Multi-variety production and assembly line automation | Preventing setup change interruptions to achieve mass production completion.
Optimize variety change control. Achieve zero downtime after switching through recipe management and fixture verification, completing mass production.
We solve issues such as unmet takt time after switching varieties and incorrect settings during changeovers in multi-variety, small-lot production through "changeover optimization design," which synchronizes jigs, transport, and control, thereby supporting the completion of mass production. - We want to eliminate line stoppages that frequently occur after changeovers in multi-variety production. - We aim to achieve zero jig setup errors and program setting mistakes during variety changes. - We want to automate the confirmation items for variety changes that currently rely on manual checks, reducing the burden on the shop floor. - We wish to establish an automatic transport line that maintains stability regardless of changes in workpiece shape or weight. - We desire a highly recoverable line that allows operators to resume work without confusion after an abnormal stoppage. The causes of stoppages in automated lines tend to concentrate "immediately after switching varieties" rather than during normal operation. Our approach is not just to line up equipment but to implement recipe management that centrally controls jigs, transport posture, robot programs, and inspection recipes via PLC, thereby proactively eliminating manual confirmation burdens and errors. In addition to shortening the changeover time itself, we minimize the outflow of defects and minor stoppages immediately after resuming. We realize a manufacturing line that stabilizes quality instantly even in multi-variety scenarios, contributing to a reduction in production preparation time. If you are concerned about "increased varieties leading to more frequent line stoppages," please consult us from the conceptual stage.
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basic information
1. Completion-type design aiming for "stability after changeover" In addition to a "consistent system," our company sets the design standard as "whether stable operation can be achieved from the first product after a variety change." We synchronize recipe management and physical verification to eliminate "balancing" on-site. 2. Control logic based on a field-oriented approach that incorporates abnormal recovery Not only is it important to avoid stopping, but it is also crucial to ensure that it is "easy to return after stopping." We automate the complex restart flow that varies by variety, compensating for the lack of resources for maintenance personnel. 3. Integration of "jigs, transport, and operation" from the perspective of a line builder We design jigs not merely as mechanical parts but as an integral part of the setup process itself. We consider the worker's movement paths, safe exchange positions, and cleanability to build an automated line that aligns with actual operations. - Automatic verification of jigs and workpieces using sensors and IDs to prevent mismatches between input work and recipes - Pre-start interlocks that detect residual work from the previous variety and inconsistencies in guide positions - Synchronized control of transport speed and stopping positions to accommodate changes in center of gravity and weight for each variety - Design of an operation screen focused on on-site recovery that visualizes where to restart in the event of an anomaly
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Applications/Examples of results
- Supported industries: Automotive parts, electronic components, medical devices, food, building materials - Application: Automated assembly for a wide variety of small lots, construction and modification of manufacturing lines with frequent product changes - Customization availability: Possible. Dedicated jigs and control designs tailored to work shape, weight, and holding position - Supported processes: Concept design, specification review, jig design, transport and control design, installation adjustment, mass production startup support
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Company information
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.
