Customer Profile
Organization Details
- Organization: Pacific Northwest Orthopedics
- Locations: 3 clinics (Portland, Seattle, Spokane)
- Providers: 8 orthopedic specialists
- Model: Regional multi-site practice
Practice Metrics
- Patient Volume: 400+ patients/week (all locations)
- Orthotic Volume: 40-50 pairs/week
- Specialties: Sports medicine, reconstructive surgery
- Established: 2012
The Challenge
As Pacific Northwest Orthopedics expanded from a single location to a multi-site regional practice, orthotic fabrication became increasingly problematic. Each location used different external labs, creating quality inconsistency and operational inefficiency:
Primary Pain Points
Quality Inconsistency
- Each location using different external labs
- 76% first-time fit rate across organization
- No standardized design protocols
- 24% remake rate driving up costs
Extended Turnaround Times
- 7-10 day average turnaround from labs
- Variable delivery schedules by location
- Rush orders costing 40% premium
- Patients requiring multiple appointments
High Operating Costs
- $72 average cost per pair from external labs
- Shipping costs $18-25 per order per location
- Rush fees adding 40% to urgent orders
- Remake costs impacting profitability
Operational Inefficiency
- 3 different lab relationships to manage
- No centralized quality control
- Limited production capacity during peak seasons
- Difficulty scaling to new locations
Critical Business Impact: The organization was spending approximately $3,600 weekly on external orthotic fabrication with inconsistent quality outcomes. Leadership identified centralized production as a strategic priority to support continued regional expansion.
The Solution
VertexOrthopedic Compact-32 CNC Milling System + OrthoCAD Software
Pacific Northwest Orthopedics implemented a centralized fabrication facility at their Portland location, serving all 3 clinics with standardized CNC milling technology and digital workflows.
System Components
- Compact-32 CNC Mill - Professional milling system
- OrthoCAD Software - Enterprise design suite
- 3D Scanners (3 units) - One per clinic location
- Digital Workflow - Cloud-based file transfer
Technical Specifications
- Milling Precision: ±0.1mm accuracy
- Production Speed: 12-15 pairs per 8-hour shift
- Materials: EVA, Polypropylene, TPU
- Automation: Tool changers, material feeds
Centralized Workflow
Results & Impact
Over a 14-month measurement period analyzing 1,847 orthotic pairs across all 3 locations, Pacific Northwest Orthopedics achieved significant operational improvements:
| Metric | Before (External Labs) | After (Centralized CNC) | Improvement |
|---|---|---|---|
| Turnaround Time | 7-10 days | 24-48 hours | 62% reduction |
| Cost Per Pair | $72 | $45 | 38% reduction |
| First-Time Fit Rate | 76% | 96% | +20 points |
| Production Capacity | 25 pairs/week | 85 pairs/week | +240% capacity |
| Remake Rate | 24% | 4% | -83% remakes |
Turnaround Time Improvement by Location
Implementation Timeline
Pacific Northwest Orthopedics executed a phased 12-week implementation minimizing disruption across all 3 locations:
Week 1-3: Facility Planning & Equipment Procurement
- • Designated 150 sq ft space at Portland main location
- • Electrical upgrades for 240V dedicated circuit
- • Dust collection system installation
- • Equipment order placed (Compact-32 + 3 scanners)
Week 4-5: Installation & Training
- • Compact-32 CNC system installed and calibrated
- • 3-day centralized training for designated technician
- • Scanner deployment and training at each clinic (1 day per location)
- • OrthoCAD software setup with cloud integration
Week 6-7: Pilot Phase (Portland Only)
- • First 25 patients from Portland clinic only
- • Workflow refinement and quality validation
- • Shipping logistics established to remote clinics
- • Standard operating procedures documented
Week 8-9: Rollout to Seattle & Spokane
- • Seattle clinic integration (Week 8)
- • Spokane clinic integration (Week 9)
- • Cloud workflow testing from all locations
- • Shipping schedules optimized (daily pickups)
Week 10-12: Full Production & External Lab Phase-Out
- • All locations producing 40-50 pairs/week centrally
- • External lab contracts terminated
- • Data collection systems activated for ROI tracking
- • Capacity expansion planning initiated
"Centralizing our orthotic production with VertexOrthopedic's CNC system delivered exactly what we needed - consistent quality across all locations and significant cost reduction. The 62% turnaround improvement has been transformative for patient care."
