A stamper needed to increase quality and capacity on several automotive seat component parts.
The existing manufacturing process used two older 600 ton presses and six operators.
Review of project
ATSI Robotics put together a proposal to design/supply and install automation for the client.
The new "press-line" System would advance production throughput whilst enhancing quality.
The client had pre-owned robots that they wanted to use to help reduce capital costs.
Review of solution
ATSI Robotics began on the system design work almost immediately as the client had a very tight window to complete the project.
As part of ATSI Robotics "prove it" philosophy, work had to be completed in the virtual world first.
This was necessary as the pre-owned customers robots were older and cycle time was in question.
Adding to this was the fact that the robot used an older network for communications.
ATSI Robotics also needed to produce a complete control system design using the latest offering from Allen Bradley, The 5370 guardlogix PLC.
Since this is a press-line, special consideration for safety had to be realized.
The new system had to be installed during current production runs. This made project coordination paramount.
This system had to fit into an existing layout as the press machines were massive machines that were anchored in a concrete pit which makes them extremely difficult to relocate (Major construction).
The new system had to have a huge impact on production throughput and efficiency.
The new system also had to reduce the number of touches by human operators to increase quality.
To top it off the existing process used an older press master system which was micro processor based.
This safety system which controls the press had to be "tied in" and integrated to the new ATSI PLC control system.
ATSI Robotics successfully completed the system and increased the system throughput by 60%.
ATSI robotics increased system reliability and available uptime, leading to an OEE greater than 96%.
Quality has also improved as the client has much more time to make die improvements, with robots loading the dies.
Part geometry has become more consistent without mislocations.