Combination Solutions
These solutions utilize the full potential of the Machine Automation Group. They are both Value Add and Waste Elimination systems. Based on years of experience we develop the production process to the expected capability; the processes for monitoring and part verification is then built into system. These systems can be expanded to provide additional information for ongoing quality requirements per the customers needs.
Grease Can Inspection & O-Ring Insertion
The grease can inspection and O-Ring insertion system provides the customer with both value add and waste elimination implementations. The grease cans are presented to the first inspection stage via a clip-fed walking beam mechanism. The first station use a configuration of rollers to turn the can as it is inspected for manufacturing and forming defects by a series of cameras. If the can is determined to be defect free, it is passed along to the o-ring insertion portion of the system where an o-ring is automatically inserted into the retaining portion of the grease can. Once inserted, the can goes through the final inspection stage. This will check for proper location and seating of the o-ring. If the can is determined to meet the customers requirements it exits the process onto an accumulation table for operator packing. During the process if a can is determined to be defective it is removed from flow and rejected into one of two bins depending on the point of defect detection.
The system is designed to be balanced with the existing process and can process up to 500 grease cans per hour.
Selector Shaft Work Cell
The selector shaft work cell is a large integration of several existing pieces of equipment, automated part handling, robotic pick and place applications, and high precision measurement and gauging systems. This system provides the customer with a single piece flow for a process that previously required multiple shifts and volumes of WIP that created long lead times for customer demand satisfaction.
The system allows for part flow from four primary machines that feed one tread roller. This in turn prresents parts to a dual robotic pick, place and inspect system. The robotic elements presents parts to two sub processing machines. They then move the parts through an inspection system and onto a final operation.
As presented, the system will remove unnecessary WIP, reduce the lead time by 73%, increase capacity three fold and eliminate the need for excess labor. It will accomplish this while providing the customer with 100% fully inspected product.
Catalytic Converter Bracket Assembly
The catalytic converter bracket cell uses two robotic part handling systems to process a family of parts through a stud insertion, welding and assembly process. As the parts are transferred from one value add process to the next, each operation is verified via applicable inspection techniques ensuring that only properly formed parts are processed and exited as defect-free product. The primary parts are presented to the system via custom designed clip mechanisms that are part specific. These clips provide for easy part change over and reduce down time of the work cell.
Lever Assembly Riveting Machine
The lever assembly and riveting machine uses custom designed part handling clips and bowl feeder mechanisms to present incoming components to a rotary transfer assembly system. There are various stations that perform value-add assembly operations and others stations that inspect the work that has been performed.
This strategy of combining value-add operation with in-process inspection and containment systems provides the customer with the highest degree of quality in their product.