Interactive Robot for automobile assembly line – Collaborative robo
Interactive Robot for automobile assembly line – Collaborative robo
At a glance
Focus: Interactive Robot for automobile assembly line Collaborative robot.
Challenge: Digital transformation journey starts with identifying processes in the entire value chain that can be transformed using IT tools or automations in a manner that will bring business
Impact: Elimination of the need of safety fencing since cobot is designed to work around and collaborate with humans
Mahindra & Mahindra Ltd
Mahindra Group's parent company, Mahindra & Mahindra Ltd., is a dominant player in the Tractor and Automobile industry. It is both an operating company (Automotive and Farm Equipment businesses) and a holding company of all its investments in subsidiary and associate companies. M&M Ltd. is among the market leaders in the Indian SUV/ MUV segment and the world’s largest tractor company by volumes. Mahindra is truly a global company with its global neural network of R&D and manufacturing facilities as well as on ground channel network. Committed to ethical values, sustainable business practices, towards driving positive change, M&M creates value by judiciously and intelligently leveraging the multiple types of capital – not just Financial Capital, but also Manufactured Capital, Intellectual Capital, Human Capital, Social & Relationship Capital and Natural Capital.
Business challenge
Digital transformation journey starts with identifying processes in the entire value chain that can be transformed using IT tools or automations in a manner that will bring business benefits. Clearly, use of these tools should lead to either efficiency or reliability improvement in processes, improvement in performance parameters, lead to financial gains or lead to enhancing satisfaction of business partners (customers, employees, suppliers, investors, etc.).
On our assembly lines some of the processes were manual. Our team identified one critical stage where because of manual operations both quality and cost of manufacturing was getting hampered.
Previously the sealant application in engine assembly line was done manually with torqueing of 6 bolts. Automation for sealant application and torqueing was a need.
But there were multiple challenges -
Space of installation
Safety of work station worker
So the team came up with a unique solution rather than the traditional robot. Collaborative robot (Cobot) was the best suitable solution to tackle the constraints. But installation of Cobot involved challenges like -
Line balancing was needed to automate this activity with Cobot
Integration of vision system & PLC with Cobot
People compatibility with new technological change
More demanding requirements in terms of quantity and quality in production necessitated a new manufacturing concept to meet the latest standards. Since this was a new concept for the company, it posed challenges related to people compatibility due to technological changes and space limitations for human and Cobot to co-work in the production shop was another challenge.
Digital checklists used between the individual process steps have resulted in a significant decrease in the frequency of errors and an increase in efficiency. Ergonomic working conditions make work easier for employees. At the same time, the torque application detection that is carried out automatically, reduces the probability of errors and decreases physical exertion.
Also, we have adopted a new technology of vision system integration with Cobot & PLC for auto correction of system offset.
Key benefits
| Area | Outcome |
|---|---|
| Safety & Workforce | Elimination of the need of safety fencing since cobo is designed to work around and collaborate with humans |
| Operational Benefit | Easy to use and program |
| Safety & Workforce | Reduction in 2 manpower/shift improving productivity |
| Cost Savings | 14 lakhs saving in sealant cost per year |
| Operational Benefit | Reduction in hazardous waste as small sealant bottle replaced with 20 kg sealant pale |
| Quality | Quality of sealant application has improved |
| Operational Benefit | Partnership with humans is one of the greatest advantage |