Multi-Robot Appliance Assembly Line for Multiple Variants
Fully automated appliance assembly line handling 8 product variants
- 15Robot Stations
- 8Product Variants
- AutomaticVariant Changeover
- IntegratedLeak Testing
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Solutions Used
Technologies
- FANUC Robots
- Cognex 3D Vision
- Flexible Fixturing
- MES Integration
- Leak Testing
Project Overview
Product variety is essential for competitiveness in the appliance industry, but it creates manufacturing complexity. An appliance manufacturer found their appliance assembly line—designed years ago for just two variants—struggling to handle eight current models.
Every changeover between variants stopped the line for manual fixture adjustments. Quality suffered as operators rushed through unfamiliar assembly sequences. And chronic labor shortages meant the line often ran short-staffed.
Flexibility by Design
AMD Machines designed the new line from the ground up for flexibility:
Automatic Fixture Adjustment
Every fixture uses servo-driven locators that automatically reposition for the incoming variant. When the MES signals a new model, the fixtures reconfigure automatically.
Universal Part Handling
3D vision-guided robots pick components from mixed bins, eliminating the need for model-specific part presentation. The same bin can contain components for all eight variants.
Recipe-Driven Assembly
Each station stores programs for all variants. When a tub enters the station, the barcode triggers download of the correct sequence, speeds, and parameters.
Model-Agnostic Testing
Leak test and functional test stations automatically adjust pass/fail criteria based on the specific model being tested.
Station Breakdown
The 15 robot stations perform complete appliance assembly:
Stations 1-3: Tub loading and component insertion Stations 4-6: Door assembly and hinge installation Stations 7-9: Spray arm and rack installation Stations 10-12: Pump and motor installation Station 13: Electrical connections and wiring Station 14: Leak testing Station 15: Final inspection and unload
Each station is designed with cycle-time margin below the line takt.
Mixed-Model Production
The line is designed for mixed-model production and build-to-order scheduling rather than batch builds. Changeover between variants is handled by the servo fixtures and station recipes described above, not by manual fixture adjustment.
01The Challenge
An appliance manufacturer needed to modernize their appliance assembly line to handle increased product variety in a tight labor market.
- Legacy line designed for 2 variants, now producing 8
- Every variant change stopped the line for manual fixture adjustment
- Labor shortage causing production schedule disruptions
- Quality issues from operator fatigue on repetitive tasks
- Need to hold a single line takt across all variants
02Our Solution
AMD Machines designed a flexible assembly line with 15 robot stations capable of automatic changeover between all 8 product variants.
Flexible Fixturing
Servo-actuated fixtures automatically adjust for different door sizes and configurations without manual changeover.
Vision-Guided Assembly
3D vision systems guide robots to pick components from mixed bins, eliminating the need for part-specific presentation.
Recipe Management
MES integration automatically downloads correct programs and parameters when a new variant enters the line.
Integrated Leak Testing
Leak test station for sealed assemblies with automatic reject handling and data logging.
03The Results
The line is built for mixed-model production: servo fixtures and station recipes handle variant changeover in place of manual fixture adjustment, 3D vision-guided robots pick components from mixed bins, and an integrated leak test station checks sealed assemblies with automatic reject handling and data logging.
Technical Specifications
- Robot Count
- 15 robots
- Robot Types
- FANUC M-20, LR Mate
- Vision Systems
- Cognex 3D-A5000
- Variants Supported
- 8 models
- Changeover
- Automatic
Our engineering team can scope a system for your parts and volumes. Let's discuss your requirements.
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