The entire program was fully designed, built, and integrated by the Tooling Technology team in Ft. Loramie, OH. They worked closely with the customer’s team to understand the floor layout, process requirements, and timing/logistics for the install. All mechanical tooling and fixturing was also built in-house using several materials and processes including CNC machining, epoxy fiberglass layup, and aluminum casting. Hardware, programming, controls, and integration were all managed internally, and included a simulated trial at the Ft. Loramie facility before final install on the plant floor. Initial trial integration, troubleshooting, and training were included on-site, along with service and warranty for future program modifications or changeovers.

By replacing manual labor, the customer was able to relocate two employees each on two shifts for a total of four people that could be relocated to other lines within the plant. With no unforeseen shutdowns, the line was able to run more hours per day, which increased the total daily output, while also adding flexibility for demand fluctuations. They also saw increased efficiency within the machine cycle and improved part quality due to the consistent flow of material. Overall, the plant expects ROI in under 2 years and anticipates this line contributing to future business awards due to its increased output and efficiency contributing to lower piece price offerings.

The company not only sees this system being used on other forming lines at this plant, but they are also investigating its integration at other plant locations. Automation is being reviewed for use on the front end of this line to load the material into the machine. In addition, the concept and technology are being developed for use in other functions, including pack-out, staging, and assembly operations within this plant and throughout the organization.