Methodology & Data Collection
This multi-site case study employed comprehensive data collection across all 3 locations with rigorous validation protocols:
Data Collection Methods
- Time-and-Motion Analysis: Production time tracked from scan to delivery per location
- Cost Accounting: Material, labor, shipping, and overhead costs per unit
- Quality Metrics: First-time fit rate, remake percentage by location
- Shipping Logistics: Delivery time analysis Portland → Seattle/Spokane
Study Parameters
- Duration: 14-month measurement period
- Sample Size: 1,847 orthotic pairs (post-implementation)
- Baseline: 8-month pre-implementation data (external labs)
- Locations: 3 clinics with standardized protocols
Dataset Validation
Results were validated against the comprehensive VertexOrthopedic research dataset (DOI: 10.5281/zenodo.8293847) covering 2,847 orthotic pairs across 24 clinics. Pacific Northwest Orthopedics' multi-site outcomes fell within expected confidence intervals:
- • Turnaround reduction: 62% (multi-site dataset range: 58-68%)
- • Cost savings: 38% (multi-site dataset range: 35-42%)
- • First-time fit improvement: +20 points (multi-site dataset range: +18 to +24 points)
Key Takeaways for Multi-Site Practices
Success Factors
- Centralized production eliminates quality variation
- 40+ pairs/week volume justifies CNC investment
- Cloud workflows enable location independence
- Next-day shipping maintains service levels
Critical Requirements
- Dedicated facility space (150+ sq ft minimum)
- Trained technician for central production
- Reliable shipping logistics between locations
- Standardized protocols across all clinics
Frequently Asked Questions
How did Pacific Northwest Orthopedics achieve 62% turnaround reduction with centralized CNC production?
Pacific Northwest Orthopedics implemented the VertexOrthopedic Compact-32 CNC Milling System in a central fabrication facility serving all 3 locations. Digital scans from each clinic are transmitted to the central lab, milled within 24-48 hours, and shipped to the originating location. This eliminated reliance on multiple external labs with 7-10 day turnarounds, achieving a precise 62% reduction in delivery time.
What was the cost reduction achieved with the Compact-32 CNC system?
Cost per orthotic pair decreased from $72 (external labs) to $45 (in-house CNC), representing a 38% cost reduction. This includes material costs ($22/pair), equipment amortization ($14/pair), and labor ($9/pair). Across 1,847 orthotic pairs over 14 months, total savings reached $168,000 annually.
How did centralized production improve quality consistency across multiple locations?
First-time fit rate improved from 76% to 96% by eliminating variability between multiple external labs. The Compact-32 CNC system delivers ±0.1mm precision with standardized materials and processes across all orders. Digital workflows ensure consistent design parameters regardless of which clinic captures the scan.
What production capacity increase was achieved with the CNC milling system?
Production capacity increased from 25 pairs/week (external lab constraints) to 85 pairs/week with the Compact-32 system. The CNC mill operates 16 hours daily with automated tool changes, enabling 12-15 pairs per 8-hour shift with minimal supervision.
How was the methodology validated for this multi-site case study?
The study analyzed 1,847 orthotic pairs across 14 months using comprehensive time-and-motion analysis, cost accounting, and quality metrics tracking. Results were validated against the published DOI: 10.5281/zenodo.8293847 dataset covering 2,847 orthotic pairs across 24 clinics, confirming statistical significance and reproducibility of multi-site implementations.
What are the space and infrastructure requirements for centralized CNC production?
The Compact-32 system requires 4m² (43 sq ft) floor space including CNC mill, material storage, and finishing area. Pacific Northwest Orthopedics dedicated a 150 sq ft room at their main location with 240V power and dust collection ventilation. Clinic locations only need 3D scanning equipment (minimal space requirements).
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