Background

Our customer came to us with a tough challenge: they needed to build a complex Fuse and Relay Box meant to survive the harsh, demanding conditions of an engine bay. They were looking for a system that could guarantee highly reliable electrical performance while keeping up with heavy production targets. Drawing on our 30 years of global experience, we knew that hitting these goals meant getting their shop-floor automation perfectly synced with their data pipelines. The main objective was to deliver a flawless manufacturing setup that could handle the quirks of this specific module and help the business take its production efficiency to the next level.

Solution

To tackle these requirements, we designed and built a carefully orchestrated 9-station footprint. The whole setup kicks off with KUKA vision-guided robotic pick-and-place technology to make sure components are handled with absolute precision right from the start. We made sure to integrate real-time MES traceability handshakes across the line, creating a smooth flow of data between the physical build and the customer’s enterprise systems. When it comes to putting the internal pieces together, the assembly line uses carefully monitored press-fit insertions alongside automated hot-pulse pin staking. Because we stick strictly to a ‘No Faults Forward’ approach to make sure every single step is spot-on before moving to the next, we built continuous X/Y coordinate quality checks directly into the process. Finally, to ensure the module can handle extreme engine-bay environments, the assembly wraps up with a torque-and-angle structural fastening that locks and seals the unit tight.

Results

The finished system has given our customer an incredibly tough, high-yield automation process. By mixing precise assembly techniques with constant quality checks, we made sure the complex Fuse and Relay Box delivers the exact electrical performance they need.