How we improved part quality and reduced cycle time by 2/3: A robotics case study
In early 2023, our team of engineers took on an exciting challenge: to significantly improve the part quality and cycle time for a global automotive manufacturer based in Alabama, USA. By leveraging our robotics experience, a systematic approach to problem-solving, and tailored staff training, we transformed their production line in just a few months.
Here’s how we did it.
Client challenges: Meeting expectations with a new technology
The client, a Tier 1 automotive manufacturer, had just launched a project to produce parts for a fully electric vehicle. However, after investing in a new production machine, they encountered multiple problems. The production line, which was supposed to output 20 parts per hour, was affected by frequent downtimes, slow robot movements, and poor part quality.
The machine fell short of their expectations, leading to inefficiencies and frustration. Robots weren’t performing as required, causing delays, and the produced parts didn’t meet quality standards. The client asked our team to step in, fix the issues, and optimize their system.
Our mission: Improve quality and speed while training their team
The client’s main objectives were clear:
- Enhance the quality of the electric vehicle battery system parts to meet industry standards
- Optimize the production line to reduce cycle time and increase production speed
- Provide training to their staff so they can manage, operate, and maintain the system independently
With these goals in mind, we set out to assess the situation and find the best solutions.
First things first: Understanding the technology and identifying key issues
Before diving into technical fixes, we started with a comprehensive assessment of the production line. The existing system included MIG welding for aluminum parts, adhesive application for sealing, and automated component handling. Our analysis revealed several inefficiencies:
- Poor adhesive application, leading to compromised part integrity.
- Misaligned robot movements, causing delays and inconsistency.
- Improper welding parameters, affecting the overall quality of the parts.
From here, we pinpointed the key areas for improvement and got to work.
Step 1: Improving the quality of parts and processes
We made significant improvements to enhance part quality and optimize the production line:
- Adhesive Application: We improved the precision of adhesive dispensing, fixed inconsistencies in mixing ratios, and synchronized robot movements with adhesive application to ensure consistent quality.
- Robot Movements: Adjustments were made to improve the robots’ speed, distance, and synchronization, which reduced errors in handling and processing parts.
- Positioning and Grippers: We fine-tuned positioning tables, replaced worn-out parts, and adjusted clamps to ensure consistent part alignment during production.
- Welding Process: Welding parameters were optimized for better penetration and uniformity. We also enhanced wire and gas feed systems and implemented a cleaning routine for welding nozzles to maintain efficiency.
Step 2: Speeding up production—cycle time optimization
Reducing cycle time was another critical task. The original system was only producing 7 parts per hour, far below the client’s target of 20.
Here’s how we optimized the production line for speed:
Detailed System Analysis
We started by evaluating the entire production line, focusing on cycle time at each station. This helped us identify bottlenecks, such as:
- Frequent robot stoppages during part handling
- Equipment failures caused by poor maintenance
- Communication errors between the robots and PLC (Programmable Logic Controllers)
- Unnecessary robot movements and inefficient speed settings
Optimizing robot movements
One of the biggest issues was excessive and inefficient robot movements. We used simulation tools to streamline their paths, eliminating redundant actions and speeding up critical tasks.
Improving algorithms and control programs
We also improved the control software. New algorithms were introduced to manage robot movements more effectively, allowing for parallel processing between stations and boosting overall efficiency.
Enhancing workplace ergonomics
We upgraded the 5S methodology to improve workspace organization and efficiency. The layout of manual stations was optimized for better accessibility and operator comfort, leading to smoother workflows.
Preventive maintenance plan
We developed a preventive maintenance plan with regular inspections, component replacements, and scheduled maintenance, aimed at reducing downtime and extending the lifespan of equipment.
Step 3: Training the client’s workforce for long-term success
Improving the production line wasn’t enough; we needed to ensure the client could maintain the system effectively. We provided extensive training for their teams to equip them with the skills necessary to manage the optimized production line.
Training for the automation team
The client’s automation team received advanced training in PLC programming, focusing on the new algorithms we implemented. They also completed both basic and advanced ABB robot programming courses and learned how to use simulation tools to test future adjustments without disrupting operations.
Maintenance team training
We trained the maintenance team in preventive maintenance techniques, including routine inspections, cleaning, and the replacement of critical components. The team was introduced to advanced diagnostic tools with an emphasis on early detection. This training allowed them to recognize early warning signs of equipment failure and keep the system running smoothly.
Operator training
Lastly, we provided operators with 5S methodology training to maintain an organized workspace and follow standardized procedures for consistent quality. We also taught team leaders basic maintenance skills so they could handle minor issues without waiting for the maintenance team.
The results: Huge improvements in just 4 months
After four months of implementing these changes, the client saw these improvements:
- The scrap rate decreased from 28% to 2%, thanks to improved part positioning, welding techniques, and adhesive application.
- Production rate increased from 7 to 22 parts per hour through optimized robot movements, cycle time analysis, and efficient algorithms.
- Downtime was reduced from 3 hours to 15 minutes per shift, due to preventive maintenance and process optimizations
- Equipment error resolution time dropped from 60 minutes to 10 minutes, thanks to targeted maintenance team training and improved system diagnostics.
Conclusion: Transforming a struggling production line into a high-performing system
Through a combination of technical expertise, strategic planning, and hands-on training, our team turned a struggling production line into a high-performing system. The key was our holistic approach: we didn’t just fix technical problems but also empowered the client’s team to maintain the system moving forward.
If you’re facing challenges with your production line, reach out to us. Our tailored solutions could make all the difference.