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RESOURCES
Explore Our Expertise
JR Automation provides resources to ensure your success in automation. With case studies, thought leadership, and brochures, you can build your expertise in automation.
JR Automation Case Studies
From assembly automation, welding, dispensing, and vision systems to process design, controls engineering, and software integrations — JR Automation has built custom technology solutions for every application, process, and industry. Our customers are global leaders in their industries, including automotive, ecommerce, healthcare, and consumer products manufacturing industries. We’ve helped them reach new heights in productivity and quality.
JR AUTOMATION'S THOUGHT LEADERSHIP
Automation solutions can evolve rapidly. JR Automation is on the cutting edge of robotics integration and data and software solutions. Learn more about this growing area in manufacturing with our thought leadership.
Advances in automation are happening in nearly every vertical. Learn about the future and trends happening from the experts at JR Automation.
Advances in automation are happening in nearly every vertical. Learn about the future and trends happening from the experts at JR Automation.
Advances in automation are happening in nearly every vertical. Learn about the future and trends happening from the experts at JR Automation.
Learn more about how manufacturers use robotics and automation to improve their production lines from the experts at JR Automation.
Learn more about how manufacturers use robotics and automation to improve their production lines from the experts at JR Automation.
Learn more about how manufacturers use robotics and automation to improve their production lines from the experts at JR Automation.
Warehousing automation can save labor costs and improve productivity. Learn how to use automation and types of automation to incorporate from our experts.
Warehousing automation can save labor costs and improve productivity. Learn how to use automation and types of automation to incorporate from our experts.
Warehousing automation can save labor costs and improve productivity. Learn how to use automation and types of automation to incorporate from our experts.
Traditional fulfillment processes are infamous for lengthy picking times, inefficient storage space, and congested shipping areas. Learn about JR Automation solutions to optimize ecommerce order fulfillment and material handling
Traditional fulfillment processes are infamous for lengthy picking times, inefficient storage space, and congested shipping areas. Learn about JR Automation solutions to optimize ecommerce order fulfillment and material handling
Traditional fulfillment processes are infamous for lengthy picking times, inefficient storage space, and congested shipping areas. Learn about JR Automation solutions to optimize ecommerce order fulfillment and material handling
Smart manufacturing is not just limited to the process of transforming materials into a product. Thanks to the exponential growth in technology, we now have faster processing powers, more extensive data-handling solutions, edge devices, and more widely available rapid networking solutions at a large scale.
Smart manufacturing is not just limited to the process of transforming materials into a product. Thanks to the exponential growth in technology, we now have faster processing powers, more extensive data-handling solutions, edge devices, and more widely available rapid networking solutions at a large scale.
Smart manufacturing is not just limited to the process of transforming materials into a product. Thanks to the exponential growth in technology, we now have faster processing powers, more extensive data-handling solutions, edge devices, and more widely available rapid networking solutions at a large scale.
Here we are living in the fourth industrial revolution: the digitization of data and systems that transform that data into information — information that operators, CEOs, and all layers in between can use to make decisions or be presented with context and recommended actions to take by the manufacturing execution systems (MES).
Here we are living in the fourth industrial revolution: the digitization of data and systems that transform that data into information — information that operators, CEOs, and all layers in between can use to make decisions or be presented with context and recommended actions to take by the manufacturing execution systems (MES).
Here we are living in the fourth industrial revolution: the digitization of data and systems that transform that data into information — information that operators, CEOs, and all layers in between can use to make decisions or be presented with context and recommended actions to take by the manufacturing execution systems (MES).
Learn more about assembly line automation from the experts at JR Automation.
Learn more about assembly line automation from the experts at JR Automation.
Learn more about assembly line automation from the experts at JR Automation.
A data-first manufacturing facility begins with defining and understanding analytics and use case requirements, then identifying and generating all data required to support them. Learn more about how incorporating data collection systems into your facility can improve your processes.
A data-first manufacturing facility begins with defining and understanding analytics and use case requirements, then identifying and generating all data required to support them. Learn more about how incorporating data collection systems into your facility can improve your processes.
A data-first manufacturing facility begins with defining and understanding analytics and use case requirements, then identifying and generating all data required to support them. Learn more about how incorporating data collection systems into your facility can improve your processes.
Turnkey Models
A fully customized solution isn't always the answer. Our standard platforms can be engineered to fit your part(s) or process.
Work with JR Automation
CASE STUDY
A Complete Overhaul from Manual to Automated Data Tracking
A leading medical device customer wanted to minimize operator errors in tracking part progress and the number of reject parts these errors were producing. They had previously used manual methods for handling and tracking processes, recording data by hand that included the part history, part location, and number of times the part had cycled through each production process. To solve the tracking issues, the JR team automated a part handling method and developed a data tracking system.
