IAC

The production at IAC’s automotive door assembly plant is highly automated with multiple industrial robots as key element. To further improve productivity, the IAC team were looking at implementing autonomous mobile robots to automate the transport of sub-assemblies between robotic automation cells and manual assembly stations.

 IAC approached the Sorion team to integrate of a fleet of MiR mobile robots into their automotive door assembly line to automate the transport of sub-assemblies between workstations.

These were the key areas they wanted to improve:

• Transform the isolated manufacturing cells into a fully automated, integrated production line

• A flexible system that can be easily expanded and adapted to changing production needs

Solution

IAC opted for a fleet of 12 MiR200 robots equipped with special top modules fitted with corner specific nests. The MiR robots avoid unforeseen obstacles and work safely alongside people and other vehicles in the plant.

The Sorion team were tasked with integrating the robots into existing processes. Interoperability with both robotic and human systems was key to a successful deployment. A fully automated and flexible system was required to ensure maximum utilisation of production capacity.

As Certified Systems Integrators for MiR robots, the Sorion team is equipped with the knowledge to offer a safe, collaborative solution to increase efficiency and, at the same time, see a rapid return on investment.

The robots are managed by Sorion’s Fleetware management software. The software integrates with the customer’s Warehouse Management System to receive and supply order data and then manages the missions by logistic priority.

Sorion’s Sextans process control software is used throughout the assembly line, acting as the interface to Fleetware and PLCs for the machine process section. Sextans offers an easy to use and intuitive interface designed for the production environment and is also used to collect process data for traceability purposes.

When a station needs a robot it will make a request to Fleetware for one to be delivered. Fleetware sends the best suited robot to each build station which have two lanes. The software decides which lane has priority, once priority has been determined

Sextans will start the process. When a station has completed its workflow process, it will determine which pre-station buffer (or buffer area) the robot needs to be sent and process pass / fail status.

The system enables AMRs to seamlessly interact with the entire production environment, including manual picking and assembly cells and machines for welding, clipping and inspection stations.

Results

The solution of fully connected AMRs transformed the isolated manufacturing cells into a fully automated, integrated production line enabling IAC to increase efficiency and reduce costs.

The system is flexible and can be easily expanded and adapted to changing production needs