Automotive industry production line automation

Industry: Manufacturing

Summary

In traditional assembly processes, multiple operators working on individual presses generate variability, excessive material handling, and loss of efficiency. An environment where every deviation directly impacts quality, lead times, and production capacity.

The MPP – Modular Pick and Place system, developed by CIP, emerges as a standardized and versatile solution that transforms these processes, allowing the customer to operate with greater productivity, stability, and flexibility to manufacture different products without complexity or extensive changeover times.

Initial Situation

The client operated multiple manual stations with individual presses for the assembly of different products.
Each part number required specific configurations, generating downtime and low standardization.
Constant material handling and human intervention affected process stability and quality levels.
Growing demand required a more efficient and flexible platform.

Challenge

Low productivity levels due to variable cycle times between operators.
High probability of errors due to manual handling, increasing scrap and rework.
Complexity in introducing new part numbers due to the lack of a standardized quick-changeover system.
Need to reduce material handling and improve operational flow.
Lack of a scalable process to support higher production volume.

Solution

Development of the MPP, a modular automated assembly system adaptable to multiple configurations.
Design of standard pick & place modules, presses, aligners, and verification stations integrated into a single platform.
Implementation of adjustable and easy-to-interchange fixtures to allow quick changeovers between products.
PLC programming and control standard to ensure repeatability and intuitive operation.
Reduction in material handling through automated flow and process-aligned stations.

Results

Significant increase in productivity, reducing cycle times and stabilizing the operation.
Substantial improvement in quality by eliminating human variability and standardizing assembly conditions.
Reduction in material handling, decreasing errors, downtime, and rework.
Greater flexibility, allowing the production of various numbers of parts with a simple input and without technical complexity.
Scalable and sustainable process, capable of adapting to customer growth and new market requirements.

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