Automation of terminal insertion lines in the automotive industry

Industry: Manufacturing

Summary

In HVIL terminal assembly processes, manual intervention often limits production speed, generates variability, and hinders traceability. The implementation of an automated insertion and verification system developed by CIP completely transformed process performance: production increased by 50%, quality was strengthened through servo-based controls and automated inspections, and the workflow was optimized with defined input and output.

Today, each approved part is marked and registered, providing complete traceability and a robust, repeatable process aligned with automotive industry standards.

Initial Situation

The quality of the assembly varied due to differences in skill, strength, and inspection criteria among each operator.
Cycle times were unstable, which created bottlenecks in the production line.
Customer demand was increasing, requiring greater capacity and a more repeatable and controlled process.

Challenge

Inability to meet required volumes due to high variability in the manual process.
Quality defects due to incomplete insertions, deformations, or misaligned terminals.
Lack of a system that would guarantee traceability and evidence of compliance with critical parameters.
Absence of functional controls that would adequately verify the quality before releasing the product.
Risk of non-conforming shipments that impacted costs, rework, and reputation.

Solution

Integration of an automated machine for the precise insertion of HVIL terminals using servomotors, force and position control.
Incorporation of automatic inspection systems that validate presence, height, alignment and correct insertion.
Implementation of a standardized process input and output flow to improve organization and efficiency.
Development of a traceability system by marking, ensuring that each approved piece is marked as evidence of the process.
Design of a flexible and safe architecture that reduces operator intervention and eliminates human variability.

Results

50% increase in production capacity, eliminating bottlenecks and stabilizing cycle time.
Significant improvement in quality, thanks to automated inspection that eliminates errors associated with visual judgment.
Full process traceability, allowing end customers to validate critical parameters of each assembly.
Reduction of scrap and rework by detecting any deviation early.
Greater safety and ergonomics, reducing manual handling of parts and tools.
Repeatable, robust and scalable process, aligned with automotive industry standards.

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