenge
ComfortFit Labs, a New Jersey-based packaging manufacturer that designs and manufactures custom orthotics, was facing a challenge with their traditional order processing workflow. The process was tedious, involving significant manual labor and long turnaround times. Customers would send plaster casts of their patients’ limbs along with paper order forms to ComfortFit. The order data was recorded manually, and when a work order was issued to the floor, technicians had to manually measure the cast and find the right mold out of hundreds to manufacture from. This resulted in an average 7–20 day turnaround time with a process that was prone to human error from order entry.
The Solution
ComfortFit Labs implemented the FactoryFour platform to create a completely digital order workflow. Customers could log into ComfortFit’s order intake portal, fill out a digital order form specific to ComfortFit’s product, and take a scan via an iPad-mounted 3D scanner. The order form was automatically validated for errors prior to submission, reducing the risk of human error. Once submitted, the order appeared instantly in ComfortFit’s manufacturing queue. Using FactoryFour’s 3D file analysis engine, measurements were automatically captured from the scan and were presented with a “best-fit” code that identified which mold to produce from. As the device moved through production, the customer received automatic notifications and visibility into the status of their order.
Operational Impact
Quantitative Benefit
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