Robotic Assembly Reduces Two-Man Operation to 15 Seconds of Automation

When a white goods manufacturer wanted to review production costs, Tex Plastics opted to invest in robotic automation of key assembly lines to achieve the saving required.

The appliance frame top took 5 minutes (and two people) to assemble by hand

The large appliance top frame was an awkward component due to in part, its size, and what needed to happen next. The frame needed expanding, so the fixing clips were wide enough apart to allow the laminate finished worktop to ‘drop’ into place. Then it was released, causing it to spring back, clamping the laminated top within the plastic frame assembly.

A universal part, the appliance top assembly was a fast moving part

As many white goods have the exact same dimensions, the ‘framing process’ was a high volume component assembly. This meant that if demand spiked, the only way of speeding up the process was by increasing the labour or investing in automation.

A win-win proposal meant lower cost assembly, more flexible delivery and a longer contract

Tex Plastics approached the client and put a proposal together which resulted in a lower unit cost per finished appliance top, delivered more flexibility in the delivery scheduling and resulted in a longer term contract and relationship. This ability to be innovative and entrepreneurial, taking a long term view – and supported by the Tex Holdings plc – is what enables Tex Plastics to give their clients The Edge.

The new robotic line assembly optimises the process and has resulted in less stock of the tops

The flexibility of assembly means the appliance tops can be called off in variable volumes. They are no longer tied to the laborious manual assembly and the line feed can be dynamically adjusted to increase volumes if required at little short notice.

Tex Plastics
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