Faucet Assembly using Five Doosan M0609 Units

Industry > MachineApplication > AssemblySector > Manufacturing

This assembly automation solution utilizes five Doosan M0609 collaborative robots to fully automate the end-to-end assembly process of faucets.

Previously, this process required a large number of workers to manually assemble each unit. By integrating collaborative robots with a conveyor system, continuous production across the entire process has been achieved.

The transition from a manual line (where 5 workers produced 1,000 units per day) to an automated line (where 2 workers produce 1,200 units per day) has resulted in a significant improvement in productivity.

Components

Robot	Robot: Doosan M0609 (5 Units) 6-axis articulated collaborative robot with 6 integrated torque sensors. Payload: 6kg Reach: 900mm Repeatability: ±0.05mm Weight: 27kg

Workflow

STEP 1.	Assembly of the faucet diverter valve plug (Robot 1).
STEP 2.	Loading the hot/cold water pipe connection plugs into the screw fastener (Robot 2).
STEP 3.	Assembly of the hot/cold water connection nuts onto the faucet.
STEP 4.	Insertion of the flow control valve (Robot 3).
STEP 5.	Insertion of the flow control valve retaining nut (Robot 3).
STEP 6.	Tightening of the flow control valve retaining nut.
STEP 7.	Flow control leakage testing.
STEP 8.	Insertion of the flow control handle.
STEP 9.	Insertion of the flow control handle fixing pin.
STEP 10.	Completion of assembly and discharge.

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Key Features

Improved Production Efficiency and Quality

Continuous Operation: Maximizes production efficiency by performing seamless, non-stop tasks with minimal idle time.

100% Inspection: Minimizes defect rates by integrating automated quality checks throughout the process.

Labor Optimization: Reduced the required manpower from 5 workers to 2 by minimizing management overhead.

Enhanced Operational Safety

Omnidirectional Sensitivity: High-resolution torque sensors (0.2Nm) on all 6 axes allow the robots to detect and react to subtle collisions from any direction, ensuring worker safety.

Shock-Minimizing Logic: Applies compliance control during picking and unloading to react softly to external forces, protecting delicate faucet finishes.

Compact Installation

Space Efficiency: Utilizes the compact design of collaborative robots to minimize the footprint; the entire automated line occupies only 2m x 6m.

Easy Work Teaching

Direct Teaching: Operators can teach points intuitively by manually moving the robot arms.

Precision Handling: Compliance control via torque sensors allows the robots to perform "soft" tasks like inserting and pushing components with the appropriate force.

Implementation Results

ROI Period	14.4 months
Key Metrics	Before: 5 workers produced ~1,000 units/day (200 units per person). After: 2 workers produce 1,200 units/day (600 units per person).
Client Feedback	As customer demand grew and requirements became more diverse, our process steps and workload increased. By automating the continuous mass-production stages with cobots, we’ve boosted productivity enough to meet the rising demand.