Production and assembly line automation | Achieving early recovery and stable operation through maintainability design.
Design for safety that allows for quick recovery after stopping. Visualize abnormal areas and minimize line downtime.
We will address the challenge of "long recovery times after the introduction of automated lines" through "maintainability design," which enables early identification of abnormalities and rapid inspection and replacement, maximizing annual operating rates synchronized with takt time. In response to the unavoidable "choco stops" in mass production, we will implement integration that allows for "equipment that can quickly return to operation" rather than "equipment that does not stop," leading to improved yield and true labor reduction. - We want to minimize equipment downtime during troubles and maximize line operating rates. - We want to improve the narrow maintenance space or the difficulty in inspections that prolong the replacement of consumables. - We desire equipment that can immediately indicate "why it stopped" on the operation screen during abnormal occurrences. - We would like the design to compensate for the lack of resources for maintenance technicians in the automation of production lines. - We want to safely carry out modifications to existing equipment while avoiding maintenance pathways and interference issues. We will reduce the inspection burden on maintenance personnel and complete a production line with stable quality. Please feel free to contact us for technical consultations regarding the construction of lines that pursue not only equipment capability but also maintainability.
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basic information
1. "Stop and return quickly" - A design philosophy prioritizing maintainability While general equipment manufacturers tend to focus on "operational specifications" such as takt time and robot selection, our company thoroughly implements "maintainability design" from the upstream conceptual stage, assuming small abnormalities (temporary stops) during mass production and minimizing recovery time. 2. "Layout and control integration" for rapid identification of abnormal areas and safe, reliable replacement By integrating machine design and control (HMI, interlock) to enable area-specific stops without halting the entire operation during abnormalities, visualizing remaining work, and ensuring accessible maintenance spaces for tools, we physically eliminate losses in on-site verification and inspection. 3. "Space and flow design capability" strong in modifying existing lines based on actual conditions In modification projects of existing lines with many constraints, we thoroughly verify not only the addition of equipment but also whether "sufficient maintenance space and worker flow can be secured after modification" based on on-site investigations. This prevents potential issues that are "difficult to inspect" after implementation.
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Applications/Examples of results
- Applicable industries: Automotive, transportation equipment, building materials, industrial machinery, etc. - Implementation purposes: New construction of automated production lines, improvement and modification of existing manufacturing line maintainability, support for labor-saving. - Customization availability: Possible (custom design tailored to the maintenance space on-site, worker movement paths, and access to consumables). - Supported processes: Conceptual design, mechanical design, control design (interlock and HMI development), installation, mass production startup. 【Features】 - "Area-specific stop design" minimizes impact without stopping the entire line during abnormalities. - "Visualization of workpieces" displays the position of remaining workpieces on jigs to prevent double feeding. - "Maintenance flow design" allows for easy tool access and ergonomic posture during replacement. - "Control design collaboration" enhances maintainability through the storage of abnormal history and appropriate interlocks.
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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.
