Batch to Single Piece Flow Cell

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Many times, it is much easier to make the case to transition to a progressive assembly program with a higher volume. For this low volume product, the changeover was justified by creating a universal fixture for mixed model production. Secondary but equally important qualifiers were job safety and ergonomics. These concerns were the driving forces in the decision to create a single flow piece, straight-line cell with online test for a mature product family with projected growth.

Plan
The first hurdle to be cleared was creating fixture for a 60-pound product that was both a manipulator and holder and could be used by multiple models thereby insuring a quick return on investment. This was achieved with a robust trunion that featured multiple parts cradles to assist the assemblers in mounting the part to the fixture. To further simplify assembly, the entire fixture and product could also be rotated in a vertical axis by activating a pneumatic lock. Each cart was also locked at a station with a pneumatic cylinder, which combined with a captive track tube, secured the unit in place for safe high torqueing of fasteners.

An additional requirement was a safe, online, high pressure, testing station. This was accommodated with a hinged impact resistant, polycarbonate exclosure. Any potential units for rework could be removed from the flow by a combination of an inline turnstyle with a rework cart, thereby eliminating lifting.
Each station was equipped with a tool trolley for overhead pneumatic tools, a shelf for tool shadow boards, a flat panel monitor display and overhead lighting. A worksurface with a lower shelf for quick cradle fixture storage was also incorporated to assist the assemblers.

The previously mentioned rework cart also had a dual function, it was also used to transport empty fixture carts to the head of the line.

To deliver a turnkey cell, the line was shipped door to door, in two plug together pieces, for same day production capability. (still photos)

The end result: a custom and ergonomic lean assembly and test cell that included many enhancements for improved efficiencies.
How can Worksmart Systems assist your team? Contact us at [email protected] or 978-356-5000.