Win-win: high quality and increased production capacity

When our customers faced a growing market, they needed to respond fast  – and smart – to stay ahead of the competition. We’re explaining how we help our customers to fulfill the needs of their customers. This is what Taking you steps ahead is all about.

Microscopic changes making large impact

Our customer required an increase in product quality and production volume. Two big goals that optimize the micro end-product drastically. In order to analyze the current production process, we paid them a visit with a free pre-automation analysis. A better cutting process and more efficient automation of the complete assembly would help them achieve these goals.

The main challenge in our work is to come up with robust solutions to improve current processes. For this customer we came up with a solution for accurate cutting. We also had to position a very thin wire into their product. The production processes of the production line contain the following steps:

• Accurately cutting and positioning;
• Dispensing glue;
• UV-curing;
• Vision inspection.

Not only are we looking at developing the production line and integration of these processes. We also make sure the line is as efficient as it can be. We improve yields compared to the current production process. Improving product quality and production speed.

Joint work for the best automation concepts

Before we start working on our production lines, we sometimes jointly define a Proof of Concept (POC). Whenever we’re not entirely sure about a process concepts, we investigate further. This can have to do with product materials or a smarter way to assemble products. We investigate the goal and determine the best fitting solutions. We conduct these Proof of Concepts to develop the best solutions possible, with minimal risk. As we performed these tests, we supported the customer in making the right decisions for the cutting techniques. As a result, we found a highly accurate and repetitive process in the use of a Femtosecond laser. This laser brings a much more robust and repeatable process compared to other lasers.

Next, automation of the complete assembly process was subject. To minimize risk and reduce total lead-time, we decided to use a modular equipment concept on which we could develop and build several process steps independently. The control system of this modular concept allows offline testing and adjusting of a new process module prior to integration on the machine. This leads to more reliable testing and validation of the machine.

Pre-automation analysis is key for the best results

The two phases above are part of our pre-automation analysis. Proof of Concepts and automation of the production, are very important to the success of the project. Our extensive automation and micro production knowledge in the field, combined with our working methods make it possible to find the best possible production automation solutions.

An overview of the production processes that are integrated on this machine

Traditional processes such as:

• De-coiling;
• Cleaning;

and more complex processes such as:

• Glue dispensing;
• Components positioning;
• Laser cutting;
• Automated Quality Inspection with Vision.

Durable partnerships for happy customers

The machine was successfully and quickly installed at the customer site. We performed a Site Acceptance Test (SAT) and celebrated another successful cooperation with the customer. The customer gained the benefits of:

• Higher quality products, resulting in better product performance and improved yield;
• Increased production capacity, during the Factory Acceptance Test (FAT), we have been able to reduce the committed cycle time by 10%.

This project represents an important milestone in establishing long-term partnerships. Both the customer as well as us are very satisfied with the professional collaboration. We both benefit from this relationship and as a result: more machines are in the pipeline and will be delivered soon. This is what partnerships are about!

Want to increase production capacity as well?

Our automation experts are ready for your questions. Get in touch to challenge us with your specific problems. We are experts in high precision that makes a big impact.