Special-purpose and target machine manufacturing case studies

Motor Controller Connector Sorting Machine

  • Produces 3 million units annually using JIGs without testing

  • Performs 200% sorting manually without testing equipment, relying on workers

  • The component consists of 9 parts, with multiple versions of each component

  • High production volume

  • High number of potential errors

  • Real risk of component mixing

  • Idea of special-purpose machine manufacturing arose

  • Semi-automatic sorting equipment

  • 20-piece buffer on both the input and output sides, synchronizing the work of the machine and the operator. Testing can continue uninterrupted for approximately 80 seconds while the operator handles new boxes or packaging.

  • Products should be placed on the input conveyor as they are taken from the box by the operator → no need for rotation

  • Products should come out on the output conveyor as they need to be packed in the box → no need for rotation

  • Planned 4-second cycle time

  • The operator only performs loading, unloading, and packaging

  • Poka-yoke for input and output

  • Continuous parallel work between the operator and the machine

  • Operator requirement for the machine: 1 person

  • Separate handling of final rejects and repairable rejects

  • Error statistics

  • Quantity reporting to central system

  • Inspection performed by 2 Keyence cameras

  • Entire product range inspected at 113 point

  • 3.6-second cycle time instead of 12 seconds

  • Freed up 12 sorting operators, now only 1 person operates the machine

  • 0 customer complaints in 3 years of operation

  • Payback in 5 months

  • Special-purpose machine manufacturing completed in 22 weeks

  • Cycle time

    Buffers on input and output sides

    Minimizing operator’s work by ensuring parts do not need to be rotated when placed into the machine; they enter as they are in the box and are rotated for packaging as needed → the operator can place or remove 2-3-4 products simultaneously from the conveyor

    We were the only supplier to suggest the concept of repairable rejects, thus reducing in-process waste

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Audi Sunshade Holder Bracket Sorting Machine

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  • Produces 1 million units annually using press and manual assembly without testing

  • Performs 200% sorting manually without testing equipment, relying on workers

  • The component consists of 5 parts, with 1 fixed ring

  • The product can be assembled with two types of springs, which must not be interchanged

  • There are 7 different colors, some of which are very similar in shades

  • High production volume

  • High number of potential errors

  • Real risk of component mixing or omission after assembly

  • Semi-automatic sorting equipment

  • Products should enter the input track in the same orientation as required for the testing position, with a poke-yoke feature at the input opening

  • A camera inspects the presence and type of the spring

  • Three precision color sensors check the color and shade of three plastic components

  • Good products are collected in a box below the machine

  • When the number of good products in the box reaches the packaging unit, the machine notifies the operator, who must acknowledge the information

  • Defective products are collected in a lockable reject box

  • Planned 4-second cycle time

  • The operator only performs loading and packaging

  • Poka-yoke for loading

  • Continuous parallel work between the operator and the machine

  • Operator requirement for the machine: 1 person

  • Error statistics

  • Quantity reporting to the central system

  • The entire product range is inspected at 47 points

  • 2.8-second cycle time instead of 10 seconds

  • Freed up 4 sorting operators, now only 1 person operates the machine

  • 0 customer complaints in 2 years of operation

  • Payback in 7 months

  • Special-purpose machine manufacturing completed in 10 weeks

  • Cycle time

  • Buffers on input and output sides

  • Minimizing operator’s work by ensuring parts do not need to be rotated when placed into the machine; they enter as they are in the box and are rotated for packaging as needed → the operator can place or remove 2-3-4 products simultaneously from the conveyor

  • We were the only supplier to suggest the concept of repairable rejects, thus reducing in-process waste

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Stirrup product assembly and testing

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  • Produces 2 million units annually using manual assembly without testing

  • Spreading the bracket and fitting it onto the housing is difficult without tools; the bracket tends to break if spread too much

  • Performs 200% sorting manually without testing equipment, relying on workers

  • The component consists of 3 parts

  • The product can be assembled with two types of brackets, which must not be interchanged, and a CPA must be installed

  • There are 6 different colors, some of which are very similar in shades

  • High production volume

  • The bracket must snap into a fixed position and cannot be installed incorrectly

  • High number of potential errors

  • Real risk of CPA omission, incorrect bracket installation, breakage, and component mixing or omission after assembly

  • The idea of special-purpose machine manufacturing arose

  • Bracket spreading JIG with guided track and semi-automatic sorting equipment

  • The operator assembles the bracket onto the housing using a poke-yoke JIG, which spreads the bracket just enough to avoid breakage or cracking

  • Products can only be placed into the input slot if the bracket is in the correct position and the housing is properly oriented

  • A Cognex camera inspects the presence of the CPA, bracket color and position, and housing color

  • A trap door prevents products from falling until they meet the good product criteria

  • Good products are collected in a box below the machine

  • When the number of good products in the box reaches the packaging unit, the machine notifies the operator, who must acknowledge the information and replace the box

  • Defects are not interpreted by the machine. If a bracket is missing or the housing color is incorrect, the operator corrects it or reports that the storage was filled with incorrect material → no in-process waste

  • Planned 4-second cycle time

  • The operator only performs loading and packaging

  • Poka-yoke for loading

  • Continuous parallel work between the operator and the machine → while the operator installs the bracket, the machine tests the previously assembled product

  • Operator requirement for the machine: 1 person

  • Error statistics

  • Quantity reporting to the central system

  • The entire product range is inspected at 21 points

  • 5-second cycle time instead of 10 seconds

  • Freed up 2 sorting operators, now only 1 person operates the machine

  • 0 customer complaints in 3 years of operation

  • Payback in 8 months

  • Special-purpose machine manufacturing completed in 12 weeks

  • Cycle time

  • Automatic packaging (the operator does not remove good products from the nest; instead, the product automaticly drop into the box)

  • Minimizing the operator’s work by ensuring parts only need to be placed into the machine, wait for testing, and no further handling

  • No in-process waste generated

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Célgépgyártás Pak Machine Kft.