Automated Assembly System

This project involved the end-to-end design and implementation of an automated assembly system for a mid-volume manufacturing environment. The challenge: reduce cycle time on a manual six-station assembly line without a full-line replacement.

The solution was a hybrid approach: a custom servo-driven pick-and-place module inserted between stations 3 and 4, paired with a vision system for tolerance verification. Mechanical design used aluminum extrusion framing with precision ground linear guides. All fixturing was designed for rapid changeover with a single wrench.

The result was a 40% reduction in cycle time, a 65% reduction in assembly-related defects caught downstream, and a capital payback period of under 18 months. The system has since been replicated at two additional facilities.