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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.
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.
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.
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.