The challenge
Manual component assembly tied up 6 operators across 3 shifts. The line stopped at every break, changeover or absence — the lack of production continuity fed straight through to cost and on-time delivery.
The outcome
We designed an autonomous assembly station with a 4-position Weiss rotary table, two vibratory feeders with a quick-emptying system and Keyence vision inspection. The operator refills the containers and feeders every few hours — the machine handles the rest.
A Siemens PLC with an operator panel, an Interroll roller conveyor and Festo servo drives give the process full parameterisation and repeatability.
- Siemens PLC and operator panel
- system for loading empty containers and unloading full ones on a roller conveyor built on Interroll components
- independent zones allowing buffering and speed control
- two vibratory feeders with changeover capability, fitted with hoppers and a quick-emptying system
- automatic assembly of components in 2 variants
- 4-position Weiss rotary table
- quality control of the finished product with a Keyence vision sensor and scanner
- Festo pneumatics and servo drives for precise process parameterisation
- SCHUNK grippers and compensation modules
- Balluff optoelectronic sensors and IO-Link signal islands
- IGUS cable guides
A few numbers that sum this project up:
- Communication protocols
- 2 (PROFINET, IO-Link)
- Servo drives
- 4
- Pneumatic actuators/grippers
- 37
- Digital / analogue signals
- 234 / 2
- Manufacturing drawings
- 408
Results of the implementation
- 4h of autonomous operation with no human involvement
- Replaces the work of 6 operators/day across a 3-shift pattern
- Repeatable assembly and no more component damage
- 100% quality inspection of every product
- 2 vibratory feeders with quick changeover between components
- Automatic packing into a container with a logistics label
- Automatic rejection and sorting of NOK parts into an enclosed space
- Lower risk of operator error
„By removing the operator’s influence on the assembly of such small, precise parts, we minimised the risk of damage and errors that are hard to detect. The process is repeatable, and the station delivers very high throughput while maintaining full quality control."
- automotive manufacturer (ATIV client)
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Industrial automation projects - ATIV technical documentation
We document how the automation projects we deliver for clients across industry actually ran. Each description covers the technical challenge, the hardware and software used, the stages of the work and the measurable results of the implementation - shorter cycle time, fewer rejects, higher output per shift or better process repeatability.
We deliver projects for the automotive (IATF 16949), FMCG, aerospace (AS9100), electronics and medical (ISO 13485) sectors. Experience with industry standards translates into machines that meet audit requirements and are straightforward for a client's quality department to validate.
Full project documentation - technical drawings, electrical diagrams, the PLC program, the operating manual and the validation report - is supplied as standard with every implementation. Get in touch to receive reference material matched to your industry.