Technical Capabilities Involed:
- software data integration
- material handling solutions
- robotics integration
CASE STUDY
Cooperation Between Automation Companies Brings Game Controller to Life
A video game developer wanted to produce their own game controller, with a contract manufacturer doing the mass production.
We were approached to help automate the key production process. At least 11 types of keys were being produced. The requirement was to transfer these keys in groups of two or four onto a single tray. The key kitting machine would then pick the different keys and arrange them into a configuration on assembly trays for the assembly process.
Technical Capabilities Involed:
- vision applications
- material handling solutions
- robotics integration
- contract manufacturing
CASE STUDY
Mirrored Positioning Systems Use Vision to Insert Material into Cells
This system was developed in response to the customer’s request for automating an existing manual process. The basic functionality of the system involved cutting a membrane into a pre-defined shape and inserting the cut material into hexagonal cells.
Technical Capabilities Involed:
- vision applications
- material handling solutions
- robotics integration
- assembly solutions
CASE STUDY
Light Switches Roll Off This Efficient Assembly System
A JR customer needed a machine to assemble flip switches. JR designed and built the 660 Switch Assembly System, which assembles and tests residential and mobile home light switches at a rate of 45 parts per minute.
Technical Capabilities Involed:
- assembly solutions
- inspection testing
CASE STUDY
Robots Handle Trays of Sterilized Saline Bags for Increased Productivity
A medical company wanted to automate the process of loading bags of saline solution onto trays for sterilization and then unloading them back on to the production line for packaging.
The machine needed to have the flexibility to handle different models of the saline bags while ensuring that they were arranged in the desired orientation. It also had to fit into the existing tight space. In addition, the system had to handle the wet saline bags after they emerged from the sterilization chamber.
Technical Capabilities Involed:
- vision applications
- material handling solutions
- robotics integration
CASE STUDY
Innovation Makes Gender Determination for Poultry Eggs Autmated and Efficient
The challenge was to concept, design, and build a system to extract allantoic fluid from various size poultry eggs for gender assay purposes. Previously, gender determination was usually accomplished manually by inspection of the young hatchling and was extremely difficult, costly, and sometimes inaccurate.
Technical Capabilities Involed:
- vision applications
- software data integration
- inspection testing
- dispense applications
CASE STUDY
Five Robots Use Vacuums to Pick Delicate Silicon Wafers
A large international conglomerate in the solar cell business needed a high-throughput line to print, inspect, and cure solar cells. Because thin substrates are cut from a large ingot, the silicon material is stressed and tends to break very easily. The dynamics of wafer handling was very important.
Technical Capabilities Involed:
- micro precision applications
- vision applications
- robotics integration
- material handling solutions
- inspection testing
- assembly solutions
CASE STUDY
Custom-Built System Tests Endurance of Earthmover Fuel Pumps
A major international manufacturer of earthmoving equipment asked us to design and build six machines to test pre-assembled fuel pumps. Each machine had to be capable of simultaneous testing. The machine design had to be durable enough to withstand cyclic loads, vibrations, and temperature requirements dictated by the customer, as well as having liquid-tight guarding and being easily moveable. In addition, all major machine components must be easily removed and replaced using only standard mechanic’s hand tools.
Technical Capabilities Involed:
- inspection testing
CASE STUDY
Drop In Software Analyzes Machine Performance Without Stopping or Missing a Beat
In the world of manufacturing, unnecessary downtime can cost a company thousands of dollars. When a valued JR customer came to us after experiencing this debilitating problem on one of their machines, we knew we had to work fast to work out the problem and ensure their machine was operating at its highest efficiency. With the help of JR’s Software Integration Team, we could do just that.
Technical Capabilities Involed:
- software data integration
CASE STUDY
Award-Winning Machine Produces High-Quality Products on Three Continents
A leading electronic component manufacturer wanted a machine to attach components onto an integrated circuit. Each attachment of a die on a wafer had to be placed within an alignment accuracy of less than 3 microns with an expected yield of more than 99.7%, all in a cleanroom environment.
Previously, the client did not have any machine capable of the same amount of yield within the same accuracy. We had to consider every specific requirement while designing and developing the machine.
Technical Capabilities Involed:
- vision applications
- robotics integration
- micro precision applications
- assembly solutions
- laser applications
- material handling solutions
CASE STUDY
Custom Data Tracking System Reports on Machines Company-Wide
Data collection after and during processes tracks progress, efficiency, and helps alert operators of issues. While working for an innovative customer, JR Automation renovated the company’s current data collection system. The network we designed was a unique version of a Supervisory Control and Data Acquisition (SCADA) system which remotely monitors operation and controls through coded signals over communication channels.
