Requirement
Fuel filter housings consisting of dozens of parts required assembly. Assembly sequence was vital due to various specifications, such as torque and insertion depth. Data tracking must be tracked through the system and any rejects or failed operations must be identified and the part must be rejected out of the line.
AEC's Solution
Complete ground up assembly cell design and build to incorporate Lean principles and ideas.
- Processes are aided by semi-automated assembly techniques using DC torque guns to control all assembly using fasteners and pneumatic pressing aided by load cells for all press-fit components.
- Placement of all components poke-yoked through use of different types of sensors as well as having the housings clamped or held into each station until all operations and components are verified to be present and complete.
- Leak testing done in a fully enclosed cell and checked using pneumatic cylinders to seal off the ports and a pressure decay testing module complete the appropriate tests.
- Use of barcode stickers and scanners to track progress through station and for data collection for each station.
- Lean stations set up with flow racks to present the components in bins to the operators in the proper order with only enough parts for one shift.
- Work flow is evenly distributed over the different stations to accommodate equal time for each operator.
- All work is presented to the operator in an ergonomic fashion with tool balancers and lift assist mechanisms for all heavy tools or assemblies.