Eight Million Brake Light Switches per Year

Sectors

Multiple sensors monitor each individual gripper within the entire complex insertion/extraction gripper system

 

Eight Million Brake Light Switches per Year

Sectors

While the Scara places contact pins in the buffer, the big six-axis robot operates the injection molding machine

Eight Million Brake Light Switches per Year

Sectors

A Scara robot and a hinged bracket robot work hand in hand in a con- fined space to produce eight million brake light switches annually

Eight Million Brake Light Switches per Year

The production of eight million brake light switches annually is subject to its own set of priorities. Flexibility is less important here than other factors such as maximization of output and reliability of process.

Multiple sensors monitor each individual gripper within the entire complex gripper system

When a car manufacturer nowadays relies on just one provider for the mass production of a component, that amounts to both an honor and a responsibility for the chosen supplier. Body Control Systems (BCS), a subsidiary of worldwide automotive supplier TRW, is responsible for the production of eight million brake light switches annually for the Volkswagen Group. As a global company with more than 4,000 employees in 12 countries, BCS supplies all the major automotive  original equipment manufacturers worldwide and therefore has the expertise and organizational structures necessary for such operations.

Close to the Zero-Fault Production

After removal, the six-axis robot places the finished molded parts into groups of eight in a workpiece  carrier. A linear system then picks up the brake light switch- es and passes them to the subsequent work stations for the prescribed quality checks, including a continuity test and measurement of the length of the contact pins. The tested brake light switches sub- sequently  leave the plant on small load carriers that have been already placed in position. The plant operates in three shifts around the clock.

“Over 10,000 brake light switches leave the production  cell per shift. With  only two to three defective parts per 10,000 units, we are close to having zero-fault production”, summarizes Jochen Ley. “In addition, the plant meets all of our re- quirements, producing parts reliably, quickly and economically. With the large- scale production  of eight million switches annually to contend with, we could not have it any other way.”

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Published in:
Kunststoffe international

publication date:
3, 2014

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