A global industrial tool and hardware manufacturer aimed to automate the process of a brushless motor for one of their power tools. They demanded an innovative solution that would enable quality consistency while reducing labor costs. They turned to Bright Machines’ software-defined automation to meet their needs.
Processes like mounting the motor control circuit board required tedious steps by human hands, including applying a sealant to the circuit board’s back and then welding it to the circuit mount. The original process also required a plug inserted every ten seconds, which was impossible to maintain in a manual operation.
The Bright Machines Microfactory handles all the essential steps: dispensing of sealant onto the back of the board, picking up the board, placing it correctly in the mount, and then welding the pieces together. By deploying a microfactory, they have created an entirely automated and virtually touchless assembly line. Demonstrating an impressive economy of scale, the new automated solution results in a 72% cost reduction, with per unit costs dipping with each subsequent shift added.
AT A GLANCE
With a microfactory at the helm, the power tool manufacturer is able to produce 510 units per hour, equating to a 17% gain in throughput compared to the previous 437 units produced by the four-person team noted earlier. Even more compelling are the dramatic cost savings. Demonstrating an impressive economy of scale, the new automated solution results in a 72% cost reduction, with per unit costs dipping with each subsequent shift added. For example, a microfactory produces sub-assemblies at $.16 per unit vs. the $.18 of the four-person team which is an 11% savings – a number that continues to get better with each shift resulting in 72% lower cost per unit when running three shifts with a microfactory.
In addition, machine learning provides a watchful eye over the entire assembly process, ensuring quality and reducing downtime waste.
This power tool manufacturer is proving that it is possible to keep up with the demands in the market. With flexible hardware and intelligent software guiding your line, efficient assembly of today’s most advanced power tools has never been easier.
- Video library: More Bright Machines Videos
- Webinar: How To Cut Production Costs of Power Tool Assembly
- Blog: Faster, Better, Cheaper: Automating Power-Tool Production with Bright Machines Microfactories
- Blog: Instant Factories
Contact us to find out how Bright Machines Microfactories can increase throughput, improve quality and lower cost in your factory.