The Challenge
Reducing Manual Labor in High-Volume Assembly Without Full Automation
The manufacturer faced a labor-intensive, repetitive flywheel assembly process requiring precise force verification. Their objectives included:
- Improving consistency in race insertion and assembly
- Verifying press operations with force monitoring
- Allowing a human operator to run the cell efficiently without full automation
- Maximizing throughput with a simple, semi-automated machine
MWES was selected to deliver a semi-automated custom press cell that would lift manual burden while retaining operator involvement.
The Solution
Compact Infeed Conveyor Press Cell with Promess Force Monitoring
MWES engineered a turn-key press assembly machine featuring:
- An infeed two-strand chain conveyor integrated into the parts washer conveyor for flywheel presentation
- Automatic centering and locating to align the assembly for pressing
- Hydraulic press equipped with a Promess force-monitoring system for press verification
- Part-flipping station for unloading the assembled components
- Operator responsibility limited to installing the load-bearing race and removing the finished flywheel
This semi-automated cell streamlines flywheel assembly by blending automated locating, force-verified pressing, and manual handling into a compact, reliable process.
The Results
Consistent Assembly at 50‑Second Cycles with Minimal Rework
The MWES press machine delivered measurable operational improvements:
- Consistent 50-second or faster cycle time per part
- Elimination of pressing inconsistencies via force verification
- Reduced rework and improved assembly quality
- Compact system requiring only light operator supervision
By integrating precise press monitoring into a semi-automated cell, MWES helped the manufacturer improve assembly stabilization, throughput, and labor efficiency.