Technical Capabilities Involed:
- software data integration
CASE STUDY
Highly Flexible Assembly System Processes Parts with Minimal Retooling
A manufacturer of high mobility multi-purpose wheeled vehicles needed an assembly and material handling system with total flexibility. The main requirement was modification without interruption to production schedules. The Transfer Case Assembly System is a turnkey project that assembles seven different models of transmissions, and has equipment logically arranged for future flexibility.
Technical Capabilities Involed:
- software data integration
- robotics integration
- material handling solutions
- inspection testing
- dispense applications
- assembly solutions
CASE STUDY
Creative, Custom Design Builds Long-Term Relationship
Our customer needed an automated hot plate welding system that lowers labor costs and increases part quality. The solution needed to be both flexible and cost effective in order to accommodate a wide variety of part types for assembly and testing purposes..
Technical Capabilities Involed:
- welding applications
- robotics integration
- inspection testing
- assembly solutions
CASE STUDY
Easily Feed Part Variations Into Any Machine, For Any Industry
Vision Guided Robotic Flexible Feeding allows for almost endless product line variations, eliminating the need for part-designated in-feed systems and machines.
Technical Capabilities Involed:
- vision applications
- material handling solutions
- robotics integration
CASE STUDY
Tight Budget Fuels Creativity
Our customer needed a machine designed and built to meet international standards for assembly and testing of small parts. Working within a tight budget, and with a required 8 second cycle time, the JR team came up with a creative solution that exceeded all expectations.
Technical Capabilities Involed:
- inspection testing
- assembly solutions
CASE STUDY
Fast and Efficient Assembly and Testing of Variable Panels
The goal was to design and build a final assembly and test system for solar panels. The system had to be able to adapt to different models with significantly different form factors. The data driven processes included diode cover, lid and leash install, generate and apply module label, and performance testing.
Technical Capabilities Involed:
- robotics integration
- vision applications
- software data integration
- inspection testing
- material handling solutions
- assembly solutions
CASE STUDY
Pellet Packaging Machine Increases Production Output by Almost 70%
A customer needed JR to concept, design, and build a machine that would double current animal growth hormone pellet production to meet increasing market demands. Special handling, cleanroom, and certain maintenance requirements had to be considered along with several packaging methods. Lastly, the customer anticipated further increased demand and wanted to be able to react to market fluctuations quickly.
Technical Capabilities Involed:
- material handling solutions
- inspection testing
CASE STUDY
Temperature Control Essential to Proper PV Cell Testing
Our customer needed a machine that could handle, test, and sort two different sizes of photovoltaic (PV) cells at a high throughput rate.
Technical Capabilities Involed:
- robotics integration
- software data integration
- inspection testing
CASE STUDY
Integrated Mold Machines Meet All Customer Requirements with Dynamic Solutions
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The JR team needed to supply an insert molding solution. The solution had to deliver five different sets of components to overhead robots for loading into an injection molding machine while meeting other customer requirements:
- Feed eight hours’ worth of bearings without using a vibratory system
- Interface with two injection molding machines running independently of one another with multiple variants of product
- Design an EOAT that could load and unload multiple components within a mold cavity
- Integrate fenceless overhead safety zones
Technical Capabilities Involed:
- robotics integration
- material handling solutions
CASE STUDY
Early Success Builds Customer Confidence
A Tier 1 manufacturer of hydraulic pumps and motors for construction and agriculture equipment builders selected our company to build a machine to test pumps. The challenges proved to be keeping the oil contained in the machine during flushing and getting the customer-supplied control valves to work properly. The goal was a total test cycle time of 10 minutes per unit.
Technical Capabilities Involed:
- software data integration
- inspection testing
- assembly solutions
CASE STUDY
Cameras Inspect All Pistons for Manufacturing Defects
Running one shift a day, with a throughput rate of 1,400 pistons an hour, it was not possible for the customer to conduct detailed quality inspections on all their products. Because of increased quality mandates from their end-users, a high-throughput inspection system was necessary to detect manufacturing defects.
Technical Capabilities Involed:
- micro precision applications
- vision applications
- robotics integration
- material handling solutions
- inspection testing
CASE STUDY
The Trifecta: Higher Speed, Higher Capacity, and Less Work
The JR team needed to create a barcode applicator, test, and packaging machine to replace multiple manual machines. The solution required exceptional speed control for handling multiple part types, and needed to increase the overall speed of the process from (1) to (6) parts per second, depending on part size and shape.
