FactoryFour Case Studies ComfortFit Labs: Digital Transformation with FactoryFour

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	ComfortFit Labs: Digital Transformation with FactoryFour FactoryFour

ComfortFit Labs: Digital Transformation with FactoryFour

FactoryFour

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
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. Read More
About 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. Read More
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. Read More Log in to view content
Contents

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

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.

About 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.

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.

Impact #1	Digital order forms with automatic error validation allowed customers to easily choose different product selections, significantly reducing input mistakes.
Impact #2	Enhanced customer experience with status visibility. With their portal, ComfortFit was able to provide their customers with automatic visibility into order status. Customers could now see order progress in real time, and they could receive automatic email notifications on certain events, such as when their order shipped.
Impact #3	Media uploading and 3D file processing. Instead of using traditional plaster casts, customers could upload and send their 3D scans directly to ComfortFit. Once the scan was received, FactoryFour’s 3D file analysis engine automatically measured the scan and provided technicians with the right mold to manufacture from.

Impact #1

Digital order forms with automatic error validation allowed customers to easily choose different product selections, significantly reducing input mistakes.

Impact #2

Enhanced customer experience with status visibility. With their portal, ComfortFit was able to provide their customers with automatic visibility into order status. Customers could now see order progress in real time, and they could receive automatic email notifications on certain events, such as when their order shipped.

Impact #3

Media uploading and 3D file processing. Instead of using traditional plaster casts, customers could upload and send their 3D scans directly to ComfortFit. Once the scan was received, FactoryFour’s 3D file analysis engine automatically measured the scan and provided technicians with the right mold to manufacture from.

Benefit #1	Decreased turnaround time on an order by 50%: from 7–20 days to only 3–10.

Benefit #1

Decreased turnaround time on an order by 50%: from 7–20 days to only 3–10.

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Overview

ComfortFit Labs: Digital Transformation with FactoryFour

Operational Impact

Quantitative Benefit