The Challenge
High Product Variety Strained Manual Assembly Capabilities
A manufacturer producing numerous hydraulic motor configurations needed a flexible assembly approach that could adapt to frequent part variation without sacrificing throughput or quality.
- Over a dozen hydraulic motor variants handled in a single line
- Manual switching between configurations increased operator errors
- Lack of in-process tracking made quality and progress monitoring difficult
- Existing process could not scale efficiently with demand
MWES was tasked with creating a manual assembly system capable of varying workflows, maintaining consistent quality, and accommodating future operational needs.
The Solution
Vision-Guided Manual Assembly with Variant-Specific Workflow Integration
MWES designed a modular manual assembly line featuring dedicated subassembly stations, integrated vision-based tracking, and flexible operator choreography.
- Discrete workstations adapt workflow per motor variant
- Vision inspection monitors assembly progress and tooling accuracy
- Station logic guides operators through variant-specific steps
- Buffering and routing manage part flow efficiently
The organized cell layout, combined with automation-grade controls, delivered a structured manual process that scales across product variants.
The Results
Process Flexibility, Quality Control & Scalable Throughput
The resulting system successfully handled high mix without automation, improving assembly reliability and throughput consistency.
- Supported assembly of 12+ motor variants on one production line
- Enhanced quality control through vision-based monitoring systems
- Reduced operator errors and assembly variability
- Enabled scalable assembly throughput aligned with product demand
MWES helped the customer retain manual capabilities while securing the flexibility and consistency typically associated with robotic systems—ideal for high-mix, low-volume production.
