PROJECT SPOTLIGHT

Automated Assembly Line with AGVs

Project summary

MWES built a complete row unit assembly line system that utilizes AGVs for an agriculture equipment supplier.

The Challenge

Our customer contacted us to build an assembly line for a new product with world-class operator ergonomics that increases assembly efficiency while delivering comprehensive quality tracking. The goals of the project were to increase the throughput with fewer operators, without causing additional physical stress.

Cycle time analysis, pre-build testing, and evaluations of various material handling techniques were reviewed. The pros and cons for various paths were reviewed with the customer and eventually led us to the AGVs.

The Solution

After a full evaluation of the project’s challenges and goals, Midwest Engineered Systems provided the customer with a complete assembly solution, which included:

  • Jervis Webb Smart Cart AGV System – 12 smart cart systems support parts on each unit and automatically travel from station to station. The carts adjust in height between stations based on the height of the next operator and the work zone of the assembly. The carts are set to travel on magnetic tape and are equipped with safety scanners. Each of these carts is also equipped with a “lazy Susan” like device that allows the part to be accessed from all sides without the operator moving
  • GCI Load Balancing Manipulators –  This feature cancels out the weight of the torque reaction arm or the manipulator arm making vertical control intuitive
  • Atlas Copco Torque Tools – monitoring and control of tightening operations performed using electric assembly tools
  • SCHMIDT Presses – torque motors are used for fast and precise movement and positioning tasks and make high forces possible
  • Loading Station – Heavy part loading station with a supermarket-based loading of subcomponents
  • Assembly Stations – Lift-assist mechanism for torque tools with angle versus distance feedback for quality control
  • Operator Hand Tool Stations – Programmable tool stations verify the operator assembly sequence when the tool is removed from the cradle
  • Part Unload Station – Quality checkpoint with large operator assist
  • Controls System – PLC-based control infrastructure controls the motion and path of the cart while verifying the correct assembly sequence and fastener torque control for each assembly
  • Safety Features – Operator push buttons, control system interface, safety interface, integration with AGV Smart Cart system. Safety system engineered with factory safety coordinator reference ISO standards and Factory Mutual for the safest working environment
  • Process Testing and Installation – All equipment was set up in the MWES facility for production trial runs and testing before installation. Final runoff testing was conducted at the customer’s site to ensure the system met all requirements

Impact to the Customer

The final assembly line system provided the customer with several benefits. Those benefits include an increased production rate, a 50% labor reduction, increased quality and consistency of the finished products, and the Muri, Muda, and Mura standards for ergonomic and wasted motion implementation. This all culminates into an intuitive and logical assembly process that reduces training time and process verification ensures a quality assembly every time.

Midwest Engineered Systems has a wide range of experience in building assembly lines utilizing AGVs. If you’re looking to improve your assembly line throughput, we have the knowledge and experience to make the project a success.

Contact us to learn how Midwest Engineered Systems can automate even your most complex and challenging operations today!

Innovation Through Automation

Related Projects

Automated Assembly & Testing Production Line

MWES provided this firm with a robotically automated...

Automated Assembly Line with AGVs

MWES built a complete row unit assembly system for...

Automated Cheese Cubing Machine

A leading national cheese supplier had existing machines...

Automated Knurling Machine

MWES integrated a turn-key fully robotic automation...

Bottle & Trigger Assembly Line

MWES provided a trigger and bottle assembly system...

Clutch Ball & Ramp Assembly Machine

MWES provided this firm with a semi-automated assembly...

Connecting Rod Assembly System

PROJECT SPOTLIGHT Home Recent Projects Connecting...

Consumer Electronics Robotic Assembly System

MWES designed and integrated a robot assembly system...

Cut & Punch Automation Machine

MWES provided this firm with a high-volume, next-generation...

Engine Block Liner Insert Automation

MWES integrated a robotic oven tending and engine assembly...

Engine Component Robotic Assembly System

MWES provided this firm with a robot work cell that...

Engine Cooler Assembly & Leak Test Automation

MWES provided this firm with a robotic automation system...

Flower Pot Edge Rolling Machine

A firm came to MWES looking to improve its plastic...

Hydraulic Motor Assembly Line

Building a single hydraulic motor production line that...

Large Component Precision Assembly System

When there needs to be heavy things accurately positioned...