Complex Component Assembly Case Study

The control module manufacturer was referred to Wes-Tech by their end-user customer, who had an existing relationship with Wes-Tech. The end-user customer was working to produce one of the most complex products they had ever designed, and they needed to do it within an aggressive time frame. They sent the control module manufacturer to Wes-Tech to get the help they needed to ensure their part was manufacturable on a large scale and could meet the tight timeline for delivery.

The challenge was a completely blank slate—the manufacturer had created a prototype but had no similar products to draw experience from, and they needed help to determine the best way to lay out a scalable assembly process. The new product was being tested concurrently as Wes-Tech was designing the manufacturing equipment, so there was room to work collaboratively with the customer to make small changes to the product design for improved manufacturability.

This was an extremely technically complex line, and the fully assembled unit was 80 lbs., making it difficult and dangerous to move around by hand. Working from these constraints and drawing on extensive experience, Wes-Tech combined conveyors, robotics, and operators into an unusual solution.

The part-handling robot delivered the part from one manual lean cell to the next. Component kits for assembly were delivered by conveyor at each location as needed. This allowed the company to use human operators to do the complex tactile and critical assembly work that is expensive to automate and the robots to complete the heavy, repetitive work. The system took advantage of human capital in the place where it would get the most return while reducing the risk of employee injury by leaving the heavy lifting to the robots.

The concept was created to be scalable. In the first year, they could staff the line with anywhere from one to seven operators to meet production requirements during the initial ramp-up. Still, adding equipment and operators to meet increased production volumes was easy, which happened much faster than was initially anticipated. This way, they could lower equipment costs until returns had already begun to pay for it.

Wes-Tech developed a scalable and flexible custom automation solution that allowed the customer to meet uncertain volume demands during initial production ramp-up and to distribute capital expenses over the 2 – 3-year launch window. In an era where keeping up with new products and technologies is crucial to business success, Wes-Tech’s innovative approach was a game-changer for the control module manufacturer and their end-user customer. The results of Wes-Tech’s efforts are evident in the automation process they implemented:

• A complete, scalable solution with a product design and manufacturing capability, including assembly and testing, ensured future success for two businesses.
• Reduction of health and safety risks by automating tasks with ergonomic concerns, ensuring a safer work environment and improved employee well-being.
• Confidence from and preferred supplier status with their end-user customer, which has not only solidified existing relationships but also opened doors to new opportunities.

This project is not just a testament to Wes-Tech’s commitment to helping their partners succeed but also a reflection of their ability to foresee and adapt to the dynamic needs of their customers. Their forward-thinking strategy and execution have set a new standard, demonstrating that with the right partner, even the most unusual challenges can be transformed into stepping stones for success.