2010-01-19 - With the general uncertainty about the future of the UK’s manufacturing sector, coupled with a fixation on achieving short term returns, many UK manufacturers are often unwilling to consider investing in capital equipment, but even in the hard hit Tier 1 auto sub-supply sector there are reasons why investment in robot automation equipment will prove beneficial even in these uncertain times.
Magna Exteriors and Interiors, Hartlip Division, based in Kent is a manufacturer of interior trim components, primarily cockpit modules and instrument panels and supplies many OEM manufacturers within the UK. Being part of Magna, one of the most diverse automotive suppliers in the world, they continually look to develop their own processes and stay one step ahead of competition. Investment in robot based automation has expanded their capacity and increased their manufacturing efficiency in many of the processes they employ.
Working with an ABB Channel Partner
Working together with ABB’s Channel Partner Geku Limited, also based in Kent, and renowned for their extensive experience as a system integrator in the field of robotic technology, Magna have fully automated the insert loading, moulding removal and quality assurance processes associated with producing large mouldings on a ‘just in time’ basis to clients such as Jaguar, Land Rover & Honda.
Robots performing multiple tasks
Magna Exteriors and Interiors in Hartlip specialize in cockpit modules for various car manufacturers where they have made substantial investments with the introduction of ABB’s IRB 6600 six axis robots performing multiple tasks such as machine tending/handling, inserting and inspection of the product directly from the two thousand seven hundred tonne state-of-the-art injection moulding machines which produce a finished mould approximately every minute. Magna have been able to increase their productivity significantly when running at full capacity. This is partly due to the fact that the robots can handle the large product whilst hot, straight from the machine and perform the twenty point inspection test in cycle before the next moulding is produced - manually this would not be possible. Once the robot has completed the inspection check the product is then transported by conveyor to manual workers to trim any sprues. The robots have quick tool changing capabilities to accommodate different grippers for each of the cockpits Magna produce, which range from plain to fully grained and unique ‘soft texture definition’ finishes, some of which incorporate an innovative and specialised three layer composite process for one major player in the UK automotive OEM market.
Consistency of processes
Nigel Richardson of Geku comments “Our close proximity to Magna was an obvious logistics advantage but I think that the technical solution we offered played a more important part in securing the order. This is a safety critical part and we had to guarantee consistency of process to ensure that in the air bag area, only one mesh was ever inserted into the tool. We did this by first designing and building a reliable mesh de-stacking system which had an independent pick up from the robot and as extra security, the mesh was accurately gauged after separation from the stack to check that only one had been collected. Then, as a post mould operation, a vision inspection system was used to ensure that the mesh was moulded in the correct place, with the right features and all these things combined ensured a robust and secure process. Once the first system was proven, Magna quickly ordered a second almost identical system, so this proved the level of confidence they had in the process we had developed.”
Robots performing specialised tasks
Roger Larcombe, Engineering Manager at Magna explains, “We are always aiming for the ‘best in class’ manufacturing techniques due to the specialised processes we Engineer and perform within our factory. We have numerous applications that require attention to detail such as the specialised embedding of reinforcing mesh on to the back of the instrument panel mouldings, and the accuracy of our laser perforation for air bag safety release. This is why investment in the latest technology is paramount to be able to meet our customers’ expectations and robot automation has undoubtedly played a significant part in helping us to meet their requirements.”
Robots offer flexibility
Magna Exteriors and Interiors have been using Industrial Robots for over 25 years so its’ no surprise to find that there are many robots on site. “Around our factory we have other ABB robots performing tasks such as routing, milling and ultrasonic heat staking which have significantly cut down our tooling and maintenance costs whilst offering more flexibility and accuracy. Our staff skill levels have also developed and our Engineers are proficient in working with robots and some of the tasks now being performed by robots have also increased our levels of health and safety,” explains Roger.
Minimising the risk of downtime
Even with their own highly skilled front line maintenance team, Magna still supplement that with an ABB Service Agreement and with the new Remote Service Monitoring technology, where a robot’s health can be monitored by ABB whilst in production so that the risk of downtime can be minimised.
Mike Badger ABB Account Manager summarises, “This is an excellent example of an experienced local robot integrator meeting the needs of a major Tier 1 auto sub-supplier through the use of state-of-the-art robot technology and a close working relationship.”