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Tag Archives: tester

Production processes – factory automation

Pozostałe wpisy:

13 December 2022
28 October 2022
25 October 2022
1 August 2022

WIĘCEJ

Production processes are all activities related to the production of products. These include the gradual completion or creation of the expected product in accordance with the design or process assumptions.

 

Types of production

The production of products is linked to a value chain that includes supply, technological processes, transport and storage. Types of production can be differentiated by nature, location or volume.

Production lines

The organization of processes is arranged sequentially,where subsequent stages follow each other, finally giving the finished product. Production lines can be manual, semi-automatic or fully automated and robotic. Highly efficient lines are usually geared towards the production of one or several different products. Efficiency comes from the speed of individual processes, and the transformation of tools to different products affects volumes. Lines that are adapted to the production of different products must be equipped with additional equipment that will allow them to handle products that differ, for example, in size.

                                Production is flexible

An example of such a solution is a line for the installation of lighting lamps. On a conveyor with several different stations, you can put one of the many types of positioning trolleys, which are adapted to specific lamp sizes. In this way, production is flexible and more products can be added – all you have to do is design and manufacture a new typeofproduct.

                               Nest production

Nest production is a more flexible variant of a traditional production line. Individual workstations or process stations are not permanently bound by the flow of the product. This means that we can produce different types and types of products by changing the order of the stations. This type of production is possible if some technological processes do not have to follow each other.

                                Hi-runner

Our nest production concept has been applied to a factory in the furniture industry. We have unified all robotic stations, so they can be rearranged according to your needs. The most common products are manufactured on thehi-runnerline. On the other hand, all the others can be produced flexibly  by making  sockets in individual technological lines.

                                 Diffuse generation

Distributed production proved itself in the era of the pandemic, when various industries suffered from lockdown  or lack of raw materials. This type of manufacturing is not tied to a specific place. Based on 3D models, production can be subcontracted depending on the availability of human and material resources. This is where 3D printing and, for example, laser cutting work great. Distributed production allows you to save your own resources and make the customer independent of suppliers. New technologies  help to produce more and faster, but in this case the emphasis should be on the security of our data – i.e. digital libraries and data transfer, for example.

 

Production processes

Production processes

– mechanical – completing and assembling, twisting, assembly, cleaning, labeling

– chemical – gluing, dispensing  liquids and gaskets, UV curing, painting

– permanent joining of elements – welding, soldering

– machining – CNC, grinding

– testing – mechanical,pneumatic, electrical, EOL

– natural – resulting from the natural action of the forces of nature – drying, cooling, etc.

Production processes – preparation of raw materials, transport, packaging and palletizing.

How do we do it at Alnea? We have extensive experience in implementing production processes on automatic lines. The Horus 3D vision system developed by us allows for offsetting of production processes and additionally image analysis and control, which allows you to maintain the highest standards and key performance indicators – KPIs (Key Performance Indicators).

Need production line or robotic station? Contact us: office@alnea.pl

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Production lines – automation and robotization of production processes

Pozostałe wpisy:

13 December 2022
28 October 2022
25 October 2022
1 August 2022

WIĘCEJ

Manufacturing companies are now facing increasing demands on the speed, quality and customization of  the production of goods and goods. The last few years indicate an increasing need for changes and development of Polish companies. Integrators are getting more and more inquiries about production lines, which means that automation and robotization of production processes is playing an increasingly important role.

 

Production processes

Production processes are all activities that affect the production of products. They cover the  entire value chain – transport, storage, material flows and direct actions on the raw materials, components and details that make up our final product. An important element are also technological processes related to, for example, soldering, gluing, welding, cooling, i.e. in general physico-chemical phenomena to which the product or its elements are subjected.

Types of production lines

The pioneer of production lines is considered to be the American tycoon Henry Ford, who more than a hundred years ago organized production processes in one sequence. Although, in fact, the very departure from the manufactory forced similar solutions in production companies. Although the lines were created, they now cover all industries and thanks to them most of the goods available on the market are mass-produced.

