Faurecia HermosilloExhaust Manipulator

February 2008

Actual Process #1• Frist Staion is “Y

Collector”• Manipulator won’t

be required here because of the weight of the unit is still low and it is still easy to manually handle the piece.

Actual Process #2• Rollover 2 (Muffler’s welding)• In this station both rear

mufflers are installed and the piece gets close to the highest weight it will get.

• We have to consider the pick up position, it is at 90 degrees from the floor, the manipulator must be able to hook to it this way an then get it parallel to floor to seat it on the next station fixture.

• Check the marked points suggested to hold the piece from.

Actual Process #3• Chrome Pipe end

Welding.• This station is optional

(muffler assembly does not always pass thru here).

• When it needs to pass thru this process it will be seated on the fixture horizontally as shown in the picture.

Actual Process #4• Leak Test• This station requires the

piece that comes either from Station #3 (chrome install) or straight from Station #2 (Rollover 2)

• Piece must be positioned horizontal to the floor same as Chrome install, fixture has almost the same points of contact. See drawing from upper view.

Actual Process #5• Gage• In this station piece

gets measured to confirm the shape and measure specs

• Fixture holds the piece same as the previous stations but actually it is located in front of Leak test and manipulator must rotate 180 degrees over his own axle.

Actual Process #6• The last stage of the

process where the manipulator must intervene is positioning the muffler assemblies on the rack as shown, 90degrees from the floor and pointing different ways from each other as the arrows show.

Actual Process Layout Top ViewRoll Over #2Chrome Welding

Gage

Leak Test

Y Collector

Manipulator(s) route

• The idea to make the line more efficient using 2 manipulators is to get all of the work stations aligned as shown on the picture below.

Proposal Layout

Y Collector

Roll Over #2Chrome WeldingLeak TestGage

Rack

Proposal Rail System

1234

5

• Manipulator #1 (cyan color) will take Assembly from station 1 and transfer to station 2, it will require 90 degree tilt function.

• After dropping assembly on station 2 the manipulator must travel to last station to transfer between gage (4) and rack this will require 90 degree tilt and 180 degree rotation over his own axle.

• Then while the first operator installs the mufflers to the assembly on station 1 operator from the last station will return it.

• At the same time operator from station 2 or operator from station 3 can transfer 2 muffler assemblies at the same time from stations 2 and three to stations 3 and 4 with the second manipulator that must be double and used only to transfer assemblies on horizontal position.

New Process Description (only where Manipulator intervenes)

Proposed functionality on Manipulators

Proposed functionality on Manipulators