- High Efficiency: Utilizes automated machinery and robotics to perform tasks quickly and consistently, maximizing production rates.
- Precision and Consistency: Ensures uniformity and accuracy in manufacturing processes through advanced control systems and sensors.
- Reduced Labor Costs: Minimizes the need for manual intervention by automating repetitive and complex tasks.
- Flexibility: Adapts to different products and production requirements with programmable and reconfigurable equipment.
- Real-Time Monitoring: Employs sensors and data analytics to track performance, detect issues, and optimize processes continuously.
- Safety: Incorporates safety systems and protocols to protect both the equipment and operators from hazards.
LINE AUTOMATION
Manufacturing Line serves as the backbone, where raw materials are transformed into finished components through a series of processes such as machining, casting, and forging.
Assembly Line takes center stage, where these components are meticulously assembled into the final product, ensuring precision and efficiency.
Body in White (BIW), where the vehicle’s sheet metal body is welded and formed, providing the essential structure before paint and interior components are added.
Stamping Line, where large presses shape metal sheets into various body panels and parts, setting the foundation for the vehicle’s structure.
Packaging Line plays a crucial role in the latter stages of production, ensuring that finished products are carefully packed, labeled, and prepared for shipment, guaranteeing they reach customers in pristine condition.
Automatic Product Life
The automatic product life cycle encompasses design, manufacturing, deployment, and ongoing maintenance, focusing on optimizing efficiency and performance through automation.
It includes regular updates and improvements to adapt to technological advancements and market demands.
Here are some of the key features of an Automatic production line:
Key Components of An Automatic Production Line
Automatic production lines come in a variety of types depending on the goods produced, and the components included in the system can also vary depending on various factors.
However, the majority of automatic production lines include the following components:
- Input and output (I/O) components: these components handle the flow of materials until they become finished products in and out of the automatic production line. I/O components include conveyor belts, automated loading/unloading machines, robots, and other equipment.
- Workstations: workstations refer to dedicated areas (along the automatic production line) on which specific tasks are performed. Specialized machinery, robots, or human operators can be assigned to the workstations.
- Control systems: the “brain” of the automatic production line system, responsible for coordinating the operation of different machines and components in the production line to ensure streamlined and efficient workflow. May consist of various software and hardware components, including but not limited to human-machine interfaces (HMIs) and programmable logic controllers (PLCs.)
- Sensors: or other forms of feedback mechanisms, play a crucial role in monitoring, controlling, and regulating the production line. The sensors provide real-time data on temperature, speed, pressure, product quantity/quality, and other variables to the control system, enabling the system to maintain an optimal workflow and make automated adjustments when needed.
Merlin colloborates with customers for below activies to successfully design and develop automation solutions as per requirement
- Core Processing
- Throughput Analysis
- Design of Complete Line
- Layout Creation (2D & 3D)
- FEA
- Virtual Simulation
- Manufacturing Drawing Creation
- BOM Creation
- Manufacturing, Assembly & Trial
- PLC & HMI Programming
- Panel Design & Development
- System Integration
- Factory Acceptance Test (FAT)
- Installation & Commisioning
- Site Acceptance Test
- Training & Handover