Case Study Videos

This 100 foot long cell is an example of a straight ESD cell with single unit flow and on line test for a high volume electro-mechanical product. Other features include custom fixtures, a powered empty cart return, lift and lowering elevators at each end of the cell and mobile parts flowracks.

This cell features single piece production with improved ergonomics, supermarket parts presentation, tool handling, on line test and many other enhancements. Other options include, height adjustability, fixturing, error proofing, elevators and automated empty pallet return.

This cell produces a heavy mechanical product. Our fixturing provided manipulation and rotation in two planes which combined with a optimized track height provided efficient worker ergonomics and simple product transfer.

Two long cells for a 250# product. The unique cart design enabled operators to on line inspect for QC. Production flow was a combination of free and powered conveyance.

Two custom Fleximate cells featuring unique overhead return of empty pallets due to unique fixturing. Cart tops featured rotation for this high volume automotive application.

This application includes a progressive flow through a low temperature oven in a clean room. Also featured is a post cure powered, section for cool down, Custom workstations were integrated into the line to minimize handling of the heavy product and fixture.

This complex mechanical assembly required some fresh thinking for multi access assembly. Custom work surfaces assisted in worker ergonomics and assembly productivity.

This cell featured a re-manufactured product which required that all reused components remain together. We provided a means of keeping the family of parts together with the product housing.

On line supermarket parts presentation supporting a high volume, high mix production schedule.

Two sliding pallet cells featuring custom tool presentation, poke yoke, universal fixturing details, and custom power, signal and air distribution. Automated pallet return with elevators and ESD control were other design criteria.

In this application, fixturing and parts presentation was created to produce completely different products. Sub assembly stations produced at point of use with quick change over capability to support mixed model flow. An overhead lift with a lifting yoke made packaging a safe, single operator operation.

This cell was designed to handle a wide range of product sizes by incorporating some unique controls and varied parts presentation.

A low volume product that was transitioned from batch to progressive assembly. Unique challenges included height adjustability, multi product, quick change, adapter plates and inline leak testing.

Electro mechanical assembly cell with fixturing challenges. Also included was a product tilt assist that transitioned the process from an unsafe, two operator lift to a semi automated, single operator, ergonomic operation.

This cell successfully transitioned a high mix, low volume production from batch to single piece, progressive production. The design wish list included the ability to handle high torque assembly, dual test bays with out production constrictions and an anti-tip safety feature.

An in depth assembly examination yielded some beneficial fixture considerations. An end of cell, lifting arrangement made packaging a safe, single operator process.

This mature product was transitioning to a single piece flow with standard work procedures. We incorporated ergonomic fixtures and a high pressure test process in line and yielded high productivity.

This cell featured a stainless steel fixture plate rolling on custom roller tracks with multiple safety features for up to a 1200# product. The high mix, low volume product line required height adjustability, low effort, production flow, and multiple test bays. A powered turntable allowed production to flow, uninterrupted, into one of three test positions.

Multiple work height stations, high performance ESD control and integration of a UV cure tunnel were just a few of the requirements for this electronic product's production.

This cell features universal fixturing for multiple models, product lift assist by a single operator and the ability to be staffed by 1 to three operators. A shuttle system provided a simple method for empty fixture and cart return from the end of the cell to the head.

ESD Assembly Cell 2020 d1

A flexible cell incorporating a custom press, universal fixturing and poka-yoke.

This project involved the mixed model assembly of a heavy product. Objectives included: error proofing, improved production flow, enhanced assembly ergonomics and maximizing space utilization.

A constriction free, multi-unit, one piece flow, test cell used for high mix production flow.

See a "U" configured assembly cell with ESD protection that allows the team to work "one ,one down" depending on product mix and production volume. Right sizing delivers maximum space utilization in tight quarters. Powered empty cart return with elevators at each end of the line eliminated operators having to deal with empty carts.

A right sized cell for a 100 pound product that single piece flows to point of use.

Lean sub assembly cells feature single piece production flow, ergonomics, on-line test and line side, point of use presentation.

Worksmart Systems' modular Fleximate Integrated Workstations are the answer for simple DIY Cell construction. They can also be the basis for automation and system integration as shown in this video. Simple, complex or in between, Worksmart has your production solution.

This unique 6 position, assembly cell features pallets flowing on ESD timing belts and individualized ergonomic height adjustable workstations. Other custom design enhancements include quick change tooling to support real time, mixed model production changeovers, on-line test and component shadow boards for poka yoke assembly.