                Manual lines

Manual lines are an organized sequence of processes in which all actions are performed by operators. An example would be, for example, a packaging line. At the conveyor belt on both sides there are employees performing on the koela activities – laying cardboard boxes, inserting furniture, spacers, screws and finally close the lid and palletize the finished package. Such a line can be efficient, requires an efficient flow of details and a large organization of employees who are basically irreplaceable in it.

                Semi-automatic lines

Semi-automatic lines are equipped with a conveyor system and equipment that helps with assembly or other processes. Such a semi-automatic line can be a production line of lamp assembly. Thepalletsbetween the individualstationsare slowly replenished  by operators thanks to automatic screwdrivers, testers, etc.

Semi-automatic lines can also have robotic sections, but between them there is always an operator station that performs some of the tasks independently

                Robotic lines, automatic lines

Automatic lines are a string of automatic stations that perform a programmed sequence of actions one by one. The operator only added components, received products and watches over the correctness of processes. Yes! With automatic lines, a human is also needed. Robotic lines are advanced manufacturing centers that, although quite expensive to buy, allow you to maintain quality and stabilize production.

               Assembly stations, test benches

Sometimes we don’t need a production line. All you need is, for example, an assembly station or a test stand. With uncomplicated applications, a properly designed human-operated station is not only more efficient, but also cheaper.

 

We build production lines

At Alnea, we have many years of experience in designing and building production lines, robotic lines, testers and assembly stations. We come to the customer, get to know his needs and requirements, and then we construct the entire machine from scratch. We have competence in the field of line construction and we recommend ourselves for cooperation. Here you can see what we have managed to create in 10 years.

Need production line or robotic station? Contact us: office@alnea.pl

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Automated assembly station

Pozostałe wpisy:

13 December 2022
28 October 2022
25 October 2022
1 August 2022

WIĘCEJ

A large part of the production is still carried out in manual or semi-automatic mode. The use of advanced machines is common for components or products with very high precision, but there is still little investment in smaller companies. Assembly processes can be automated, a small change can give a big effect in the form of more stable and accurate production. It also allows you to exploit the potential of the operator.

Which assembly processes are easy to automate?

The simplest assembly processes for automation are usually soldering,twisting, folding (e.g. plastic part of the housing). Of course, some products are manufactured in such a way that automation will be unprofitable, or simply the product requires human intervention in terms of accuracy, manual sense or visual control.

Other  processes  do not directly interfere with the product, but contribute to faster production – e.g.  transport, packaging or palletizing.

Assembly stations

Alnea specializes in the construction  of machines, production lines, but we also create assembly stations. Typical mounting stations can be purchased from many companies. However, we equip our stations with equipment according to the customer’s demand. In addition, we create production testers that increase efficiency and reduce losses associated with further processing of defective or non-compliant products.

 

Semi-automatic assembly

To move away from manual installation, we can use semi-automatic installation. This is a good solution when some processes are easy to automate and others require operator involvement. An example of this is the position where the employee pre-assembles the product and then the machines weld, foil and label it.

Robotic assembly station

Bentley among the production stations is a robotic assembly station. The operator’s task is to deliver components, and integrated robotics and automation systems perform all activities including packaging.

The use of the Horus vision system significantly accelerates the offset of production processes, including assembly processes. Our riveting station for  sub-gutter hooks  has been designed to reduce employee interference.

At Alnea we will design a assembly station for you for the construction industry,  automotive or electronics.

See what robotic assembly looks like

 

Need conveyor stsems? Contact us: office@alnea.pl

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Find the optimal solution – production test

Pozostałe wpisy:

2 December 2022
8 August 2022
18 March 2022
7 February 2022

WIĘCEJ

Modernizing the production line is sometimes a big challenge. A good process analysis performed in front of an experienced integrator allows you to identify areas of change in the production process or the product itself (if possible). How to find the optimal technological solution? – you need to test several different possibilities. Here are some of our experience as an  integrator  in a lighting company:

 

Production tests

Robotic position in the assembly line. The robot took the glass and placed the lamp in the housing, and then screwed the corners withagiven accuracy.

