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Faced with challenges of rate, quality, and safety, an automotive parts manufacturer specializing in snowmobile clutches undertook an ambitious automation project.
The objective was to replace a fragmented and manual production line with a robotic assembly cell, thus transforming a complex process involving 10 machines and 10 operators into an autonomous solution supervised by a single person, while meeting all fixed performance targets.
Context
Our client manufactures a wide range of snowmobile clutch parts, varying in size and requiring different assemblies including several types of accessories. Before the project, assembly required a series of semi-automated workstations, each demanding the presence of an operator for a single operation. This workflow created significant constraints regarding production rate, repeatability of actions, quality, and posed safety issues related to the use of presses and moving machinery. The need to optimize the process and achieve improvement objectives was therefore pressing.
Suggested solutions
The solution involved the design and implementation of a complete assembly cell that replaced all the previous operating tables. While the client took charge of the mechanical part and 3D modeling, NEXRUN managed the engineering and design of the entire automation part. This included the strategic choice of components (sensors, actuators), the design of electrical plans, risk analysis, panel manufacturing, as well as setup and commissioning. This integrated project allowed for production optimization, moving from 10 machines and 10 operators to a single machine and a single operator to start and supervise production.
Concrete benefits
The project allowed for the achievement of all established objectives and significantly improved operational performance. The assembly time, previously measured in hours, is now 55 seconds per part, which represents a significant gain in efficiency. Automation also strengthened quality control by ensuring greater consistency and better repeatability of operations. In terms of health and safety, the reduction of risky manual tasks has decreased team exposure. Finally, the reassignment of employees to higher value-added responsibilities contributed to optimizing resource utilization and supporting the overall performance of the organization.
A proven automation solution—delivered by NEXRUN.
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