Case Study: How did we manage to reduce labor costs and increased productivity by automated assembly

automated assembly of custom made parts by FT Metal

A very important part of our manufacturing business has been the assembly of 2 or more components ( Mostly parts made of zamak, steel and plastics manufactured by us ) to get the final product as our customers ordered. 

Usually these assembly and some secondary tasks like threading have been conducted by skilled workers. However, in this very competitive world, in order to increase both the production capacity and quality of final products we prefer to invest in automated assembly machines, lines and special purpose machines.

This proved to be a very effective way to match the expectations of our customers.

Here we show some works that we accomplished by using assembly machines and automation.

 

1.- Assembly Line for Parts used in washing machines of a leading Turkish Manufacturer

Assembly Process Before Automation

assembly of washing machine parts
The assembly process was manual before switching to automated system.

Assembly Process After Automation

Design of automated assembly line
We designed an effective automated line for the assembly process of parts

The Result

The view of assembly line
  • The number of workers reduced from 8 to 3.
  • The quality issues have been totally eliminated.
  • The production capacity have increased with automation.

2.- Improving the Production Process of a Lock Mechanism Part with Automation

Assembly Process Before Automation

Before improving the process, the 3 components of this critical part from an industry leading European manufacturer were being assembled manually.

The 2 components other than the spring were manufactured by us and then they were asembled and packed as per customer requirement.

Lock mechanism part production and assembly
The assembly process was manual before switching to automated system.

Assembly Process After Automation

Automation of assembly

The Result

Finished assembled part
  • The number of workers reduced from 4 to only 1
  • The quality issues have been totally eliminated.
  • The production capacity have increased with automation.

3.- TV Socket Production and Assembly of Components after Manufacturing Processes

Assembly Process Before Automation

This TV socket comprises of 5 components. These components are manufactured by us and after required tasks like coating they go through assembly line.

As quantities are large and quality is vital as it is always, we designed and made an assembly system and automated the process.

TV socket manufacturing and assembly
The final product formed by assembling these 5 parts.

Assembly Process After Automation

The Result

  • The number of workers reduced from 5 to 2.
  • The quality issues have been totally eliminated.
  • The production capacity have increased with automation.