The assembly and inspection line used to produce front and rear media hubs was manual and labor-intensive. The process required eight human touch points, which limited units produced per hour and consistently resulted in high defect rates. With a flexible Bright Machines Microfactory the assembly became faster and dramatically improved yield.
Components of these media hubs are very small and require tremendous accuracy to perform insertion without damaging the product. In the best case, those defects are caught in the inspection and the component is discarded, but on this line, it was also possible that defective product could make its way onto the car lot and eventually customer’s driveway, resulting in expensive warranty costs and, worse, lost trust between the car company and customer.
The Bright Machines Microfactory completes assembly and inspection of two different models on the same line, thanks to lightning-fast change-over. For this product, some of the insertion needed to happen at specific angles to avoid damaging components, and this level of specificity and precision is a specialty of the microfactory. While pick-and-place sounds like a simple task to automate, in reality, it requires precise rotation and positioning of the robot arms while also changing speeds from fast to slow. Precise programming ensures that the end-of-arm tools are hitting the right angles every time, at the right speed, and in a perfectly repeatable way.
AT A GLANCE
This microfactory solved the issue of high defect rates, which were an ongoing financial drain for the manufacturer, while also increasing output of the media hubs. The microfactory effectively eliminates the need for human touches on the assembly and inspection line, further driving cost down while production and quality increase. The microfactory has resulted in meaningful changes to the line’s efficiency, including:
- Productivity increased by 60%
- Units per hour increased by 40%
For more information, check out:
- Product Page: Bright Machines Microfactories
- Video: Microfactories: Explained
- Video library: More Bright Machines Videos
- Webinar: EMS 2.0: How To Remain Competitive in Electronics Manufacturing
- Blog: Got Back-End Blues?
- Blog: Instant Factories
- Blog: Auto Industry Takes Moore’s Law for a Drive
- Blog: BMW i Ventures Joins the Bright Machines Journey
- Blog: EMS 2.0: What’s Next for Electronics Manufacturing
Contact us to find out how Bright Machines Microfactories can boost production and reduce defect rates in your factory.