Technical Capabilities Involed:
- software data integration
- material handling solutions
CASE STUDY
Machine Processes Plates to Determine Vaccine Potency
A customer required increased production and potency verification in order to meet rising product demand. The machine had to process plates to prepare for automated vision counting of plaques in order to determine batch potency.
Technical Capabilities Involed:
- vision applications
- software data integration
- material handling solutions
- inspection testing
- dispense applications
CASE STUDY
Flexible, Modular Design Allows for Easy Machine Changes with the Product
Leveraging the success of the Rotary Indexer Platform (Ring Dial), it was essential to provide a linear motor based, in-line assembly and test platform. The design needed to be created in a modular fashion that facilitates the capability to add or remove sections as needed.
Technical Capabilities Involed:
- inspection testing
- welding applications
- vision applications
CASE STUDY
Robots Calibrate Each Other for Pinpoint Accuracy in this Award-Winning Solution
A large hard disk drive manufacturer needed an improved system to robotically load and unload hard disk substrates into vertically hung pallets for a sputtering process. The most challenging aspect was that the disk had to be loaded into a groove that provided only 0.012” total clearance without touching the disk sides. But, due to intense in-process heating, the aluminum pallet plane could be warped by 0.080" locally about a hole, so the robot had to precisely load substrates into warped pallets.
Technical Capabilities Involed:
- robotics integration
- vision applications
- material handling solutions
CASE STUDY
Produce Strong, Light Welds Without the Intense Heat
In the automotive industry where fuel economy rules, a car’s mass is an important factor. It takes more energy to move a heavier vehicle. Every part of a car adds to its weight, so each step of the process must be examined closely.
The traditional welding process, for example, adds weight to the original material. Additionally, arc, MIG, and TIG welding use a lot of energy to produce the heat required; in some cases, the heat warps the part and ultimately wastes time, money, and material.
Technical Capabilities Involed:
- welding applications
CASE STUDY
Assembly System is "Certified Fresh"
A customer required a system to make freshness indicator tags. The challenge was to design and build a solution that was able to continuously and ultrasonically weld together polypropylene webs, while simultaneously forming, filling, and sealing a pair of liquid pouches. The seal in the web pouches was required to be both hermetical and frangible.
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Technical Capabilities Involed:
- welding applications
- plastics processing
- dispense applications
- assembly solutions
CASE STUDY
Three Robots Cooperate to Monitor Test Plates for New Discoveries
A large international drug company needed a high-throughput drug discovery system that could accommodate a multitude of simultaneous processes. It was required to handle microtiter plates with heavy stainless steel lids. Typical robots working in drug discovery were laboratory type robots on long linear tracks. These robots had light payloads, were less than rugged, and slow.
Technical Capabilities Involed:
- software data integration
- robotics integration
- vision applications
- material handling solutions
- dispense applications
- inspection testing
CASE STUDY
First of Its Kind: Dual Robot Cell Carves Cabinets
Our customer needed a cell that could assemble face frames without using manual labor. The JR team came up with an innovative solution by automating a highly complex process that, in this case, had never been done before.
Technical Capabilities Involed:
- assembly solutions
CASE STUDY
Proven Machine can be Customized for Many Industries
The goal was to make an existing field-proven rotary indexer design customizable for many industries with a concentration in the healthcare, consumer products, and electronics industries. Adaptability was made possible through software teachable points and utilize independent and standard controls.
Technical Capabilities Involed:
- vision applications
- laser applications
- welding applications
- inspection testing
CASE STUDY
Tooling Carts Save Customer Time and Money
The JR team had to develop machines that were able to press laminate three part types. Two critical elements for the press were constant heat for bonding, and a focus on preventing wrinkling and puckering of the fabric. JR created a custom solution using rolling carts and closed loop water heating with ported tooling.
Technical Capabilities Involed:
- material handling solutions
- plastics processing
- assembly solutions
CASE STUDY
Machine Takes Up Half the Floor Space and Cycles Faster than Required
Our customer needed a machine that could assemble and test right and left hand fabric covered sun visors on a single assembly system with minimal operator contact and a 15 second cycle time. Cleanliness was also an important consideration, as it was necessary to avoid staining the light colored fabric.
Technical Capabilities Involed:
- vision applications
- welding applications
- inspection testing
- material handling solutions
- robotics integration
- assembly solutions
CASE STUDY
Eight-Station Dial Forms Rubber Extrusions for Truck Doors
The objective was to create a machine with the capability to heat-form a rubber extrusion used on the rear door of an extended cab truck. The team based their solution on an eight-station rotary dial concept with a cycle rate of 90 seconds.
