The quality criteria for the development and construction of sports car transmissions are very high. In order to meet the increasing demands for flexible and economical assembly, Plan B was commissioned to plan and implement a partially automated assembly line with over 150 different assembly aids.
The small series assembly is subject to the same very high demands on quality and documentation of process data as are usual in highly automated assembly in the automotive industry.
Assembly Planning:
Planning and temporal evaluation of assembly processes
Product design of components suitable for assembly
Planning and technical design of machines and systems (including layout)
Assembly Solutions:
Design and construction of the assembly line and equipment
Design of the control technology (including worker guidance system)
Monitoring of suppliers
Plan B has more than 20 years of project experience in the planning of gearbox assembly lines and is able to support the customer in all project phases - both in planning and implementation.
Our customer benefited from the Plan B team extensive skills and cross-industry experience, which enabled innovative and tailor-made solutions to be generated that meet the high quality and economic requirements of this project.
Sports car transmissions are exposed to very high loads and rapid load changes, which is why the assembly of these products is subject to very strict dimensional and manufacturing specifications. The quality requirements for the assembly of such complex products, which consist of many individual parts and a variety of joining processes, is a major challenge, especially in small series. The joining processes range from the manual joining of two components to the automated pressing process for oversize fits.
Complete documentation requires reliable processing, storage and clear presentation of all process data. It must be ensured that all components are assembled in the correct order and in the correct position. To support the workers, a worker guidance system in the form of a panel is used at each station, which displays the assembly contents and care points both textually and graphically. This means that the process data of electronic joining processes - e.g. Wi-Fi screwdrivers and presses - are displayed directly and clearly and the installation of function-critical components is validated by camera processes.
The gearbox is transported by the Plan B Workflowliner™, which transports large and heavy components from one station to the next with little effort. These are specially converted low-lift trucks that enable flexible, adaptable and therefore ergonomic assembly.
Planning a customer-specific, economical system
Supporting the customer in designing products for assembly
Production capacities tailored to requirements
Reduction of manual errors and increase in product quality
Realization of the flexible assembly line consisting of 11 stations with different levels of automation
Design and manufacture of 150 different assembly aids and load-handling devices
Transportation of the gearboxes using Plan B Workflowliner™
Complete logging of processes and increased data traceability
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