Manufacturing Projects
Every company that produces a product does so using a unique manufacturing process that is designed to fit their business model and manufacturing needs. There comes a time when the manufacturing process will need to meet higher productivity, reliability, quality, availability, increased performance, and reduced operating costs and defects. Our experienced engineers have the expertise to work with you to design, build, and implement a customized, automated solution that fits your specific production process and budget.
Aluminum Fence Assembly
Building Materials Industry
The Project
Manual assembly processes can be time-consuming and less efficient compared to automated systems. The challenges of increased labor costs, safety and quality issues, a need for increased production capacity, as well as cost & efficiency concerns lead to the development of this project. This assembly system was designed to be operated by one or two operators. The station will directly reduce the number of employees needed to build product; it will increase the speed of production as well as increase quality.
Battery Assembly Line
Battery and Energy Industry
The Project
Future proofing your battery manufacturing process is a key element of any automation project. This project required Alliance Automation to assemble and test battery packs on two separate lines. The customer was not certain of the future of the specific battery, so Alliance developed a design that would allow the customer to alter the type of battery packs that would run on the line and could also reduce the number of operators need to operate it in the future. This system also offers English and Spanish text, ensuring that no matter who operates it they can read the screens.
Battery Assembly and Inspection
Battery and Energy Industry
The Project
Due to the increased demand of batteries, companies are looking to Alliance Automation to develop innovative designs to overcome assembly challenges. Mistake proofing the assembly process is paramount to the assembly cells, quality is king in battery production and testing. Assembly cells must increase speed of production, reduce scrape, improve throughput efficiency, and allow for minimum operator interaction. To reduce floor space, each cell will assemble multiple configuration types to be ran on the same equipment with a fast change over. Scanning and collecting test data from production is readily available.
Dial Table Assembly & Test Cell
Consumer Goods Industry
The Project
Alliance won the AAV Assembly machine project because we could resolve the four manufacturing challenges; condense floor space, reduce labor, increase rate speed, and finally remove the bottle neck at the leak test station. The original process used 4 operators in 2 separate stations to produce two separate sized products at a rate of 350 parts per hour. Alliance was able to provide a single assembly cell that would accommodate both sized parts using different nests. One operator was able to operate the machine and pack-out the products all while producing 720 parts per hour. This increased rate was achieved by putting all key functions in one machine and having the parts on a dial table.
Extruded Deck Board Stacking System
Consumer Goods Industry
The Project
Manually stacking extruded deck boards is a repetitive job that requires strenuous labor and operator’s full attention. This stacking system is designed to allow for multiple unload/load bays and uses a 2-axis gantry. By implementing two of these gantry systems, our customer was able to free up multiple material handlers which allowed them to add value to other areas of the business.
Pallet Stacking System
Automotive Industry
The Project
This single operator pallet stacking system was designed to replace a very manual system. Alliance Automation has worked with the customer to ensure a 60 second part-to-part cycle time to stack specific pallet sizes that works with the existing plant machines and equipment. In addition to automating this existing station, Alliance removed the existing equipment, installed and integrated the new equipment, and finally programmed the system onsite for the customer. Automation means different things to different company’s, give us a call to discuss your challenges that may benefit from being automated.
Automated Panel Saw
Consumer Goods Industry
The Project
This system was installed to ensure accuracy in cuts and to make the operation safer for employees. By having the operator load the panels and scan each product label the system takes over the dangers part of the process and automatically adjusts the saws for a perfect cut every time. The operator does not have to do anything further until the system sends the completed product to the unload area where it is physically removed from the line.
Planetary Machining
Consumer Goods Industry
The Project
The Planetary Machining project aimed to develop a comprehensive robotic solution to focus on automating key steps of the process such as cross drilling, reaming, bushing & shaft pressing, and tray handling. By automating the stages of the process, the project increased production throughput, improved product consistency, and reduced reliance on manual labor. The modular design allowed for versatility in handling different bushing assembly styles. The integration of advanced automation technologies and the user-friendly HMI interface contributed to the project’s overall success in enhancing efficiency and quality in blender production.
Slitter Table
Consumer Goods Industry
The Project
Engineered with a paramount focus on safety, the automated SMC slitter table has maintained its operational efficiency for over 15 years with minimal maintenance. Equipped with dual safety light curtains, pneumatic pilot-operated check valves, a safety PLC, and safety-wired fasteners, the system ensures the well-being of your team while minimizing potential damage to molds. The utilization of servo motors within a closed-loop feed control system results in rapid and precise cycle times without compromising accuracy. The innovative quick change-cutting system integrates standard utility knife blades, obviating the need for costly cutting wheels that require frequent sharpening. Enhanced by a recipe-based PLC, the system offers precise and flexible data recording capabilities. Its compact footprint enhances facility versatility and is bolstered by the industry-leading service department of Alliance Automation.
Wire Whip Hub Machine
Consumer Goods Industry
The Project
Alliance won the AAV Assembly machine project because we could resolve the four manufacturing challenges; condense floor space, reduce labor, increase rate speed, and finally remove the bottle neck at the leak test station. The original process used 4 operators in 2 separate stations to produce two separate sized products at a rate of 350 parts per hour. Alliance was able to provide a single assembly cell that would accommodate both sized parts using different nests. One operator was able to operate the machine and pack-out the products all while producing 720 parts per hour. This increased rate was achieved by putting all key functions in one machine and having the parts on a dial table.
Manufacturing Automation Opportunity Areas:
- Assembly
- Inspect
- Palletizing
- Packaging/Shipping
- Testing
- Material Handling
Companies need a partner they can trust to install robotics, vision, laser inspection, sensors, and part testing into their production lines. Whether it is a fully automated line or specific tasks, automated equipment is ideal for completing repetitive tasks like moving parts across stations, applying sealants, and joining materials.
Who We’ve Worked with in the Manufacturing Industry
Is Manufacturing Automation Right for your Business?
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Is your current manufacturing process struggling to meet quality standards?
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Do you have a new product or change to a product that needs added to your production process?
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Is it time for your company to bid for new business opportunities and gain assistance?
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Have you struggled with labor requirements for production?
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Are your current customers requesting new functions or testing to be integrated into production?
Why you should Join the Alliance
When you partner with Alliance Automation you're getting more than just a robotic solution.
Alliance Automation is here to design, build and install a custom solution to fit your exact needs. Our products will solve your business challenges. How? We follow the Alliance Proven Process. Alliance Automation doesn’t just sell you a product; we get to know your business and find solutions to help you reach your goals.
What we offer:
- Project Review
- Risk Analysis and Risk Assessments
- Budgetary and complete project proposals
- CAD Designers
- Fabrication
- Toolmakers
- Machinists
- Mechanical Engineers
- Electrical Engineers
- Controls Engineers
- Project Managers
- Full Implementation teams