Screwdriving

Automotive Lighting Screw Driving

Automotive Lighting Screw Driving by JAKA Zu 7 Cobots

Total number of cobots

About the Company

The company is a national high-tech enterprise and an enterprise technology center in Zhejiang Province, focusing on automotive lighting design, development and manufacturing. The company mainly supplies equipment for GAC Toyota, GAC Mitsubishi, GAC Passenger Car, FAW Volkswagen, FAW Toyota, Dongfeng Nissan, Tianjin Toyota, Yamaha and other OEMs.

Company’s Challenges

The company faced a series of challenges with a particular screw driving task, in the production of an automotive lighting component.

First of all, the production was slower than desired.
Second, the company had to spend time and money looking for new employees and training them. With repetitive tasks, employee turnover tends to be high, making for a constant expense.
Third, over the course of a shift, it is hard for people to maintain focus and concentration on screw driving tasks, leading to errors.

The main concern that the company had regarding automation was that production had to be fast, it had to match or exceed their existing processing times. Moreover, deployment and debugging had to have minimal impact on production.

Solution

After consultation, the company chose two JAKA Zu 7 cobots to automate their screw driving task.

Thanks to their flexible, fast installation, they were able to be fitted upside down, screwing vertically downwards, working in tandem on the same component.

The plug-and-play functionality allowed for minimal disruption to production, and they now operate non-stop without the need for human supervision.

Results

Each of the two JAKA Zu 7 cobots freed up four employees to focus on more creative, intellectually demanding tasks.
The floorspace taken up by this section of the assembly line has been drastically reduced, as the cobots are able to operate in a tight cabinet.
The ROI was significant, with a payback period lasting less than 14 months.

automotive screw driving robotic project

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Address

Building 33-35, 610,
Jianchuan Road, Minhang District,
Shanghai, China.

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jaka cobots for car light tail screwing automation

Tail Light Bar Screw Driving

Tail Light Bar Screw Driving by JAKA Zu 7 Cobots

Industry

Automotive

Application

Screw driving

Integrated Cobots

JAKA Zu 7

Total number of cobots

About the Company

A developer and manufacturer of automotive lighting, capable of producing standard and specialist lighting products.

Company’s Challenges

In the final production stages of a particular tail light bar, one of the company’s processes involves securing structural and functional elements together, to create a bar that stretches the width of a car, integrating plastic light casing with a metal rim.

This involves first aligning the two parts, and then driving a series of heavy-duty screws. The company felt that the screw driving part of the process was ripe for automation, given its repetitive yet precise nature.

The challenge was to find a robot that could work alongside a human worker, who would be completing the first part of the process, and that could also easily be reprogrammed to match the screw driving layouts of different tail bars, for different models of car. For these reasons, traditional industrial robots weren’t ideal, so the company turned to cobots.

Solution

With the help of a professional cobot integrator, the company installed two JAKA Zu 7 cobots to complete the screw driving task.

Thanks to their compact size and relatively small weight, they were able to be mounted upside down in a cabinet, meaning the tail light bars could be secured below, with holes facing up.
The human worker now completes the first alignment stage, then places the bar into the cabinet, where the cobots are supplied with screws, and go to work on supplied parts automatically.
The worker doesn’t need to be concerned about safety, as the cobots’ in-built collision detection will cause it to cease operations the moment an unexpected force is met by any part of the robot arm.

Results

The company successfully automated the repetitive, dull and physically demanding process of screw driving. As a result, the turnover of staff was reduced, leading to a reduction in the money and time spent on training.
There was a significant increase in both the volume and quality of production. The cobots are able to operate 24/7, without error, which led to a 35% increase in the number of units processed per day.

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+86 400-006-2665

marketing@jakarobotics.com

Address

Building 33-35, 610,
Jianchuan Road, Minhang District,
Shanghai, China.

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screwdriving cobots for electronics manufacturer

LCD Panels Screwdriving

JAKA Cobots for LCD Panels Screwdriving

Industry

3c electronics

Application

Screwdriving

Integrated Cobots

JAKA Zu 18

Total number of cobots

About the Company

An optoelectronics manufacturer and leading provider of smart vertical solutions backed by premium display technologies. The company has succeeded in earning worldwide recognition for its total solutions with its strong R&D capacity, solid manufacturing expertise, and comprehensive product portfolio to meet the diverse needs of the market.

Company Challenges

During company’s production of LCD panels, there is one task that involves driving sixteen screws, in order to secure structural and functional components to one another. Previously, each workstation performing this task required two workers, across day and night shifts.

The company identified a few issues:

First of all, given the repetitive nature of the task, it was difficult for staff to remain focused.
Second, there was a high turnover of staff, meaning that time and money was frequently being spent on training new employees.
Third, with the current epidemic situation, having a large flow of people, coming from various areas, placed the factory at risk of an outbreak, which would prove fatal to production.
Finally, the safety of the workers was a concern, as the task presented some physical risk.

As a result of these factors combined, the company decided to seek out robotics solutions to automate the screwdriving task, freeing up workers for more creative, fulfilling, safe roles.

Solution

After consultation with JAKA, and with the help of a cobot integrator, the company chose eight units of the JAKA Zu 18 cobot to install.

They were chosen because of their high levels of safety, their ease of use, and their flexibility. The cobots were fitted with a vision system for reading mark points, and custom end effectors, each of which are capable of carrying and driving ten screws at a time.

The screwdriving process was automated in the following steps:

First, the components to be screwed are received via the assembly line.
Next, the cobot loads up on screws. It moves to the component and reads the first of two MARK points to determine the precise location of the holes, then proceeds to drive the ten screws.

As the whole task involves sixteen screws, and the end effector carries ten, once the first batch are complete, it loads up on screws again, returns to read the second MARK point, and completes the task.
After completion, it informs the PLC, and the finished component automatically descends from the working area, out along the assembly line.

Results

All of the challenges identified by the company in their initial evaluation of the task were overcome.

Bills were saved on water and electricity, as there was no need to maintain the conditions necessary for human comfort during night shifts anymore.
The decrease in physical tasks increased worker safety, and automation reduced the flow of people around the factory floor.
The consistency of the cobots eliminated human error, meaning the quality of the products increased, leading to an increase in repeat customers.
All in all, thanks to the screwdriving cobots, production capacity was increased by 50%, and the payback period was less than a year.

Looking for cobots to automate repetitive tasks?

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talk to jaka experts

Contact Us

Your opinions are important to us. Whether it is a simple question or a valuable suggestion, we are here 24/7. You can call us by phone or email us directly.

Info

+86 400-006-2665

marketing@jakarobotics.com

Address

Building 33-35, 610,
Jianchuan Road, Minhang District,
Shanghai, China.

Name *

Email *

Company Name *

Industry *

Company Size *

Type *

Message

Country *