Industry: Home Appliance
Material Handled: Cupboards, wardrobes, kitchen cabinets, loose furniture, safes
Product Category:
Activity to be Mechanized/Automated::
- Assemble child parts into main units (cupboards, kitchen items, wardrobes) with optimized takt time and efficiency.
- Ensure quality in assembly and packing while integrating data capturing with WMS & SAP.
- Minimize time and manual effort in assembly and packing operations, maintaining the production sequence.
- Connect processes between painting and production warehousing.
This innovative automation system revolutionizes home appliance manufacturing by integrating pallet-based assembly processes with advanced controls, ensuring safety, efficiency, and seamless operations across painting, assembly, and warehousing.
Challenges vs Solutions
| Challenges | Solutions |
|---|---|
|
Proven heavy-duty slat conveyor systems involved deep pits, unsafe operations, and uncertain cupboard transfers |
Pallet-Based Carousel System to enable safe and efficient assembly operations in a continuous loop. |
|
Difficulty in conveying furniture components and reliance on unreliable technologies. |
Low Floor Power Roller Conveyors with platforms, ensuring stability and minimal dependency on complex technologies. |
|
Complex assembly processes requiring high precision and alignment with production sequence. |
Low Floor Turn Tables with safety guarding for seamless directional changes within a loop system. |
|
Ensuring operator safety and equipment reliability with no redundancy allowed. |
Scissor Tables for manual lifting from overhead conveyors and Overhead Suction-Based Pick and Place Systems for safe component handling. |
|
Managing cost control amid frequent design and specification changes. |
PLC & IPC-Based Control Panels for streamlined integration with WMS and SAP systems, minimizing rework and inefficiencies |
Results / Benefits:
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Cost Effective: Achieves ROI within 1 year, ensuring the lowest cost of ownership.
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Increased Efficiency: New pallet carousel system significantly reduces assembly time and aligns with production takt time.
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Energy Saving: IE 3+ motors with energy-efficient, torque-optimized transmission systems.
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Low Capital Investment: Leveraging proven technologies and components reduces upfront costs.
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24x7x365 Running Capacity: Maintenance-friendly designs ensure minimal downtime and uninterrupted operation.
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High Productivity: Simplified yet robust technology enhances operational reliability and capacity utilization.