Automation of the Vehicle Assembly Line for Automotive Industry
Our customer is a well renowned Indian motorcycle manufacturing brand, known for creating modern classics since 1901.For any manufacturing organization, it isn’t just the vehicle designs or the features of the end-product. It is also about finding a right solution to its operations, especially for Vehicle Assembly Line process, which is the most critical and the time-consuming task that needs to be done more efficient. This can be accomplished through IT process automation.Our customer already had such solution implemented by a different channel partner. But for the second phase of this project, they chose Hitek Automation to further improvise and customize the automated assembly line.
We clearly understood that this project is an intricate blend of automation and human input. The entire assembly line is optimally automated using Mitsubishi’s PLC MELSEC iQ-R series products for high-speed and high memory capacity. The solution is designed in such a way, each event of the whole assembly line process is captured and stored in the server/cloud. This software programmecompletely controls the assembly process. A conveyor line that just begins with an engine meets 600 components from 60 different technicians working simultaneously. It takes just 55seconds to assemble a motorcycle. While many of the assembly line tasks and workflows can be handled by technology, there is still a human element involved.
Our solution has added value to our customer by ensuring an error-free vehicle assembly line operation. This is achieved by customized solution which tracks each component and its specifications. When any one of the 600 components are missed by a technician, our solutions trigger an alarm. In this way, the missed element can be incorporated immediately. Also, in the backend the data which includes the specs of the all components are captured, classified and stored in SQL database. This helps our customer to track down to the component level in case of any escalations in the future.