Our Client develops and builds high-quality, cost-effective state-of-the-art automated solutions for the automotive, medical, and other industries across North America. 


The scope is to design complete assembly line for the sunroof module with 13 in-line stations and 3 off-line stations with aggressive timelines using Solidworks software.

Why APA? 

APA has around 8 years of experience in the design of automation equipment, welding fixtures, assembly line and testing line automation, work stations/work cells, and EOAT (End Of Arm Tools). 

Design Challenges involved: 

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

  • Built-in safety features
  • Poka-Yoke features to ensure fail-proof assembly
  • Ergonomics

Design Process:

  • Understanding each station’s function and sequence of operations performed to determine the design elements. 
  • Designing 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. Incorporating pins and pneumatic clamps. 
  • Performing sizing calculations to select, linear guides, bearing, servo motors, actuators either linear cylinder or rotary cylinders  
  • Incorporating safety features such as rod lock cylinder, shot pin cylinder, safety laser scanner, guarding with light curtains and emergency stop 
  • Designing different hole positions and hole sizes for assembly process Poka-Yoke. Using sensors and vision cameras for the assembly checking process.
  • Incorporating ergonomic aspects such as table height, operator reach, seating height, etc.,
  • Ensuring reach and negate any clash.
  • Preparing assembly drawings and bill of materials.

Value Delivered:

  • We have performed sizing calculations of long-lead items such as Linear actuator, Linear guides, shot pin cylinder, etc., and get the confirmation from the respective manufacturers during the initial stage of design completion. This helped to speed up the construction schedule. 
  • APA Engineering is an “On-Demand Extended Design house” for our client. Design cost was just 40 % when compared to onshore. 

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