Case study improving car producers engine dress up assembly - Atlas Copco Egypt
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How to generate savings with process control in assembly

Discover how mistake proofing techniques improve your process control, increase connectivity and generate savings.

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Customer Challenge in automotive engine dress up assembly

An automotive manufacturer was in need of a new solution to improve it's engine dress up assembly. For the last years they have been working with a limited PLC based error proofing solution at one of the dress up lines which could only be expanded to other lines by a huge investement. Furthermore, the PLC based solution in  place was not able to manage NOK results to guide operators in rework or to identify and control the assembly in case of specific engine variants. This led to inefficency as well as high rework and operstors training costs.

Discover how we solved the issues and how many savings were generated: 

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SOLUTION
SOLUTION
In close cooperation on site we were able to understand the existing production process and specify renewal needs, in order to provide a smart connected Atlas Copco solution with a clean and fully integrated software platform.
 
In close cooperation on site we were able to understand the existing production process and specify renewal needs, in order to provide a smart connected Atlas Copco solution with a clean and fully integrated software platform.
IMPACT
IMPACT

NOK rate is now five times lower, Operators' training time is reduced by nearly 90% and the flex plate assembly is completely automated. 

 

NOK rate is now five times lower, Operators' training time is reduced by nearly 90% and the flex plate assembly is completely automated. 

REWORK COST SAVINGS 471.000 € (per year) 

REDUCTION OF OPERATORS' TRAINING COST: 65.000 € (per year)

INEFFICENCY COST SAVINGS 619.000 € (per year)

REWORK COST SAVINGS 471.000 € (per year) 

REDUCTION OF OPERATORS' TRAINING COST: 65.000 € (per year)

INEFFICENCY COST SAVINGS 619.000 € (per year)

 

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Download case study!

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Discover more about process control and error-proofing the production process!
Contact our experts for a free Walk-the-Line to analyze your optimization potential and find-out the great benefits for you, all at a short Return on Investment.

Download our Case study on Error-proofing and Process Control of engine dress up assembly here:

Error Proofing Automotive Quality Assurance Productivity Error proofing solutions Quality Case Studies Industry 4.0 & Smart Connected Assembly