Automation of EOL assembly inspection machines in the automotive industry

Industry: Manufacturing

Summary

Final inspections performed solely with manual presses limited the ability to detect defects and left gaps in product validation. With the implementation of the automated End-of-Life (EOL) system developed by CIP, it became possible to integrate more than 60 inspections, laser marking controls, and comprehensive functional tests, significantly increasing process reliability.

The result: a robust, repeatable, and fully automated system that ensures assembly quality, reduces field risks, and provides the customer with a level of verification that meets the most demanding industry standards.

Initial Situation

The client performed the final inspection of products using manual presses, with limited validations dependent on the operator.
The process only allowed basic inspections, without the ability to verify critical assembly parameters.
Fault detection was visual or low-level functional, leaving a risk of non-conforming parts reaching later stages or the end customer.
Production volume and product complexity were increasing, demanding a more robust and reliable inspection method.

Challenge

High risk of quality leaks due to insufficient and subjective inspections.
Absence of a system capable of integrating multiple tests and verifications in the same cycle.
Dependence on human judgment, generating variability and potential errors.
Inability to document or trace accurate final test results.
Urgent need to comply with more demanding automotive standards in functional and structural validation.

Solution

Development of a fully automated EOL machine with more than 60 integrated inspections including mechanical, dimensional and functional.
Implementation of laser marking controls to automatically identify and trace approved parts.
Integration of advanced functional tests, guaranteeing the validity of the assembly before sending it to the end customer.
Design of dedicated fixtures and high repeatability measurement systems to ensure consistency in every test.
Automation of the entire flow: loading, inspection, validation and product exit.

Results

Total quality assurance, by eliminating human variability and establishing objective, measurable and repeatable inspections.
Significant reduction in failures and rework, thanks to the early and thorough detection of any deviation.
Trazabilidad completa, con marcado láser y registros automáticos de todas las pruebas realizadas.
Increased operational reliability, meeting automotive standards and avoiding risks of non-conformities in the field.
Scalable process, adaptable to new requirements and the incorporation of more future tests.
Greater efficiency, by integrating multiple inspections into a single system without increasing cycle times.

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