The Challenge
High-Speed Water Outlet Assembly With Error-Free Leak Testing
Manual part handling and inspection introduced inefficiencies and variability into the production process. The customer needed a robust automated solution to::
- Maintain consistent quality at high production volumes
- Automate spin weld assembly and limiter installation
- Perform real-time leak detection and visual inspection
- Automatically sort failed parts and pack good parts efficiently
MWES was chosen for its expertise in high-speed robotic automation for injection-molded components and precision assembly environments.
The Solution
Integrated Robotic Cell for Assembly, Testing, and Final Packing
MWES engineered a fully automated robotic system that combines part handling, welding, inspection, leak testing, and packing into a continuous, hands-free line.
- Fanuc M710ic/20L robot with dual end-of-arm tooling for part handling and layer packaging
- 2D vision inspection camera to validate degating and post-weld blacklight tests
- Spin weld station for assembling housings and inserting limiters
- Pneumatic port-probe system for automated leak detection via shuttle stations
- Automated reject logic: failed parts diverted, good parts stacked and bagged into Gaylords
- Dual-layer box packing with pad separation for part protection
This integrated solution eliminated manual intervention from start to finish, ensuring a reliable and repeatable production process.
The Results
Fully Automated, 25-Second Cycle with Single-Operator Oversight
The automated cell delivered these operational benefits:
- Achieved consistent 25-second cycle time per part, running three shifts per day
- Consolidated full assembly, leak testing, and packing from unassembled parts
- Required only one operator to load parts and monitor system flow
- Improved throughput, reduced defects, and minimized labor costs
By combining robot-driven assembly, integrated inspection, quality testing, and layer-based packing, MWES enabled enabled scalable, high-speed water outlet production with minimal labor involvement and high product reliability.
