The Challenge
Labor Constraints and High Part Variety Across Multiple Finishing Stages
This foundry faced workforce limitations and a production backlog due to skilled labor shortages. The project required:
- Handling up to 30 different casting variants with flexible tooling
- Integrating multiple finishing processes, including grinding, cutting, and inspection
- Consolidating operations into a single, hands-off production line
- Enabling a minimal staff member to manage end-to-end finishing
MWES was brought in to design a system that could replace a labor-intensive, high-mix manual workflow with a scalable automated solution.
The Solution
Multi-Robot Production Line with Versatile Tooling and Automated Flow
MWES engineered a full finishing line using 18 Fanuc industrial robots and custom clamping systems capable of accommodating varied casting geometries with one set of tooling:
- Seven robotic finishing stations designed for grinding, cutting, or deburring
- Universal fixturing to support all part variants without tooling swaps
- Scrap conveyor and skid-based automation to manage byproduct and finished parts
- End-of-line human inspection and skid loading station for final quality control and packaging
This system enables a single operator to oversee both the automated finishing and downstream material handling. The modular design accurately handles each unique casting, allowing seamless transitions between part types.
The Results
Dramatically Reduced Labor with Consistent, High-Speed Finishing
The MWES solution transformed casting finishing metrics across the board:
- Average cycle time: 36 seconds per part
- One operator now handles tasks previously requiring a larger crew
- Maintained process consistency across varied parts with minimal changeover
- Built-in scrap recovery and skid handling improved operational flow and OEE
By consolidating disparate operations into a cohesive, automated system, the customer gained higher throughput, consistent quality, reduced working hours, and improved overall equipment effectiveness.
