Lamp Assembly Automation Using Yaskawa GP12 and Robostar RPA80-4B

#LampAssembly#AssemblyAutomation#AutomotiveManufacturing#YaskawaRobot#SCARARobot#InspectionAutomation#QRCodeLabeling#ProductivityImprovement

Process Overview

This assembly automation solution automates automotive lamp assembly and inspection processes using Yaskawa GP12 and Robostar RPA80-4B robots.

By utilizing two Yaskawa (vertical articulated) robots and two Robostar (horizontal articulated, SCARA) robots, the entire process is divided based on takt time, enabling continuous operations to be completed within a short cycle time. In addition, the solution performs inspection processes and QR code labeling after assembly, achieving end-to-end process automation and minimizing defect rates.

Components

Robot	Yaskawa GP12 x 2 units 6-axis articulated robot Payload: 12 kg Working range: 1,440 mm Weight: 150 kg Repeatability: ±0.08 mm Yaskawa MotoMINI x 1 unit 6-axis articulated robot Payload: 0.5 kg Working range: 350 mm Weight: 7 kg Repeatability: ±0.02 mm Robostar RPA80-4B x 2 units 4-axis SCARA robot Payload: 20 kg Working range: 800 mm Weight: 74.5 kg
Peripherals	Pallet lifting device x 3 units Pallet discharge device x 3 units Discharge conveyor x 3 units Turntable workstation Internal heating device Internal compression device Lamp front cover assembly device External compression device Cooling station Performance inspection device Industrial QR code printer QR code reader Vision system for part position verification

Workflow

STEP 1.	Product picking
STEP 2.	Air blowing
STEP 3.	Load product onto turntable
STEP 4.	Insert internal assembly parts
STEP 5.	Internal heating
STEP 6.	Internal compression
STEP 7.	Front cover assembly
STEP 8.	External compression
STEP 9.	Product cooling
STEP 10.	External compression
STEP 11.	Lamp performance test
STEP 12.	QR code labeling
STEP 13.	QR code inspection
STEP 14.	Defective/NG product discharge
STEP 15.	Discharge pallet stacking

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Key Features

Improved Production Efficiency and Enhanced Quality

Improves production efficiency through continuous operation by minimizing idle time
Minimizes defect rates by performing 100% inspection and testing processes
Reduces cycle time by optimizing work distribution based on LOB (Line of Balance)
Optimizes the process flow based on product manufacturing characteristics
Reduces the number of operators by minimizing management points

Implementation Results

ROI Period	26 months
Key Metrics	Improved productivity Improved quality through 100% inspection and testing
Client Feedback	We required continuous operation due to a short takt time, and through Nautechnics’ solution, we were able to redistribute the process and improve both productivity and quality.

Lamp Assembly Automation Using Yaskawa GP12 and Robostar RPA80-4B

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Estimated Project Duration: 0week

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Process Overview

This assembly automation solution automates automotive lamp assembly and inspection processes using Yaskawa GP12 and Robostar RPA80-4B robots.

Components

Workflow

Key Features

Improved Production Efficiency and Enhanced Quality

Implementation Results

Lamp Assembly Automation Using Yaskawa GP12 and Robostar RPA80-4B

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