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Pick and Place Unit

Pick and place unit

Tolerance Optimization for Enhancing Assembly Quality

A Robust Design review and redesign was performed on a complex pick and place unit (PPU) for auto-injector assembly with ~270 parts per unit on a fully automated aseptic assembly line delivering 50 units/min. The review and redesign was done using the RD8 Software.

The goal was to mitigate excessive use of fine tolerances to cope with 116 additional parameters needed for PPU to work. The baseline is 1 issue per assembly.

A Robust Design review was done on the 3D CAD model via the RD8 Platform, an analyssi of assembly process was done and on-the-job training in robust design methodology was provided for 5 engineers.

Impact

This approach took 8 weeks with 1.6 FTE's and improved the quality of assembly with the following improvements:

Elimination of need for fine geometrical tolerances (+/- 0.02 mm)
Reduction in variation of forces to control moving parts
Elimination of unintended stresses in assembled parts
Reduction in overall scrap-rate and resource-use during run-in
Increased customer satisfaction
Cost reductions of 5%
Pick and Place Unit for auto-injector assembly

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