Automotive Windshield Glass Assembly
How a strategic automated assembly solution saved a manufacturer over $1mil and reduced their assembly area footprint by 50%
Company Profile
Carlex is a leading manufacturer of automotive glass, specializing in the production of frontlite, sidelite, and backlite glass. Known for its high-quality products and innovative solutions, Carlex has been a key player in the automotive industry for years.
Objective
The customer needed a new solution for windshield glass assembly. The challenge was to develop a cost-effective, smaller footprint solution with similar throughput for lower-demand products.
Previous Process and Challenges
Traditionally, windshields are assembled on large, automated assembly lines. While efficient, these systems required substantial floor space, significant capital investment, and were difficult to reconfigure for new product lines.
The existing production line was at capacity and needed repurposing for new business. A cost-effective alternative was required to continue producing the existing windshield and a new one in a different facility. The main challenges were reducing the footprint and cost while maintaining production rates.
Project Scope
The objective was to create a system that could:
- Pick formed, treated, and printed front window glass from two racks.
- Apply primer for adhesive promotion.
- Install a camera bracket, perimeter seals, locating pins, and a wiring harness.
- Verify all components' presence and proper installation.
- Test wiring harness continuity.
The system needed to be flexible to handle multiple part numbers with minimal tooling changeover.
Timeline
The project had a strict 9-month timeline, from concept to start-up on the customer's floor, requiring precise solutions and flawless execution.
Project Challenges
Several challenges were encountered:
- Gentle Handling: Glass requires careful handling to avoid breakage while meeting cycle time requirements.
- Technology Implementation: New technologies were needed to ensure product quality.
- Glass Variability: Formed windshield glass inherently has variations in edge position and curvature.
System Overview
The automation cell designed by Arnold Machine featured:
- **Glass Handling:** Racks of formed and printed front windshield glass were unloaded from intoexisting dunnage racks.
- **Squaring Station:** Robot 1 picked glass, squared it, and then re-picked it for edge positioning.
- **Primer Application:** Robot 1 moved the glass to a primer station, using a fixed dispense head and robotic motion, with a vision system to ensure correct application.
- **Camera Bracket Installation:** Robot 1 placed the glass on a camera bracket table. A 3D vision system identified the exact location for the camera bracket.
- **Plasma Treatment:** Camera brackets were plasma-treated by Robot 2 for adhesive promotion.
- **Urethane Application:** Robot 3 applied urethane to the camera bracket and verified the application with a vision camera.
- **Bracket Installation:** Guided by 3D vision data, Robot 3 placed the camera bracket on the glass.
- **Seal and Pin Installation:** Robot 4 placed the glass into fixtures for perimeter seal and locating pin installation.
- **Wiring Harness Installation:** The operator installed the wiring harness and performed a continuity check on a dedicated table.
- **Quality Control:** Any QC failures triggered an operator intervention to address the issue via the cell HMI.
How End Product Helped Company
The automation cell met the customer's budget and space constraints while fulfilling their production and quality requirements. It provided flexibility to produce multiple part numbers at similar rates to larger systems. The cell's compact design and cost-effectiveness also allowed for easy retooling for future products.
Results, ROI & Future Plans
The project was executed successfully, meeting the desired cycle time and repeatability. Delivered on time and on budget, the system allowed Carlex to maintain production without sacrificing quality or throughput. Operator training ensured the system operated at its full potential.
Metrics
- Labor Reduction: Reduced dependency on manual assembly, potentially saving several operator positions.
- Enhanced Quality: Automated verification reduced the likelihood of errors, improving overall part quality.
- Material Savings: Controlled application of materials minimized waste.
- Production Impact: Provided the necessary production capacity, enabling Carlex to pursue new business opportunities.
Cost Savings
- Initial Investment: The new cell cost approximately $1.4 million, saving about 40% compared to the $2.2-$2.5 million cost of a large assembly line.
- Space Savings: The new cell occupied about half the floor space of the larger systems.
Future Expansion
Carlex is now better positioned to secure new business, with the potential for further collaboration with Arnold Machine for additional automated cells. The project's success demonstrated the feasibility of producing windshields with reduced costs and floor space, paving the way for future growth.
Lessons Learned
Key takeaways include the importance of precise handling of glass, effective implementation of new technologies, and the value of thorough operator training. The project's success has reinforced the potential for innovative, compact, and cost-effective solutions in the automotive glass industry.
