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Our challenge was to build a work cell to assemble three parts shown in photograph, decorate, test and place the assembly into cartons.
Parts are delivered to the work cell in bulk and placed in vibratory hoppers or hoppers with vertical discharge cleaned belt conveyors.
The components are singulated and oriented in vibratory bowls. The polypropylene part is ultrasonically welded into the base. Meanwhile, the cover is being decorated with our exclusive hot stamping head. The decorated cover is placed on top of the base and presented to the seal and test area for validation.
The top and base are heat sealed together and tested. The testing includes checking that all air passages are open and the proper pressure drop across the unit is maintained.
Assemblies that successfully pass all quality control checks are packaged in bulk and all rejected parts are diverted off line.
Throughout the assembly process the parts are inspected and tested. Components or subassemblies that fail are diverted off line to eliminate adding additional labor to a failed part.
Our controls and software were written to augment our customer’s, already in place, Six Sigma and lean manufacturing policy.
Another example of a project on time and within budget!
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