This piece consists of three separate case studies, which highlight the problem-solving ability of CIMTEC. The company names will remain anonymous.
1) Problem / Requirement:
Problems holding tolerances on upstream processes and manual assembly, resulting in high scrap levels of finished products.
Solution: Precision Assembly System
CIMTEC developed an automated assembly using two six-axis robots, with the robot presenting each component to a camera for inspection prior to assembly so out-of-tolerance sub-components would not result in a scrapped final assembly.
The customer not only achieved huge savings by eliminating the amount of scrap, but also increased overall quality and production by detecting faulty components before final assembly.
2) Problem / Requirement:
Scrap on a multi-layer web line was too high, due to problems with web movement causing poor seals.
Solution: Dynamic Tracking System
CIMTEC engineers provided a system that added cameras to measure the web position in both X and Y axes, with servos to move the press based on data from the camera.
The accuracy provided by this measurement system resulted in a measurable reduction in scrap, thus increasing product quality. The savings were dramatic, and the customer is moving forward with similar applications on more lines of productions within the facility.
3) Problem/ Requirement:
The company needed to maintain tighter tolerances on steel plate thickness used by their customers in stamping operations.
Solution: Laser Thickness Measurement System
CIMTEC developed and installed laser thickness monitoring to log dimensions and reject out-of-tolerance steel plate. Data derived from logging over time allowed a reduction in plate thickness from the previous manufacturing method.
The company saved a considerable amount by reducing raw material cost. Data derived from logging over time allowed a reduction in plate thickness from their supplier, saving them hundreds of thousands of dollars.