Technical Capabilities Involed:
- dispense applications
- plastics processing
CASE STUDY
New System Processes Copier Tubes More Quickly and with Higher Quality Results
The challenge was to concept, design, and build a system to process copier tubes faster and with higher quality results. The work had be done in not only a cleanroom, but also an explosion-proof environment due to hazardous chemicals.
Technical Capabilities Involed:
- vision applications
- assembly solutions
- robotics integration
- material handling solutions
CASE STUDY
Packing System Doesn't Get Tangled Up in Multiple Yarn Varieties or Busy Schedules
A major U.S. manufacturer of polyester yarn required an automated system to move 40 lb. yarn packages from spinning frames to an inspecting, testing, and palletizing area. All the yarn varieties produced across the multi-acre spinning floor looked alike, but they differed in formulation and filament count. Data tracking would be required to prevent mixing the product between spinning and packaging. A spindle of 6 yarn packages would finish every 30 seconds, and they needed to be removed quickly.
Technical Capabilities Involed:
- robotics integration
- software data integration
- material handling solutions
CASE STUDY
New System Significantly Increases Speeds While Handling Product More Gently
The customer was in need of a better system involving the transferring of bottles containing special patented fluid used in cancer drugs. JR's challenge was to design and build a new system that could operate without operator assistance and without damage to the bottles or the bottle contents. The bottles had to be transferred without any splashing of the liquid inside the bottle onto the cap. The Automated Roller Bottle System (ARBS) Transfer System moves bottles to and from two identical warm rooms at the customer’s facility
Technical Capabilities Involed:
- material handling solutions
CASE STUDY
Light-Weight and Strong, This Machine Rivets Components to Aircraft Fuselages
Create a portable drilling and fastening machine for body skin panel and splice fastening to aircraft fuselage structural components. The automated system must apply and maintain a large, opposing force between skins and frame components while drilling and counter sinking a hole, and inserting and bucking the rivet takes place. The system must have an exceptional strength-to-weight ratio.
Technical Capabilities Involed:
- software data integration
- assembly solutions
CASE STUDY
JR Solution Leads to Cost, Time, and Operator Savings for Customer
A flexible welding cell had to designed and built for low volume production runs of more than 100 different part types. Additional requirements included automated rapid changeovers of less than one minute, cycle times of (3) seconds per weld, eliminating the need for operators to move heavy weld fixtures, focusing on quality control for different part materials and thicknesses, and improving weld consistency.
Technical Capabilities Involed:
- welding applications
- robotics integration
- material handling solutions
CASE STUDY
Implementing automation helped grow production rate
This system was developed in response to a customer’s request to design and build an assembly line that could assemble two products: valves with two shutters and a one-way valve.
Technical Capabilities Involed:
- assembly solutions
- inspection testing
- laser applications
- robotics integration
- welding applications
- vision applications
CASE STUDY
Automated Production Plans Optimize Operator Time and Product Material Usage
A JR Automation customer had a problem—their CNC mill could only run product in batches, and to change batch size, numerous operators had to manually adjust the product fixtures. Additionally, production planning had to be manually entered into an Enterprise Resource Planning (ERP) system. The process was inefficient, hard to optimize, and decreased product throughput.
Technical Capabilities Involed:
- software data integration
CASE STUDY
SmartAttach - Industry 4.0 Ready Automated Machine
Oftentimes, enabling IIoT is not considered at the time of an automation or machine tool deign in the industry. SmartAttachTM is a leading edge-technology in terms of automation to install nut plates. The machine is Industry 4.0 ready off the shelf.
Technical Capabilities Involed:
- assembly solutions
- software data integration
CASE STUDY
Continuously Operating Line Inspects All Two Million Test Strips Made Every Day
The objective was to design and build a glucose test strip assembly line with continuously operating web platforms making use of metalized PET materials, while inspecting all products as they are being manufactured. Additionally, each test strip must be equipped with a built-in calibration code so that the patient does not have to enter a code into their meter.
Technical Capabilities Involed:
- vision applications
- laser applications
- inspection testing
- assembly solutions
CASE STUDY
Custom Laser Welder and Automatic Unload Keep Cycle Time Low
The JR team had to develop a machine that used a laser to weld components of a liftgate actuator through its plastic outer-layer. The machine needed to accommodate three part types with minimal changeover. Complete cycle time for this machine, including operator load and unload, needed to be under 25 seconds.
