Southeast

6 Cylinder Aluminum Head Cell

Featured Equipment:  
Industry:  Automotive, Consumer Goods, Commercial
Machine Type / Process:  Robotic Automation, Set-up Reduction
Challenge

The customer wanted their new block machining line to be completely automated in order to increase production throughput and eliminate ergonomic issues associated with manual loading. The large system had a timeline of 18 weeks to order, ship, and automate 18 Horizontal Machining Centers.

Assessment

Given a blank slate,  the skillful team of engineers and staff at Ellison Technologies Automation had to develop the most cost effective layout to fit the customer’s facility and production levels. In addition to machining the blocks, ET Automation created an efficient part making and barcode reading process to track the products throughout the entire manufacturing procedure. They then integrated it with third party vendors on the parts washer and leak testing equipment.

Solution

ET Automation’s exceptional team of engineers developed a solution that combines efficiency with production. This automated solution utilizes The FANUC Robotics R-2000iB/165F & M-710iC/50 robots. These FANUC Robotics models were chosen because of their payload and reach, their handle on part transfers, and their load/unload capabilities using dual grippers, which reduces the time required at an individual station. Other components of the automated cell include an inbound/outbound conveyor system, pin stampers, and Ellison Technologies Automation’s cell controller and safety system.

End Result

Switching to an automation cell reduced the amount of manual labor and increased throughput production. The customer’s challenge was solved with integrated part making, barcode reading, and by giving the customer access to work with third party vendors. The large, multi-process is ergonomically designed, giving the operators a healthier and safer environment. In addition, this automation cell now gives the customer a continuous process that does not require intense manual labor for its operators.

Before:

Intense manual labor
Average throughput
Difficult process

 
After:

Integrated with different parts
Increased throughput
Simplified, ergonomic process