Efficient Assembly Lines: Automation as a Competitive Advantage

The level of automation should not be defined solely by output volume. Decisive parameters are variant diversity, the required repeatability of joining processes, the demanded depth of documentation, and the cost of errors in manual production.

An economic analysis should always consider OEE (Overall Equipment Effectiveness) and the scalability of the system, rather than focusing solely on pure cycle time.

The answer lies in modularity and software flexibility. By using standardized interfaces (hardware and software), assembly cells can be designed so that product changeovers occur primarily via software parameters rather than mechanical rebuilds.

Flexible feeding systems based on optical machine vision also enable the handling of different component geometries without physical change parts.

The greatest challenge is not programming but the safety assessment (risk assessment). Cobots require precise calibration of operating speeds to the real environment, along with consideration of pinching and crushing hazards.

We focus on adaptive safety concepts in which the robot dynamically adjusts its speed based on the distance to the human operator, minimizing cycle time losses.

A retrofit is worthwhile when the mechanical base structure of the system still meets requirements, but the control technology or IT connectivity no longer meets modern Industry 4.0 standards.

By replacing outdated PLC technology with IIoT-capable controllers and integrating modern sensor technology, the service life of a system can be significantly extended at considerably lower investment costs than a new build.

In addition to physical process reliability (Poka-Yoke), we rely on data-based monitoring. Every critical assembly step is validated by sensors (force, displacement, torque, vision). The resulting process curves are digitally archived.

This not only enables the sorting-out of defective parts, but also serves as root cause analysis for statistical deviations in the manufacturing process.

Software architecture is the backbone of the system. We rely on open standards and decoupled logic. This means that process modules (e.g., a screw-driving module) can operate independently of the overarching line controller and communicate using standard protocols (OPC UA, MQTT).

This ensures interoperability between different sub-systems and simplifies connection to MES or ERP systems.