Finding Solutions for Limited Resources

Combining Processes and Cutting The Costs

Posted on 01/23/2019 | by The Orbitform Blog Team


High Workload, Limited Workforce

Limited resources… It’s a problem many manufacturers are currently facing – plenty of work, purchase orders, and customers to work with, but not enough qualified employees to complete the workload. When the workload continues to grow, but the workforce is sparse, how do you manufacture assemblies that impress your customers?

Multiple Solution Options

Orbitform recognizes that an assembly solution is not always in the form of a simple machine. We have been working with many customers recently to solve this exact issue. Manufacturers have purchase orders to fulfill, but far too few qualified workers to take on the workload. Often times, solutions may also include eliminating production steps, decreasing cycle times, and reducing machine operators.

Increased Production with Limited Resources

Recently, we were contacted by a customer who was facing this exact issue – three separate production steps and cells to produce their shock mount assembly. As production volume increased, how could they continue to manufacture their product with limited resources?

A Unique Solution

Orbitform worked directly with design engineers to produce a simple, yet unique solution for this customer – a 12-station dial machine to combine three processes into one. This dial assembled a casting, loaded the rubber isolator, placed the steel washer, formed over the washer, and provided a quality check to complete the assembly in only seven seconds.

Integration of Automation

Previously, the assembly would have taken three operators through three separate manufacturing processes with high cycle times. Through the integration of automation, the customer received their desired outcome; a cost-cutting assembly machine that required fewer resources. The complete solution dial included two smaller dials for an operator to pre-load parts to be fed into the larger dial. In addition to that, the large dial included stations for component assembly, part presence check, top cap/steel washer placement, roller-forming and auto unload.

Our Pride is in Your Solution

At Orbitform, we pride ourselves on the ability to provide solutions. This project provided exactly that; a solution to limited resources and a large work-flow. We are pleased to deliver the right solution to impress our customers and stand ready to help find a solution for you, however big or small. Contact us today to find how we can support your assembly manufacturing process.