Sub Assembly 'No Faults Forward'

The Opportunity

Our automotive IP / consoles customer has a very wide range of small assemblies, that together form full instrument panels and consoles for an automotive OEM.

A critical part of the assembly process is a 'No Faults Forward' methodology. When a single missing part can cause customer plant rejections - it is imperative that each assembly is right first time!

The huge variety of designs within the vehicle generates a massive amount of potential for failure of the process so it is essential that they are stopped at source and prevented from escaping the assembly process.

The Solution

Using a standard bench format, in a range of sizes, we design and manufacture NFF sub assembly systems equipped with Torque driver(s), process control HMI assemblies, bar code scanners, sensor IO, bar code printers and a variety of materials and techniques to engineer a process that cannot allow a faulty part to escape.

Part sensing, clamp engaged sensing, DC tooling feedback is used to control the assembly process at each step - with the process moving forward only upon receipt of an appropriate sensor confirmation, synchronised with operator instructions via the assembly process. 

The examples below use a Desoutter Infinity HMI for process control and monitoring of IO via ethernet from the remote panel, which is fully integrated into the customer plant for traceability. The result is a fully Poka-Yoke'd assembly process, to survive the rigours of 24/7 use.

The Benefits

• Lower operating costs
• Improved worker safety
• Reduced factory lead times
• Ability to be more competitive
• Increased production output
• Consistent and improved part production and quality
• Optimal utilization of floor space
• Easy integration
• Maximized labour
• 24/7 non stop production with minimal maintenance