Automation

Build to Print

Converting

Engineering Services

Machining Services

Case Study # 1

Filter Assembly Machine: 

The objective was to create a flexible Automated Assembly Line to manufacture a product family of high volume water filters.  The customer required an optimum production rate of 20 parts per minute.

Design Challenges:

• The new machine design must be able to accommodate new models and product line changes.  The existing assembly system, costing approximately $1,000,000, became obsolete after only 3-4 years due to a customer product change. The current machine utilized traditional automation rendering the system unable to be modified to build the new filter line.

• The products required 100% inspection for leakage and flow rate by a single machine that would fit in the allotted space. The current testing equipment required a test time of 45 seconds per filter.  Eight (8) of the current test systems would be required to meet the increased production rate.  This created issues in material handling, space and cost constraints.

• The new machine design must be reliable. The client projected 1^st year annual production of 2-3 million parts with 20-30% annual growth rate expected. In 3 years it was estimated the machine would have accumulated 12-14 million cycles.

• The machine had to be simple to operate.  The customer’s primary workforce was supplied by a temporary staffing agency and many workers had limited English reading and language skills.

Summit’s Solution:

We felt the best solution would be an integrated machine -- one that would assemble and test each piece. First, we needed to prove that by developing a new new leak-flow testing process. To validate our concept for the new process and reduce risk for the client and Summit, we proposed building a small prototype test fixture. 

The initial results of the test fixture were impressive. The overall testing time per part was reduced from 45 seconds to 12 seconds. The repeatability of the leak testing accuracy also improved while reducing the false failures by more than 80%. A side benefit of reducing scrap created by the previous test process was also realized. 

The breakthrough in the testing process greatly simplified the automation process. Summit designed and built a flexible and modular system around a Montech pallet style conveyor.  The pallets were outfitted with quick change tooling for the different filter products 

Each station used a Denso Six Axis Robot to provide for flexibility of product changes. The Denso Robots were specified based on the field reliability for the application. Based on the speed and payload, Denso predicted that the minimum mean time before failure would be 11 years of operation. Two of the six Robots used vision to guide their motion and to allow for easier loading of components into the automated machinery.