Technical Capabilities Involed:
- plastics processing
- material handling solutions
- robotics integration
- laser applications
CASE STUDY
Machine Integrates More Complicated Processes Without Increasing Cycle Rate
Our customer needed an upgraded version of an existing system that could make and weld together the body side portion of a colostomy bag. The new machine had to handle many more processes without a substantial increase in cycle rate. The processes that were added included orienting the pad, orienting the flange, and storing/feeding/picking/placing the lock-ring.
Technical Capabilities Involed:
- plastics processing
- assembly solutions
CASE STUDY
Three Robots Cooperate to Assemble CD Disks
Our customer requested that JR design and build a system to automate the process of assembling IBM compact disks for computer data.
Technical Capabilities Involed:
- software data integration
- vision applications
- dispense applications
- assembly solutions
CASE STUDY
New Solution Leads to 16,000% Decrease in Process Time
A flexible high-speed automation processing line had to be designed and built for the production of prescription optical eyeglass lens blanks. The solution had to produce lens blanks every 10 seconds, with a process time of less than one day, and the flexibility to handle up to 45,000 unique prescriptions.
The present manual process yielded a high variation in product quality, as well as a process time of almost two weeks per lens.
The present manual process yielded a high variation in product quality, as well as a process time of almost two weeks per lens.
Technical Capabilities Involed:
- plastics processing
- assembly solutions
CASE STUDY
Wing Skin Topology Verification
The objective was to come up with a solution that is able to verify that the complex milled surface and thickness of jumbo jet wing skins meet manufacturing tolerances. Bowing of less than 2 inches is allowable, but accuracy better than 0.02 inches must be maintained in a factory environment with large temperature swings. The skins can be 10 feet tall by 110 feet long and vary in thickness between 0.25 and 2 inches.
Technical Capabilities Involed:
- software data integration
- micro precision applications
- inspection testing
CASE STUDY
Precise Machine Meets Requirements for Speed, Uniformity, Quality for Various Part Types
Our customer needed a system to punch/ burn the drainage eyes and trim the funnels of latex catheters. The dial tooling had to handle all part sizes with minimum changeover, and be quick and easy to load. The catheters came in a range of sizes from about ⅛” to around ½”. The machine had to punch properly aligned holes in latex that were the same size and shape every time, with smooth edges. The funnels had to be trimmed, leaving clean smooth edges.
Technical Capabilities Involed:
- plastics processing
CASE STUDY
Two Robot Cells Work Together to Cool and Trim PV Panels
Robotic integration was used to automate the process of cooling and trimming warm laminated photovoltaic (PV) panels. The system had to be able to accommodate panels with varying length and width.
Technical Capabilities Involed:
- material handling solutions
- robotics integration
- assembly solutions
CASE STUDY
Operator Work Instruction and Work Monitoring - LMI
In any manufacturing and assembly process, operators and automation require combinations of scheduling, recipe management, work instructions and work execution monitoring to ensure first time, in-station quality. There is never better quality than when products are manufactured in sequence using the original operators, equipment and processes. In this case, our customer required JR Automation a fully functional system which would provide all of these functions.
Technical Capabilities Involed:
- software data integration
- assembly solutions
CASE STUDY
Solution Dispenses and Tests Gel Modules for Terminal Blocks
A customer asked JR to design and build a gel dispensing system that assembles and dispenses silicone gel into terminal blocks used in the telecommunications industry. The machine assembles both legged and non-legged inserts into driver modules, fills the driver modules with silicone gel, degasses and cures the gel, tests the parts for fill level and gel hardness, and inserts the parts into a plastic slide tube.
Technical Capabilities Involed:
- assembly solutions
- dispense applications
- inspection testing
CASE STUDY
Proven, Customizable Tray Loader Works Where Vibratory Feeds Don't
The goal was to create a proven, small footprint tray loader that could be used in the absence of a vibratory feed. This design can be readily tooled for many industries with a concentration in the healthcare, consumer products, and electronics industries. This could be used for parts that cannot be vibratory fed. Adaptability provided through software teachable points and utilize independent, standard controls. This unit can be used for unloading trays or used as a buffer and will load parts into the trays.
Technical Capabilities Involed:
- vision applications
CASE STUDY
Craft Aircraft Engine Parts with the Help of Sensors and 3D Models
The challenge was to craft a perforated shell, used as an insert to an engine cowling. Sensors and 3D models helped to direct the path of a large rubberized wheel so that a composite material could be pressed onto a figure resembling the outer geometry of one-half of an aircraft engine.
Technical Capabilities Involed:
- software data integration
- dispense applications
- assembly solutions
CASE STUDY
Prototyping and testing led to confidence necessary to automate processes
A venture capital company with an exciting new intra-ear, disposable hearing aid had a design ready for mass marketing. With a targeted consumption rate of 5 million units per year, production rates needed to be fast. The problem was that the product design engineers were not experts in design-for-automation. Some redesign was needed.
