Client: Reputable Automation Equipment manufacturer supplying to major OEMs.                                                           


Develop complete assembly line for the sunroof for a new automotive program.  The assembly line contains 13 in-line stations and 3 off-line stations with aggressive timelines using Solidworks software.  

Design Challenges involved: 

Every station designed, either manual, semi-automatic or fully automatic, should consider 

  1. Built in safety features 
  2. Poka-Yoke features to ensure fail-proof assembly 
  3. Ergonomics 

Design process: 

  1. Understand each station’s function and sequence of operations performed to determine the design elements.
  2. Design the fixture/ end of arm tooling for robots to ensure reach, where to hold the component and determine material depending upon the component to be held. Incorporate pins and pneumatic clamps.
  3. Perform sizing calculations to select, linear guides, bearing, servo motors, actuators either linear cylinder or rotary cylinders 
  4. Deploy safety features such as rod lock cylinder, shot pin cylinder, safety laser scanner, guarding with light curtains and emergency stop
  5. Design different hole positions and hole sizes for assembly process Poka-Yoke. Deploy sensors and vision cameras for assembly checking process. 
  6. Consider ergonomic aspects such as table height, operator reach, seating height etc. 
  7. Ensure reach and negate any clash. 
  8. Prepare assembly drawings and bill of materials. 


Value delivered: 

  1. APA Engineering is the “Design house” for our client.
  2. Design cost is just 40 % of the cost of design and consulting work were it to be done on-shore.