Design, Assembly, and Tech Case Study

The motor drive manufacturer needed to design, manufacture, and assemble a new, more efficient pump motor that was different from anything they were currently making. They also needed to integrate their ERP system into the new line to track metrics and maintain control of the process. The company’s European arm gave them design basics. Still, in taking ownership of the process development, they wanted to partner with a U.S.-based systems integrator not only to be a source for manufacturing equipment but also a source of advice on creating a more cost-effective design that was easier to assemble.

In addition, the company wanted to ramp up production in phases. The manufacturing and assembly automation needed to be flexible enough to add more volume as the product gained traction in the market. Partnering with Wes-Tech early in the planning process allowed them to use Wes-Tech’s engineering knowledge and experience in the discovery phase and throughout the partnership.

Wes-Tech engineers worked concurrently to help the manufacturer develop their product while designing the manufacturing and assembly automation. Wes-Tech developed a semi-automatic collaborative workstation as part of a fully automated line with standard and custom-designed features. Using Tech-Trak single-strand conveyor as a base, Wes-Tech innovated to create two new modules: a pallet lift for improved ergonomics and a side shuttle to remove pallets from the line for testing.

Wes-Tech helped the company speed up a curing process known for its inefficiencies with a novel heating method. Wes-Tech also added robot-tending on vertical racks where curing products could sit rather than take up floor space. Reduction in the size of the curing buffer reduced the area and equipment required for the containment of volatile fumes emitted from the curing process.

The modular design kept the initial equipment cost lower but allowed easy modifications when needed. Phase one was implemented with the expectation that when the customer met production volume in a few years, they would add to the line and scale up production with minimum interruption to the business.

Wes-Tech also added an interface to integrate the line into the plant network for automated management. Now, orders from the ERP system come directly to the machine, instructing it to produce any of four variations of the drive and change parts style on the fly. The assembly automation can also handle single parts made to order or large batches depending on production volume requirements indicated by the ERP system. At the end of the line, the ERP can track multiple pack-out locations so that finished goods can be packed and completed right at the line.

Part of Wes-Tech’s comprehensive engineering solution is to design for automated assembly to make the process and product more robust and reliable. In this case, the concurrent design process allowed vast improvements in the product and line designs that:

• Made it easier and more cost-effective to produce the product, ensuring a leaner operation with maximized profitability.
• Fit in a reduced footprint, demonstrating that high performance doesn’t require high space, which is a testament to Wes-Tech’s efficient use of resources.
• Integrated with the ERP system for more flexibility and control, allowing for real-time data analysis and decision-making that propels productivity forward.
• Decreased potential health and safety hazards, demonstrating a deep understanding of the customer’s demanding operational environment.
• Were part of a modular design for lower initial cost and easy scale-up, accommodating business growth with ease and efficiency.

Wes-Tech’s forward-thinking ability to design products optimized for automated assembly ensures efficiency and future scalability. Designing with the future in mind ultimately empowers companies like motor drive manufacturers to rapidly adapt to market changes and technological advancements, maintaining a competitive edge in ever-evolving industries.