When we did the production tests for the installation of the lamps, we had a serious problem with the spacer, which was supposed to protect the fast during transport. The robot sometimes took the glass at the same time as the paper spacer, which created additional difficulties and simply took time. We did production tests and we were still not happy with the tacktime. We took a closer look at the spacer and found that it was completely unnecessary. Fast, they were extremely scratch-resistant. So we reduced spending – for the supplier, adding paper cardboard was also problematic and we accelerated the production process.

Positioning

The robot takes the LED plate and places it in the lamp holder.

We had a big problem with the positioning of the plate – there was no element in the housing to which the robot could position the plate so that it did not move. After analyzing the design of the housing, we proposed to change the casting so that the outline of the place for the plate is consistent with its circumference. Since the customer was able to redesign the housing, we gained on the accuracy of the insert arrangement, but also reduced the installation time.

Excessive tool wear

We have designed a tool specifically for the customer to screw screws into the housing. However, after implementation, it turned out that it wears out faster than weanticipated. It turned out that the product going to the paint shop had nosecuredplaces  for screws. The paint-drenched thread made it difficult to screw, destroy the tool and slow down the process. Simple solution – securing screw seats gave us savings  and faster lead times..

Production testers

Why invest in production testers? According to the OEE principle, it is better to produce less and better than more with defects. Production testers allow us to reject defective products so that they do not take up space, time and components for products made correctly. This is also important because of the level of energy consumption, the waste of which costs more and more. One such danger zone is the painter’s. Incorrect painting of an element makes it sometimes impossible to correct it anymore.  Testing the elements coming in and out of the painting shop – e.g. the Horus vision system –  allows for significant savings. The higher the Overall Equipment Effectiveness (OEE) rate, the better the production rate. Lepiej is to produce feweer elements, but of higher quality than more with high recoil.

Online consultation

A pandemic does not save manufacturing companies. So we offered our business partners a new solution. During the maintenance period of the machine [closed plants due to COVID],owe have put ina series of online consultations along with streaming the image from the production. We were able to optimize the process and changed the program on the machine.

After the implementation of the machine and after the warranty stage, the customer often introduces a new product type and changes need to be made – this sometimes applies to a very large number of machines. A safe option is to run tests on one device and then make changes and scale the solution to the next machine.

We adjust cooperation model at the project stage to ensure investor safety. Thus, the largest tranche of payments is accepted once the entire technical project has beenestablished. We treat customers as partners so we use flexible business models.

If you would like to receive a new or refresh the old offer for a difficult time of crisis
write to us as soon as possible: biuro@alnea.pl

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Production tester – project optimization and scalability

Other entries:

2 December 2022
8 August 2022
18 March 2022
7 February 2022

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We have made a project   for a optical fiber production company. The manual test station was intended to help the operator to difficultly pass the correct marking and position of the fiber optics in the sockets. We have prepared the position for three different types of products – thanks to which the return on investment was shorter than expected.  The production tester designed by us ensured optimization and ergonomics of work and allowed for the scalability of the project.

 

Testing station

Our testers are designed to be simple and operator-friendly. The test station is equipped with an HMI touch screen, thanks to which the operator chooses the right model. The prepared ribbon is laid out in the  darkroom, and the other end is then pluged into the power socket. The closing of the darkroom  is verified  by  the  induction sensor because the quality of the test depends on the lack of external light.

The video sensor controls the order in which the fiber ribbon LEDs light up, allowing the operator to guide the product step-by-step through the testing process. Subsequent ribbons in the fixture A are postponed to fixture B in the correct order detected by the video system. The PLC management system,  in turn,  generates labels  which  ensures our  quality.

 

Quick application

The biggest challenge of the project was the high standards of the process, which had to take place in a complete darkroom, and then further steps should be done flawlessly. We know how important it is to maintain quality with a small number of NOKs. Our production tester was able to implement quickly, and a satisfied customer ordered another 5 testing stations.

If you are interested in purchasing production testers – contact us. We will make analyses, design and perform a production tester for you. We have experience in building electrical, electronic, vision system controll, pressure, leak and other testers.

If you need a dedicated vision system
write to us as soon as possible: biuro@alnea.pl

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ALNEA SP. z o.o.
Księcia Janusza 23/10
01-452 Warszawa

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