Automotive Assembly Systems–Assembly Line for Rear Suspension Modules

Fori supplied a rear module suspension assembly line utilizing Fori Rail Guided Carts (RGC) as a conveyance and assembly method alongside two fully automatic drive-thru module alignment systems.

Features:

  • Assembly Jobs Per Hour: 45 jobs
  • Keys to Success: RGC conveyance, drive through alignment
  • Results: High build efficiency
  • Solutions: Pallet error proofing
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Drive-thru Suspension Module Aligner for Automotive Assembly

The assembly line consisted of (22) RGCs, two drive-thru aligners, (16) operators and various torque tools. The product for the rear suspension module varied between all-wheel drive and rear wheel drive vehicle variations. The build pallet on top of each RGC accommodated those variants and manipulated the ride height setting of the five link suspension by manually setting the ride height wheel in the correct position verified by a switch on the pallet.

A drive-thru aligner was also utilized within the system to help streamline the process. A lift and locate unit was located in each drive-thru aligner that would pick the pallet from the RGC and accurately present the suspension assembly for alignment.

Utilizing Fori’s RGCs allowed for a timelier changeover. The RGC system also provided long term flexibility supporting:

  • Accommodating future product changes that could add new stations.
  • Production increases that can affect station to station cycle times.
  • Production line shape if required.
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Fori Rail Guided Carts (RGC) with Custom Tooling Pallet

For more information about Fori Automation’s RGCs and assembly systems, please visit our website.

 

Automotive Assembly Systems — Assembly Line for Suspension Modules

Fori retrofitted an existing assembly line to accommodate the integration of a new vehicle platform.

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The required changes to the existing front corner, rear corner, rear main line, and front main line were accompanied by many challenges, including:

  • An increase of jobs per hour (62 jobs per hour)
  • Minimal downtime during retrofit
  • Increased product complexity
  • Rework of two existing module aligners

During extensive layout and process reviews, all areas that required rework were identified so a plan could be developed to add field kits which consisted of new portions of assembly line. In order to be flexible and to accommodate the heavy variation in product, a number of robotic torque applications were added each with a common trombone torque tool to be utilized on all module complexity types.

In order to accommodate the new product, two additional aligners were reworked from another customer plant and installed on a new conveyor section of the assembly line.

For more information about Fori Automation’s assembly products, please visit our website.