Creating a Flexible Workflow: Seamless Transitions Between Processes

06 Dec 2023

Sometimes a successful case is just a few extra steps away! Our customer, a specialist in automobile lighting systems, asked us to enhance their existing headlight production line. 

For regular brands, parts are assembled using solder or glue, while premium brands demand an extra touch with screwdrivers. With the premium production being smaller, creating a separate line seemed impractical. So, an extra screwing station was added to the regular line, and we were tasked with seamlessly connecting it to enable easy switches between standard and premium processes. 

The torque at the station is controlled by AGW software, guiding the operator through a streamlined process: 

  • The operator scans the serial number of the part. 
  • If the system identifies it as a part for high-end cars, an additional step is added to the production route, involving the precise screwing of extra bolts into a PCB connection. 
  • If the part is intended for regular car models, the system smoothly moves it to the packing station. 

To perform the operation successfully, an operator must secure bolts according to specified parameters. The system provides guidance and traceability throughout the process, measuring the tightening force and angle of each bolt, and issues prompts indicating success or potential issues, ensuring the operator is informed. Our system also features a controller that oversees the screwing station. In case of an error or if the operator forgets to scan the part, the system halts further actions until the issue is resolved. 

One challenge was the torque device from an unfamiliar brand, requiring time to determine the suitable connectivity profile. After identifying and setting up the correct connectivity device, the equipment was connected to the system. 

Fast-forward to the future, the same customer requested the integration of an additional screwing station due to their production expansion, all within a tight deadline. The challenge lay in the addition of a traceability system for this new station, requiring the integration of unfamiliar equipment using entirely new connectivity protocols. 

Finally, our customer presented yet another challenge: the integration of an additional screwing station at a different site. This particular station operated on a Modbus connection, a connectivity protocol we were not previously acquainted with. 

In summary, we encountered three unique challenges in equipment connection, each involving connectivity protocols unfamiliar to our team. Despite this, our team effectively addressed each task, seamlessly integrating several new equipment pieces into the customer’s network, showcasing the adaptivity and flexibility of our solutions.