Automated Assembly Platform: Capacity for More Than 250 Part Numbers in a Single System

Industry: Manufacturing

Summary

The client faced the challenge of producing a large number of part numbers using varied processes, resulting in operational complexity, lengthy changeover times, and limitations in production capacity.
CIP developed a highly flexible assembly machine designed to integrate and automate multiple operations within a single platform, enabling it to process more than 250 part numbers with accuracy and efficiency.

The solution optimizes the production flow, reduces manual interventions, and standardizes critical operations, allowing the customer to increase capacity, improve delivery times, and respond more quickly to the demand for their product portfolio.

Initial Situation

The customer operated multiple manual and semi-automated assembly processes for a wide variety of part numbers.
Managing more than 250 variants involved constant adjustments, tool changes, reconfigurations, and high operator dependence.
Production was limited by long changeover times, errors due to human variability, and a lack of standardization.
The client needed to increase their production capacity without multiplying stations or significantly increasing staff.

Challenge

High operational complexity due to the large number of part numbers and different processes.
Low productivity due to long setup times and constant adjustments between variants.
Variability in quality, caused by manual operations and differences between operators.
Difficulty in scaling up, since each new part number required modifying existing processes.
Absence of a flexible system that could handle multiple products without high reconfiguration costs.

Solution

Development of a highly flexible automated platform, designed to produce more than 250 part numbers on a single machine.
Implementation of interchangeable modules, servomotors, sensors, verification systems and configurable tools.
Design of adaptable fixtures and smart stations that allow product changes without complex adjustments.
Centralized control via PLC/HMI with configurable recipes for each part number.
Standardization of the assembly flow in a single architecture that integrates the different required processes.

Results

Significant increase in production capacity, by unifying multiple processes on a single efficient platform.
Drastically reduced changeover time, allowing for quick transitions between part numbers.
Quality improvement, by eliminating human variability and applying automated parameters for each recipe.
Real scalability, allowing the incorporation of new part numbers without redesigning the entire line.
Standardized and repeatable process, facilitating training, operation and maintenance.
Optimization of space and resources, avoiding multiple dedicated workstations for each variant.

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