Realizacja

Fully Automated Wiper Assembly Line

Name
Robotic Assembly Line for Automotive Wiper Systems
Industry
Automotive
Scope
Comprehensive design, construction, and commissioning of a fully automated assembly line for the production of automotive wiper mechanisms. The line covers the entire process — from automatic component loading, through advanced assembly operations, to final labeling and packaging of the finished product.

Challenge

The project was initiated to introduce a new wiper mechanism model into production while simultaneously increasing the volume of existing products. The client faced the challenge of improving efficiency, reducing cycle time, and optimizing the assembly process. Until then, the process relied on manual operator work. The existing manual assembly line proved insufficient — workstations were often idle, and two operators alternated on tasks, leading to wasted time and resources.

The goal of implementing the robotic workstation was also to showcase the plant’s modern production capabilities to the OEM end customer.

Technologies and Solutions

Component handling robots – 5 KUKA robots with grippers Hydraulic actuators for pin crimping Vision inspection station NOK reject station Dedicated assembly tools for multiple references, including Stanley automatic screwdrivers and Pick&Place system Quality control systems (rotation angle inspection, vision-based completeness inspection, start position verification) Labeling and packaging system Detailed process simulation in Plant Simulation Visualization – Siemens TP1200 HMI TDK Lambda GEN-40-38-PSINK power supply and Blocsma lifter Workstations equipped with light curtains and mechanical barriers Devices and tools for specified products – D3P2 LHD, BMW F6X LHD, BMW F6X RHD

Process and Execution

The project began with an in-depth analysis of the existing manual process. Our engineering team conducted optimization workshops and created a digital simulation of the entire process, considering every stage: operation sequence, robot layout, cycle times, and tooling requirements.

Based on the collected data, the equipment was designed and manufactured. Before final implementation, the entire line was tested in our assembly hall. After a successful trial run, the line was installed at the client’s site and finalized with operator training. The project also included after-sales service and technical support.

Results

Cycle time reduced to < 30 seconds per unit

Increased efficiency and throughput of the entire process

Reduction of workstations from four to one without compromising quality

High stability and repeatability of assembly

Quick changeovers between different product models

Finished products leave the line fully labeled and packaged