The Challenge
Manual Assembly Process Hurt Throughput and Quality Control
Assembling heavy outboard motors required extensive manual labor, creating ergonomic challenges and safety risks for workers. The existing process limited throughput and exposed employees to repetitive strain while handling large, heavy components—a persistent concern for both productivity and workplace safety. The customer needed automation to:
- Seamlessly integrate spin welding, limiter installation, and leak testing
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Maintain high accuracy in compressive installation of intake and exhaust valves
- Ensure leak integrity via inline testing and vision inspection
- Minimize manual labor while increasing production flow
They selected MWES to design a holistic, multi-operation assembly and testing line tailored to their precision and throughput goals.
The Solution
Multi-Robot Assembly Line with Integrated Spin Weld, Test & Inspection Stations
MWES designed and integrated a modernized manual assembly line featuring an oval overhead gantry system with eight suspended carriers. Each carrier includes rotating and vertically adjustable universal mounts, allowing operators to precisely position motors throughout the assembly process. A lift-assist system eliminates manual lifting, while intuitive push-button controls enable easy rotation and height adjustment at each station.
Safety was incorporated throughout the system with integrated emergency stop handles accessible at every workstation. The solution maintains human-centered assembly while significantly improving ergonomics, consistency, and process control.
The Results
Under 35-Second Cycle Time, Fewer Operators, and Traceable Quality
The updated assembly line dramatically reduced manual lifting and ergonomic strain, improving workplace safety and operator comfort. Adjustable carriers and streamlined controls increased assembly efficiency and supported consistent throughput. The customer achieved a safer, more productive process without replacing skilled labor—demonstrating how targeted automation and material handling upgrades can deliver meaningful operational improvements.