Technical Capabilities Involed:
- welding applications
- material handling solutions
- software data integration
- inspection testing
- laser applications
- assembly solutions
CASE STUDY
Vision Guided Robots Perform Precise Tasks for Semiconductor Company
A large US semiconductor manufacturer needed to precisely align and seam weld a window structure to an optical processor substrate in a low humidity chamber that contained a precise mixture of helium and nitrogen gases.
Technical Capabilities Involed:
- welding applications
- micro precision applications
- inspection testing
- assembly solutions
CASE STUDY
Proprietary Algorithm Keeps Cards Within Specifications
The customer wanted the team to design a system to punch rows from screen-printed Mylar cards. Cards are 325 ± 1mm square and have 1x18 rows printed to a card. Tolerance for punched row width is 15.00 ± 0.03mm, but more importantly, the screen-printed artwork must be maintained at ±0.05mm. Artwork on the card to the edge of the card is not held any better than ±1.0mm. Also, screen masks stretch as they are used for production, which changes the pitch of the artwork between each row.
Technical Capabilities Involed:
- vision applications
- micro precision applications
- assembly solutions
CASE STUDY
Fusion of Large Scale Robotic Systems and Digital Technologies
An aerospace customer needed automation of large-scale robotics, component processing, and conveyors while integrating an MES system with their ERP system. Their complex array of CNCs, CMMs, OMMs and custom cells all made unique parts – in quantities of one. Additionally, different parts required different machine setups and configurations.
Technical Capabilities Involed:
CASE STUDY
Small Machine Measures Force with Great Precision
A US manufacturer supplying interconnect components to the semiconductor industry required an automated, contact force measurement system capable of measuring compression forces of very small devices on a 300mm substrate.
Scaling their products for the larger wafer size, the customer required an easily configurable system for testing thousands of measurements over a multitude of part types at a rate of up to 3,000 tests per hour, providing accurate force and height data.
Technical Capabilities Involed:
- micro precision applications
- inspection testing
CASE STUDY
Automated Prescription Drug Dispensing Increases Hospital Efficiency and Wins Awards
A large public hospital in Singapore wished to automate its prescription dispensing process in its outpatient pharmacy. The hospital’s dispensing of prescription medications was labor-intensive, time-consuming, and very dependent on trained manpower. The heavy reliance on manual resources also made it susceptible to human errors. In view of this, the hospital decided to revamp and improve its process.
Technical Capabilities Involed:
- software data integration
- material handling solutions
CASE STUDY
Contact Lens Production System Exceeds Strict Customer Requirements
The customer was in need of a system that was able to produce contact lenses in an oxygen-free environment. The challenge was to introduce carriers, along with mold halves, into a production environment that has an oxygen content of 200ppm or less while maintaining a cleanliness rating of Class 1000. Liquid dispensation, component transportation, and all related processes had to be done within this controlled environment, while all preventative maintenance had to be performed from outside it.
Technical Capabilities Involed:
- robotics integration
- plastics processing
- assembly solutions
- material handling solutions
- inspection testing
CASE STUDY
New Automated Solution Increases Output Three Times the Previous Amount
A leading medical devices manufacturer wanted machines to manufacture home dialysis kits for kidney patients.
Production encompassed a series of sub-assembly machines and a final assembly machine to form the finished product. As each machine had to process more than one type of product at any one time, the inline QC system had to be flexible to handle different product models, and highly accurate to ensure that there would not be any error in identifying and sorting the varying products.
Technical Capabilities Involed:
- inspection testing
- assembly solutions
- software data integration
CASE STUDY
Unique Solution Leads To Partnership
To meet the needs of one of our customers, JR designed and built a machine that ensures parts are free of flash and installs bearings with the correct force and distance.
Technical Capabilities Involed:
- vision applications
- assembly solutions
CASE STUDY
New Process Flow Improves Efficiency and Flexibility
The objective was to concept, design, and build a machine to assemble actuators for automobile HVAC systems. In addition, design or technology enhancements were needed to increase throughput, efficiency, and performance over the previous machine design. The general system concept needed to provide not only a solution to the application at hand, but also to provide an automation platform with the functionality and flexibility to be the basis for future systems.
Technical Capabilities Involed:
- inspection testing
- assembly solutions
CASE STUDY
Innovative, State-of-the-Art Solution
A JR Automation customer needed a system that could load inline blood filters at a rate fast enough to keep up with an existing vacuum-form packaging machine and with precise orientation for the different parts. Quick tooling changeover was a priority. There were also strict FDA cleanliness guidelines and a tight budget.
