Pakistan Response | Automotive Body Assembly Line Automation and Integrated Design and Construction
Optimally merging robots and manual work. We will establish a "functional line" that operates stably even in the harsh environments of overseas sites.
We will construct a "optimal hybrid line" that highly combines automated welding by robots and manual work on a turnkey basis at our customer’s factory overseas (in Pakistan) for the side body assembly process of automobiles.
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【Equipment integration capability to solve on-site challenges】 ■ Concept and design capability: In addition to avoiding robot interference and adhering to takt time, we design jig structures that consider the posture and safety of operators. Even challenging projects that cannot be realized according to specifications are guided to a "feasible form" using simulations. ■ Advanced electrical control: We ensure quality through close collaboration between electrical and mechanical systems, optimizing interlocks for improved takt time and preventing welding defects caused by voltage drops. ■ On-site completion capability: We flexibly respond to unique challenges such as unstable power supply and dust environments overseas, as well as sudden process changes. By repeatedly teaching and making fine adjustments on-site, we take full responsibility until operations commence. Rather than simply "automating," we achieve a truly user-friendly and uninterrupted production line by considering design, control, and construction as a cohesive whole, tailored to the local production volume and investment balance.
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[Case Study] Pakistan: Automotive Side Body Assembly Line (Mixed Robot and Manual Work) ●Challenges Faced: Considering the balance between production volume and investment at overseas locations, coexistence with manual work was required instead of complete automation. Additionally, measures to address environmental factors that hinder stable operation, such as unstable voltage and sensor contamination due to dust, were essential. ●Implemented Measures: - Process Optimization: Conducted a high-difficulty simulation where two robots alternately produced parts on the left and right. Consolidated two jigs into one in some areas to reduce costs and space. - Electrical Stabilization: Implemented additional power cables and voltage boosting measures to address voltage drops in the manual welding process, stabilizing quality. - Refinement of Interlocks: Improved takt time through adjustments to control logic based on actual machine verification while ensuring safety. ●Results and Achievements: By consistently managing everything from concept to construction, a stable operation line tailored to the local environment was completed. The optimal balance between manual work and automation significantly contributed to the customer's production planning success.
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We, Thermix, a top-tier production line builder with proven expertise, handles automation and line construction for production equipment across diverse fields including automobiles and automotive parts, aircraft bodies, and industrial machinery. We provide full turnkey solutions from concept and specification review through design, manufacturing, installation, commissioning, and maintenance, ensuring reliable mass production launch. Leveraging our production technology expertise, we organize and visualize the current state, including process feasibility, integration with existing equipment, and safety. Utilizing industrial robots, image processing, conveyance/inter-process transfer, and material handling, we propose realistic automation roadmaps without unnecessary strain. We address challenges like “We want to reduce staffing on lines that can't be stopped” or “Equipment investment decisions are difficult,” accompanying you from small-scale PoCs to full-scale deployment with our project management expertise. Leveraging our domestic and international launch experience, we collaborate to create the optimal production line.
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