Achieving Efficiency in Automotive Parts Assembly
Challenge
A Tier 2 automotive parts manufacturer faced the challenge of producing eight assemblies with exact attachment and quality requirements. The goal was to reduce operator reliance, minimize cycle time, and meet customer demand effectively.
Solutions
- Single In-Line Work Cell: Operated in tandem with assembly responsibilities, ensuring finished assemblies met quality standards in real time.
- Dowels with Integrated Sensors: Fixtures equipped with dowels and sensors verified part assembly and inspection criteria.
- Advanced Vision Sensors: Capable of verifying clip attachment, component presence, and color accuracy for enhanced inspection precision.
- Barcoding Implementation: Enabled part traceability across the production line, ensuring accountability and quality assurance.
- Real-Time Rework Capability: Allowed operators to manually correct parts failing inspection, reducing scrap and improving efficiency.
Outcomes and Benefits
- Cycle Time Reduction: Automation of key assembly and inspection processes simultaneously decreased cycle time by 20-40%.
- Enhanced Productivity: Enabled a single operator to meet customer requirements for all parts within one shift at 100% accuracy.
- Comprehensive Quality Verification: Vision inspection systems and data collection ensured all finished assemblies met customer standards.
By integrating cutting-edge technology and real-time rework capabilities, this in-line work cell optimized assembly and inspection processes. With reduced cycle times, improved traceability, and exceptional accuracy, the solution delivered tangible results for our automotive client.
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