Mul­ti-sta­ti­on Assem­bly Dial

InvotecCase Study, Complex Assembly Equipment, Machine Vision Systems, Mechanical Assembly Systems

The Chal­len­ge: Incre­a­se Pro­duc­tion While Eli­mi­na­ting Error

One manu­fac­tu­rer, known for their high-qua­li­ty con­su­mer pro­ducts, faced fore­casts that their cur­rent pro­duc­tion capa­bi­li­ties could not hand­le. As a result, they nee­ded to deve­lop a sys­tem that could bet­ter faci­li­ta­te part chan­geo­ver and redu­ce cycle times—all while main­tai­ning the inte­gri­ty of their pro­duct.

In addi­ti­on, the com­pa­ny was moving pro­duc­tion from Euro­pe to the US. To keep cos­ts low, the sys­tem had to accu­rate­ly assem­ble, inspect, and test their pro­duct with mini­mum ope­ra­tor sup­port.

Designing an Index­ing Dial

Dials are an effi­ci­ent way for a sin­gle ope­ra­tor to move parts through mul­ti­ple sta­ti­ons with pre­cisi­on. They occu­py a rela­tively small foot­print, and their index­ing speed allows for low cycle times.

In this case, Invo­tec lever­aged an index­ing dial to take com­pon­ents through assem­bly, inspec­tion, and tes­ting. Here’s what we kept in mind while crea­ting this solu­ti­on:

Effi­ci­en­cy: Com­pon­ents were manu­al­ly loa­ded into the fee­der bowls at four loca­ti­ons, allowing a sin­gle ope­ra­tor to sup­ply and moni­tor mul­ti­ple parts.

Qua­li­ty: The bowls fed tes­ting sta­ti­ons whe­re cri­ti­cal parts of the pro­duct were impact tes­ted to expo­se any weak joints pri­or to assem­bly. A visi­on inspec­tion of the impact-tes­ted pro­duct veri­fied qua­li­ty.

A hot stamp mar­ked appro­ved parts while rejec­ted parts were removed—reducing the risk of mixing the two.

Con­trol: Once assem­bled, inspec­ted, and tes­ted, the parts were injec­ted with a con­trol­led, mea­su­red amount of gre­a­se. The com­ple­ted pro­duct was then off­loa­ded to a good parts bin for ship­ment.

The over­all pro­cess requi­red only one ope­ra­tor with a 5‑second cycle time and 30 minu­te chan­geo­ver rate.

The Results

With the mul­ti-sta­ti­on assem­bly dial, the manu­fac­tu­rer was able to meet their pro­duc­tion goals while main­tai­ning the con­sis­ten­cy and qua­li­ty their pro­ducts are known for.

Pro­duc­tion was so suc­cess­ful, in fact, that the manu­fac­tu­rer later built a second sys­tem to fur­ther incre­a­se capa­ci­ty.

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