The Challenge
Multiple Manual Assembly Steps Reduced Through Automation
The customer needed a high-speed assembly system to move molded parts through spin welding, limiter installation, leak testing, inspection, and unloading—all while reducing labor and ensuring consistent quality.
- Spin-weld ports onto injection molded bodies reliably
- Install multiple brass compression limiters per part
- Perform leak testing to guarantee pressure integrity
- Integrate vision-based inspections to detect assembly defects
- Maintain future flexibility with expansion capability
MWES was chosen for its ability to combine multiple assembly operations into one cohesive, high-efficiency system.
The Solution
Robotic Assembly System with Smart Material Handling & In-Line Inspection
MWES delivered a modular assembly line incorporating automated material handling (via smart carts), robotic welding, compression limiter installation, automated testing, and quality inspection—all controlled through intuitive PLC logic and safety systems.
- Robotic dunnage unload using 2D vision and re-grip stands for precise part positioning
- Spin welding station for attachment of ports to base components
- Pallet load/unload stations to shuttle assemblies through the line
- Gantry robot install of four compression limiters per part
- Integrated leak testing and laser marking to validate pressure integrity and traceability
- Vision inspection station for checking assembly correctness and identifying defects
- Reject/unload logic to divert nonconforming parts via robot unloading
The layout supports near “lights-out” operation and allows future expansion without re-engineering.
The Results
Streamlined Assembly, Fraud-Proof Quality & Expanded Capacity
The implemented system produced quantifiable improvements in throughput, quality, and operational efficiency—even with minimal staffing.
- Enabled sub-35 second cycle times per part
- Reduced labor needs dramatically while maintaining process reliability
- Enhanced part quality and reduced defect rates through dual inspection steps
- Designed with future flexibility in mind to support additional operations and expansion
This fully integrated assembly line demonstrates MWES’s ability to blend robotics, vision, testing, and production logistics into a high-performance system.