Technical Capabilities Involed:
- assembly solutions
- material handling solutions
CASE STUDY
RoboSync Platform Limits Downtime with Quick, Easy Multi-Robot Synchronization
Robots are programmed to perform the same tasks over and over again. Their precise movements allow for quality control and reliable results. However, traditional interfaces for programming and teaching robots require advanced knowledge and skills. Our customer approached us with a problem: sometimes robot points needed manual adjustments due to part variation, then those adjustments needed to be made on every robot in the machine, a process that resulted in a lot of downtime.
Technical Capabilities Involed:
- material handling solutions
- software data integration
- robotics integration
CASE STUDY
High-Speed Fuel Inject Assembly Redesign Leads to Repeat Business
The customer's current assembly technology was no longer sufficient. In order to accommodate new part designs and increase the speed and quality of production, JR designed and built an enhanced precision fuel injector assembly system. Each injector consisted of almost twenty small parts. The challenge was taking existing assembly technology and enhancing that to accommodate new configurations required by a European auto manufacturer. External dimensions, internal components assembly, and performance specifications were changes that the manufacturer sought from the team’s new design.
Technical Capabilities Involed:
- vision applications
- inspection testing
- material handling solutions
- assembly solutions
CASE STUDY
Test Stand Checks All Baby Bottle Liners for Leaks
Disposable plastic baby bottle liners are popular in the consumer market. Flat-design plastic bottle liners captured this market first, but were hard to use. PBM Plastics perfected the current design, a one-piece pre-formed tube liner with a rigid rim that rests on top of the bottle. PBM Plastics needed a high-volume machine to test the tube liners for complete 100% no-leak no-fail accuracy.
Technical Capabilities Involed:
- inspection testing
- material handling solutions
- software data integration
CASE STUDY
Flexible Design Leads to Worldwide Use
A customer needed our JR team to produce anti-lock brake cartridge valves at a high speed, over 1000 good parts per hour net rate, yet with a system flexible enough to re-tool later for product design changes.
Technical Capabilities Involed:
- contract manufacturing
- assembly solutions
- material handling solutions
- software data integration
- inspection testing
CASE STUDY
Variable Machine Configuration Gives Customer Flexibility on Shop Floor
The client, a wafer die manufacturer, wanted a machine to inspect wafers for die alignment, surface defects, contamination, and dimple depths. Our machine afforded the client flexibility since it could be configured as an inline or standalone machine.
The machine must be able to detect specific size and unique patterns on the wafer. Accordingly, specially customized image processing routines had to be developed to detect and characterize the various defects and patterns found in the wafers.
Technical Capabilities Involed:
- micro precision applications
- inspection testing
- vision applications
CASE STUDY
Custom Machine Tests for Two Types of Leaks
A large medical manufacturer required a machine to automatically leak test a five-lumen (port) tube, called an umbilicus, used for blood component separation.
The specification required testing the umbilicus for lumen-to-lumen and external leakage. The threshold for lumen-to-lumen leakage was 2.15 cm3/minute. The specification for external leakage was an overall pressure drop of 1 psi over a five second test period from a starting pressure of 20 psi.
The specification required testing the umbilicus for lumen-to-lumen and external leakage. The threshold for lumen-to-lumen leakage was 2.15 cm3/minute. The specification for external leakage was an overall pressure drop of 1 psi over a five second test period from a starting pressure of 20 psi.
Technical Capabilities Involed:
- inspection testing
CASE STUDY
JR Solution Reduces Cycle Time by More Than 50% and Doubles Original Output
The client commissioned a machine to manufacture its new product at high levels of accuracy and output. This machine would laser-cut and attach a soft adhesive layer onto each flex circuit on a reel, then carry out the laminating process to ensure a full and durable bond.
After considering our ability to meet all the stringent requirements, the client selected us over their previous provider. Another key deciding factor was our proven track record of providing comprehensive after-sales services.
Technical Capabilities Involed:
- plastics processing
- laser applications
- assembly solutions
- vision applications
- material handling solutions
CASE STUDY
Automatic Storage and Buffer Machine Maximizes Production Line Efficiency
A leading global electronics manufacturer needed an automatic storage buffer machine to temporarily store and retrieve excess parts of inkjet cartridges in its high-volume production lines. Storage capacity would range from 10,000 to 40,000 parts.
The client required a cycle rate of 40 to 150 parts per minute, 99.9% uptime, 24/7 operation, constant tracking of all parts and data integrity to prevent any mixing of batches or errors in sequencing.
Technical Capabilities Involed:
- software data integration
- metal processing
- plastics processing
- material handling solutions
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