Process layout
Process Overview
Philliper had been handling the process of inserting nuts into the machine tool manually. Due to the repetitive nature of the work and insufficient precision, this led to reduced productivity and quality issues. To resolve this, they implemented an automation solution using four Hyundai robots and two Doosan robots.
Project Background and Objectives
Background
Philliper was experiencing work inefficiency and inconsistent quality in the existing nut-loading operation due to a manual process.
Key issues
Speed loss and quality variation occurring during manual operations
Increased operator fatigue and reduced productivity
Operator burden caused by repetitive tasks in the nut insertion process
Objectives
Improve production efficiency by automating repetitive tasks through robot deployment
Secure consistent quality and reduce defect rates through accurate insertion
Improve the work environment by reducing operator fatigue and strengthening safety
Components
| Robot | Hyundai Robotics (HH020-03) Doosan Robotics (H2017) |
|---|
Workflow
| STEP 1. | Pick nuts from the feeder |
|---|---|
| STEP 2. | Insert nuts into the product hole inside the machine tool |
| STEP 3. | After receiving the machine-complete signal, unload the product |
| STEP 4. | Load the product onto the conveyor |
| STEP 5. | Repeat the same sequence with alternating operation. |
Features
Maximized Efficiency
Using robot OLP, pre-validated programs can be uploaded immediately, reducing on-site setup and commissioning time.
Two robots are deployed on a single process for parallel operation, increasing cycle speed and throughput.
Improved Quality
Accurate insertion reduces defect rates.
A vision system is used for final quality inspection.
Flexible Production Environment
Integration of the robot and feeder supports handling multiple nut sizes.
With dedicated robot teaching support, the job can be completed in less time than expected.
Results
| Key Benefits | Productivity improvement: Parallel operation increased process speed by 20%, and continuous robot operation increased output volume. Quality consistency: Precision robot operation reduced defect rates by 15%, and integration with a vision system improved inspection accuracy. Improved work environment: Reduced operator fatigue and injury risk, and helped prevent musculoskeletal disorders caused by repetitive tasks. Lower operating cost: Higher efficiency compared to manual labor reduced overall operating cost. Faster project completion: By using pre-simulation and robot OLP, the project timeline was shortened (completed 20% faster than originally estimated). |
|---|---|
| Client Feedback | The customer stated, “After introducing robots, nut insertion inside the machine tool is now performed faster and more accurately. As a result, we achieved improvements in both process speed and quality. In addition, Marosol’s specialists provided direct teaching support, making on-site deployment very smooth. We were especially impressed with the thorough upfront preparation using OLP.” |

Unauthorized copying or reproduction of any content on Marosol may violate the Unfair Competition Prevention Act and Copyright Act.
Recommended Solution
Laser Welding of Round Bars using Yaskawa Robots
This welding automation solution utilizes the YASKAWA GP8 robot to perform high-precision laser welding on round bar products from multiple angles. Previously, an operator had to manually lift each workpiece, load it into the welding machine, and repeat the process for the opposite side once the first side was finished. This manual sequence has been fully automated using the robot. Continuous production is now possible regardless of operator availability. By leveraging the fast and precise YASKAWA GP8, the system achieves both guaranteed quality and enhanced productivity.
PCB Flex Cable Insertion using Epson N2 and FT Sensors
This assembly automation solution utilizes the Epson N2 robot and FT (Force-Torque) sensors to automate the highly difficult process of inserting Flex Cables into PCB connectors. It is the optimal solution for performing high-precision assembly tasks while minimizing cycle times within confined workspaces. This project was initiated to automate the Flex Cable insertion process, which previously relied entirely on manual labor.
Steel Plate Press Assistance using Dual Yaskawa Robots
This automation solution utilizes two YASKAWA robots to assist in steel plate press operations. By automating the machine tending process, the system secures high operational stability and safety. Due to the nature of press processes—characterized by extremely short cycle times and high-risk environments—industrial accidents involving human operators are frequent. In this specific solution, the robots hold the workpieces during the pressing operation itself. By having two robots perform continuous, synchronized cross-work, the cycle time is minimized to just 2 seconds per unit, maximizing overall productivity.










