LOGICDATA is an innovation leader and the leading supplier in the field of motor controls, operating elements and actuator elements for electronically adjustable furniture. Their challenges are high volume products with various customization possibilities. This leads to many different product versions, based on only a few basic versions. The basic versions are produced in high volumes on specific production lines and then manually finalized before packing. The experiment implemented in ReconCell is an assembly of a slimdrive module, which is used in adjustable furniture.
The Logicdata use case showed the need for a robust, reliable and modular measurement system. The pre-assembled drive system is manufactured off-site and is delivered with undefined values of certain properties (e.g.: stator rotation, spindle length…). As these values effect certain aspects of the assembly, they need to be determined beforehand. The finished assembled product also needs to have these properties set to predefined values. The integrated visual measurement system, which uses camera-in-hand approach, showed to handle the mid-assembly measurements well and provides the needed results for assembly adaptation and final parameter settings.
The final assembly and customization includes:
- assembly in final housings,
- adding customer specific parts and labels
- flashing customized software.
Main Objectives of the Experiment
Customization far away from the customers leads to long delivery times, especially for those who are located overseas. The automated robot workcell will give the opportunity to do the final customization close to the costumer in a cost efficient way for all different products.
- Final assembly and customization of all different products
- Easy and quick change between product groups
- Throughput that matches our future market demand
- Easy worldwide setup possible
- Fast introduction of new variants without knowledge of robot programming
The final output is the ReconCell workcell, including the new modules for the use case. The workcell had been reconfigured by manually interchanging modules, like the tool rack trolley, part trolley and fixture trolley in order to accommodate the assembly of this product. So the expected results are:
- Technical feasibility checked
- Data for economic calculations generated
- Business case validated
With the implementation of ReconCell, it will result in a reduction of manual work from 24 hours to 8 hours. Also, it will give a reduction in changeover time and an increased capacity. Three scenarios encompass benefits like improved product quality, lower product rejection rate, higher product value due to smaller product batches, shorter changeover time, more flexibility, reduced cost in building fixtures, etc.
The total yearly benefit or value creation of using ReconCell has been calculated to €302,218.