Case Study: Automotive Compressor Assembly and Test
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Overview:
This project represents one of ATW's largest single projects. This system was duplicated at a second plant for expanded production and proved to be a strong system for many years. The initial project held many challenges by needing to support a Greenfield plant that had never manufactured a compressor prior to start up. The results were tremendous and recorded the best start up in this customer's history in a new plant with a new product. Another challenge was the implementation of a high level of automation on a product design that was just finalizing during the project. ATW's dedication to communication and project management throughout the project allowed for an on time delivery and start up at a foreign plant location as promised.  
Values & Benefits:
  • During first year of production only 2 parts per million rejects occurred
  • At startup first time throughput was in excess of 90%
  • Multi-line concept allows for segmented production
  • Test process integration provides quick response
 
Solution:
  • This overall system consisted of six (6) integrated palletized assembly lines that contained a total of 91 stations.
  • The majority of the stations were automated to provide a TAKT time of 8 seconds for the system.
  • Transfers between lines are accomplished by robots to provide re-orientation and flexible placement capabilities.
  • Select fit of components is a major requirement for this assembly due to tolerance requirements in the product.
  • Unique gauging, handling and documenting of these select fit processes provide a robust solution.
  • Testing was also a significant pert of the system including IPV stations and EOL functional tests to approve all assembly operations.
  • A "CE Mark" qualification was obtained on this total system.
Highlights:
  • Signature analysis of each assembly including average torque, discharge pressure and flow.
  • Oil fill verification by combination of three IPVs - VEK meter, flow meter and product weight check
  • Variable position bushing press that allow flexible position within a six (6) inch square through the use of a 3-axis closed-loop servo
  • placement and press mechanism.
  • Vision system verification of manual assembly operations.
  • RF communication system provides data control that facilitates a product build parameter accumulation.
  • Torque and angle monitoring of all fastening processes.
  • All press operations are verified by monitoring of force and distance during cycle.
  • Intelligent valve banks allow for easy troubleshooting / expansion.