The Challenge
Modernizing a Complex and Inefficient Testing Conveyor System
The customer faced mounting inefficiencies and throughput limitations due to an overly complex material handling and testing system. Their objectives included:
- Automating the testing and material handling for over 300 refrigerator units
- Reducing the number of accumulation conveyors without sacrificing throughput
- Integrating RFID to link test results to individual serial numbers
- Capturing real-time test data using wireless technology
MWES was selected for its ability to design and control large-scale, data-driven production systems tailored to complex assembly environments.
The Solution
RFID-Driven Conveyor System with In-Motion Testing and SCADA Integration
MWES engineered a smart, scalable solution that achieved all project requirements while supporting future product expansion. Key system features included:
- Mobile electrification and Zigbee wireless to enable in-motion testing of over 300 units
- Distributed I/O architecture (ASI Bus) controlling 1,200 conveyor zones and 8,000 I/O points
- Wireless RFID technology for real-time part tracking and data capture
- Powered chain-driven live roller conveyors for quiet, modular material flow
- SCADA system for distributed process monitoring and centralized control
- Chain conveyor transfers and three high-speed transfer cars replacing 24 traditional transfers
The result was a leaner, quieter, and more efficient assembly and testing system with seamless data connectivity and minimal operator involvement.
The Results
82-Second Production Rate and Seamless, Scalable Testing Automation
The MWES system delivered transformative improvements in production throughput, traceability, and floor efficiency:
- Enabled simultaneous in-motion testing of 300+ refrigerators
- Achieved a production rate of one tested unit every 82 seconds
- Reduced operator interaction while increasing reliability of data tracking
- Minimized noise and footprint with quiet, flexible conveyor design
This automation project streamlined the customer’s end-of-line process, empowered full data accountability via RFID, and built a scalable foundation for future product lines.
