Realizacja

High-Efficiency Assembly Line for Premium Grills

Name
Robotic Assembly Line
Industry
Home Appliances (HA)
Scope
The project covered the comprehensive design, prefabrication, delivery, and commissioning of an assembly line that executes a range of advanced production processes: from precision screwdriving with torque control, through leak testing and flame tests, to product transport and buffering. Subsequent stages include labeling, closing and automatic carton sealing, visual inspection of labels, followed by automatic strapping, palletizing, and stretch wrapping.

Challenge

The client was opening a new plant and required a complete assembly line for the production of premium gas grills. The challenge was to create a highly efficient line designed for a large number of product variants differing in dimensions, weight, and accessory sets.

Technologies and Solutions

FANUC robot Siemens control system and PLC Control cabinets and HMI panels designed and manufactured by PROPOINT SERVICES ET200S control modules Integration with the client’s SAP system

Process and Execution

The project began with an advanced simulation in the Plant Simulation environment, which enabled precise analysis of workstation layouts, staffing requirements, and detection of potential production bottlenecks. As a result, the client gained an optimized assembly line layout tailored to real spatial and logistical constraints.

After concept approval, we integrated the efforts of all departments – from mechanical and electrical design, through PLC and robot programming, to system installation. The project, spread over several months, required effective coordination of deliveries, especially regarding electronic components. To maintain workflow continuity, temporary control modules were implemented with the plan to replace them with new versions once the supply chain stabilized. The final production line was designed for maximum efficiency and quality – handling technological processes in a logical sequence: from screwdriving and torque measurement, through leak and flame testing, to labeling, final packaging, and automatic carton sealing.

Results

Increased production efficiency up to 800 units per shift

High OEE achieved through optimal process organization and quality control

Full integration with the SAP system, enabling complete control of product models and production flow

Elimination of repackaging thanks to an optimized assembly process layout

High repeatability and end-product quality ensured by advanced technologies and automation

System readiness for future expansion and increased robotics integration