Flexible Production Upgrade for Control Arm Welding
A PLC and HMI upgrade on two Lower Control Arm welding lines added a new production mode, allowing left-hand, right-hand, or paired parts to be produced independently. This resolved inventory imbalances caused by rejected parts and improved overall production flexibility.
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The welding lines were originally configured to produce left-hand and right-hand lower control arms as matched pairs. When a fault resulted in a rejected part on one side, an inventory imbalance was created between left-hand and right-hand components. These unmatched parts could not immediately be used to fulfill production requirements and often had to be stored until the inventory balance was restored.
The project included extensive PLC programming modifications and the development of new material-handling routines across robotic cells and fixture stations. Updates were implemented throughout the production process, including input, marking, milling, welding, and exit stations, ensuring reliable single-side production while maintaining existing line functionality.
HMI enhancements included production mode selection, status indication, and operator messaging to support the new operating modes.
Key Benefits
- Improved management of left/right inventory imbalances
- Increased manufacturing flexibility
- Reduced work-in-progress storage requirements
- Improved production efficiency following reject events
- Enhanced operator visibility and control
- Seamless integration with existing automation systems
