How two large Electronic Component Manufacturers got benefited!

Fluid Filling, Robotic Dispensing, and Meter Mix Dosing are critical functions that have always been challenging areas to automate. This is a story of how we helped two international giants gain a significant competitive advantage by doing just that.

Among our many customers, we have served two of the world’s largest original equipment supplier to the global automotive industry. For them, we helped to completely automate the electronic potting process, a significant element of their task to set up a fully integrated plant.

Both these international giants were striving to scale-up their operations. They were looking to drive towards their development through the installation of automated production lines. However, these two world leaders had to address the following common concerns associated with the potting processes that were being followed –

  1. While automation was important, potting called for ensuring unmatched accuracy and quality and that there
    are zero compromises made with throughput. Quality Control was an integral part of the potting process.
  2. Complete automation, both in upstream, as well as downstream potting, was essential.
  3. As automation was made a cornerstone of the company’s manufacturing process, it was equally important to optimize not only the space but employing the right workforce was another major issue to be dealt with.
  4. The two industrial brands were focused on establishing benchmarks in process throughput of the process and to completely redefine the output of the process.
  5. It was critically important to closely monitor the production cycle.

Twin Engineers had the opportunity to partner with these companies to help them achieve these goals.huge

The solution

Twin Engineers had addressed the needs of this complex process by combining the three processes (currently requiring three stations) into a single brand-new machine. In the newly-automated potting process that is available in the modular system, conveyors carry the material on trays from a pre-heating oven to the potting machine and from the potting machine to the curing oven. This automation was deployed for both efficient atmospheric and vacuum potting.

The automation of these production lines for both our customers was a clear success. The automation delivered some vital benefits –

  • The automation had a direct and positive impact on throughput in the manufacturing process. The automated process needs no human intervention, hence provides improved efficiency and throughput.
  • The setting up of automated production lines had optimized the process layout.
  • The automation of production lines had given the company much greater control over their processes.
  • The automated process allows easy data logging for Quality Control and production monitoring on the factory floor.
  • Another benefit automation had brought was that now less space was required for the potting process since the three stations were effectively merged into a single location.
  • With production lines completely automated, the need for manual intervention, and the labour needed had reduced considerably.

A look into the future!

The automation of the potting production lines is already delivering significant benefits to these auto-component giants. However, there is always room for greater improvement. Twin Engineers are focused on driving more innovation in solutions that will provide even greater automation for delivering quality products. This is the right choice for driving both scale and quality for companies big and small looking to conquer the global markets.