The legacy process for installing screws on Thorn Lighting’s products was labour-intensive. It relied on an operator manually installing screws repeatedly throughout the day, lacking data collection and error proofing, with no method to detect if screws were missed or at the wrong torque.
To remove human error and inconsistencies in the production line, Thorn Lighting wanted to implement an automated, reliable, and quality-controlled solution.
Our automation experts conducted numerous site visits to assess the application before specifying a Cobot and screwdriver system. We conducted feasibility studies and factory acceptance testing before our in house of installers commissioned the system for use. We also supported with operator training and ongoing optimisation support.
The manufacturing automation ensures all screws are tightened in a pre-programmed sequence with, the assembly tooling ensures torque accuracy and full data traceability. Combining manufacturing automation with advanced assembly tooling ensures the assembly process is error free.
“Abbey took the time to fully understand our process and delivered a solution that combined automation and assembly tooling seamlessly. The project was managed professionally from concept through to installation, and the results have exceeded our expectations in terms of quality, productivity and traceability. Their technical expertise and ability to provide a complete integrated solution make them a valuable partner.”
Gary Pilkington | Manufacturing Engineer
By automating the assembly operation, it eliminates missed screws and removes human error, ensuring consistent product quality while providing full data capture and traceability for every screw installed. Operating 24/7 with a takt time of 41 seconds, the cobot has also increased throughput and allowed operators to focus on higher-value tasks.
The solution delivers long-term flexibility and cost savings, with the ability to be reprogrammed for future applications as production requirements change. With an expected lifespan of 10 years, the cobot is forecast to pay for itself within 18 months, generating annual savings of around £10,000 and reducing labour costs by approximately £25,000 per year.
Thorn Lighting first partnered with Abbey Industrial Solutions over 10 years ago and the latest project is to implement manufacturing automation solutions highlights Abbey’s commitment to finding solutions to manufacturing problems.
At Abbey, we understand that successful manufacturing automation is about far more than installing a cobot. Delivering real manufacturing improvements requires the right combination of automation, assembly tooling, process expertise and application engineering. We design and implement complete turnkey solutions that optimise productivity, quality and return on investment.
From assessing the application and selecting the most effective assembly tooling, through to designing, integrating and commissioning the automation system, our team manages every stage of the project. This ability to combine industry-leading tooling technologies with advanced automation expertise enables us to deliver robust, future-proof manufacturing solutions tailored to each customer’s unique requirements.
