3M in Gagnef produces welding helmets, respiratory protective equipment and hearing protection, and is market leader in welding protection with Speedglas, welding helmets with automatic shade.
When 3M had to build a new final assembly line for a new range of models, the assignment went to Goodtech.
The semi-automated assembly line can assemble several different models simultaneously, and there is full traceability of incoming information. The control system manages communication from the business system to the line and back to the business system again.
About the delivery:
To enable the new line to cope with a production increase of around 200,000 units a year with the same staffing level, it was necessary to achieve a high degree of automation. After the manual soldering of PCBs, all assembly, testing and calibration could take place automatically.
The major challenge was that the continuous line had to handle several different models of the product simultaneously. This was achieved by building a layout based on a pallet handling system. The pallets have an identity label (RFID) that defines how the product is to be handled at the various stations.
The control system (PLS) keeps track of where the pallets are. The ID readers on the pallets are directly linked to the PLS, which communicates with a central database via Ethernet (TCP/IP) to obtain information about what each pallet contains.
The operator logs in at the soldering stations by swiping his ID card through a card reader. This enables the system to know who is sitting at the various stations, which order he is working on and how much he has produced during the day. When the operator logs in, he is given a list of which orders are to be produced in order of priority.
To optimise quality assurance on the assembly line, a process was created to handle faulty products. Products that are flagged with a fault at any of the control/test stations are returned to a manually staffed repair station. The pallet’s ID carrier states where the fault was detected, what is wrong and suggests a course of action. After being repaired, the product is returned to the line for new tests and final assembly. This work method guarantees that all products that are packed and sent to customers have been assured for quality and function.