ASG-Robotics is a proven innovation partner for car manufacturers and tier-one suppliers. We designed and implemented a solution for one of our clients to automate the Sealant and Anti-Noise Mastic Application (ANM) area. Design challenges included overcoming spatial constraints and avoiding disruptions to ongoing production. The project was delivered against tight deadlines and has effectively doubled our client’s productivity.

Background

Our client identified that the current organization of the Sealant and ANM area is the bottleneck for a planned 1.5- to 2-fold increase in production. To address this critical challenge, we were asked to explore the possibilities and propose a solution to upgrade the area of production to improve efficiency.

Challenges

The project had several practical challenges. The height of the production facility did not allow the use of standard overhead conveyor solutions. It was also impossible to create pits for placing equipment without interrupting the production process on the line.The decisive success factor was the non-standard solution of the site equipment. Despite the complexity of the project, we were creative and professional and provided a solution that exceeded all expectations.

Solution

We designed and built a twin precision conveyor equipped with 56 skids and rotatable cantilevers to hold car bodies, ensuring the precise application of sealant and ANM using Fanuc robots. The conveyor works in synchrony with high body positioning accuracy at the stations, eliminating the risk of misalignment and increasing the efficiency of the workflow. The bottom sealing line includes six stations: body loading, sealant, control, mastic, control, and body unloading. The total project time was 16 weeks from start of design to implementation, and factory installation was completed in two long weekends to minimize the impact on daily operations.

Results

• The automation initiative was nothing short of transformative for our client. The productivity of the targeted area increased by 100%, and improved quality through a more consistent and accurate application. Our solution also contributed to financial savings through reduced labor costs and material waste.
• This case study demonstrates ASG Robotics’ unwavering commitment to continuous improvement and innovative problem-solving, enhancing productivity at all levels of operations. Our expertise in robotic integration and customized machine building allowed us to deliver a tailored solution that met our client’s unique needs. By leveraging cutting-edge technology and precision engineering, we were able to optimize the manufacturing process and enhance productivity.
• If you’re interested in learning more about how ASG Robotics can help your organization, please get in touch. Our experience gained over the last 35 years allows us to deliver custom solutions that streamline production processes and drive efficiency. We are committed to helping our clients achieve their automation goals and drive success in their industries.