Fori Automation recently provided a turn-key automated assembly line for the build of utility trailers for a customer. Fori provided (4) duplicate assembly lines to support their facilities in GA, VA, TX & IA.
The utility trailer assembly line included a variety of improvements over the customer's traditional assembly lines, including overhead lift assists, automated transfer utilizing rail guided carts (RGCs) and DC electric tools for fastening and traceability. Fori was responsible for supplying (4) systems, each system comprised of (6) RGCs, (5) overheads with custom lift assists and (11) DC Electric Tools.
The customer wanted to ensure a flexible assembly system that can be leveraged across all their plants. The RGCs provided were able to be used at their four facilities by modifying the track layout based on floor space, building columns and ceiling heights.
Tooling pallets were designed with quick change features to accommodate (16) trailer variations ranging from 4’ x 5’ up to 6’ x 12’. To lift the various components such as frames, axles, gates and tongues, custom overheads with lift assists were provided to improve ergonomics for the operator.
Another design consideration was traceability for fastening, this was completed with the implementation of DC electric tools and ToolsNet from Atlas Copco. With the integration of barcode scanners, the trailers fastener torque data is saved on a database linked to the trailer serial number.
The lines were installed during the first quarters of 2021.
Complex assemblies matched with high production requirements mean reduced ability to provide repeatable operator output. In an industry with constant pressure to boost efficiency and improve quality, automation becomes the solution most look for.
The suspension module assembly consisted of a heavily automated system. The equipment included a rear suspension module line, front suspension module line, front and rear combo module line and a front coil over shock assembly (FCOS).
Rail guided carts (RGCs) were provided for conveyance of the product down the assembly line. The front and rear corner assembly consisted of (13) RGCs, robotic hub assembly & caliper torque cell.
The front suspension assembly line consisted of (16) RGCs, a semi-automatic ride height and trending set machine that positioned the links within a slot. The equipment could be adjusted based on the tolerances provided by the OEM.
The rear suspension assembly line consisted of (37) RGCs, (2) automatic alignment systems, ride height set automatic torque cell and a robotic flip station.
The new RGC assembly line was installed during the first quarter of 2019.
Fori Automation recently provided a rail guided cart (RGC) based engine dress line. The RGC system was provided as a replacement for traditional conveyor based assembly systems.
In some ways, a traditional conveyor is reliable, proven & effective. However, when new challenges are proposed changes to the traditional methods are questioned, proven & improvements arise.
Fori’s RGCs were selected to accommodate the customer’s need for a flexible conveyance solution. The RGCs were unmatched in price when compared to traditional methods of overhead power & free chain conveyance systems. By pairing the Fori RGC with its kiln of flexible tooling, it enabled the assembly line to become whatever shape it wants without major rework to the entire system.
Not all customer plants are built the same. With the ability to provide a Rockwell or Siemens control solution Fori is able to best fit our customer’s needs. In this case, the plant is utilizing a Rockwell based controls architecture, offering seamless integration into the assembly plant.
The engine assembly line is composed of (37) RGCs & (43) operators. The new RGC assembly line was installed in late October & was production ready early first quarter of 2020.
Fori Automation recently provided a module assembly and alignment line with limited floor space available. The system is between an existing assembly line & plant wall with the inability to get material to all parts of the assembly line required a unique process.
The minimal footprint available for assembly provided challenges for common 22unload areas within an existing assembly line. The Fori RGCs were utilized to accommodate our customer’s need for a flexible material handling system.
The assembly system included a consolidated kit area. The kit area was specific to loading and hand starting parts followed by an area for torqueing. Due to the foot print constraints the process had to be strategic on how to best utilize the available space. The project also included a fully automatic suspension module aligner & backup semi-automatic aligner.
The utilization of Siemens controls matched the controls architecture for the end user and provided a seamless integration into the assembly plant.
The rear main assembly line was composed of (17) RGCs, (16) operators, (1) automatic drive through suspension module alignment machine & one semi-automatic backup alignment system.
The new RGC assembly line was installed early June of 2018 & was production capable in Fall of 2018.
Large numbers of variations in assemblies matched with high job per hour requirements is challenging. Fori Automation provides solutions to correctly sequence multiple variants to the assembly area. These systems are designed to maximize floor space and can be quickly updated to accommodate variant count changes.
The module assembly project consisted of a lean automated system. The commodities involved are FCOS assembly (both spring & air ride models).
The choice of automated conveyance for this project was the Fori’s rail guided cart (RGC). The customer currently has (4) programs in production utilizing the Fori RGC with a 5th project to be operational in 2020.
The FCOS sequencing & assembly system consisted of (7) RGCs, (4) semi-automatic FCOS assembly cells and (1) upper isolator to upper mount assembly press. This system also included a large sequencing area. This “market place” style area worked directly with the customers manufacturing execution system (MES) to direct the RGC cart to the correct product storage position. Pick lights were activated to assist operators in the selection of the correct variant of spring, shock or air shock as requested by the OEM.
The new RGC assembly line was production capable in September of 2017.
The Fori module assembly system sequences and processes multiple product variants utilizing Fori’s Rail Guided Cart (RGC) assembly solution.
Features:
Assembly Cycle Time: 32 jobs per hour
Keys to Success: Automatic camber set, automated front coil over shock assembly, automatic lateral runout, flexible product transport from dunnage to line
Results: System capable of sequencing multiple variants, increased quality
https://www.youtube.com/watch?v=zzAw5dgQn9U
Fori’s integration of manufacturing execution systems with the RGC system allows the value added assembler the means to create multiple variants of brake systems. The sequenced brake systems are then assembled as requested by the original equipment manufacturer (OEM) and ready for installation into the vehicle.
The single loop style conveyor system consists of 13 RGCs to transport front brake corner and strut components (front vertical assembly) from incoming material dunnage through the various assembly processes including:
Vision system inspection and verification of caliper selection and installation
Vision verification of brake pad presence
Automatic front coil over shock assembly
Automatic setting of camber angle and marriage of front coil over shock to brake corner
Utilizing experienced resources, Fori developed a viable process, engineered the system, manufactured the equipment and integrated the assembly line at the end user. The module assembly system has resulted in positive results for the customer and OEM.
For more information about Fori's modular assembly systems, please visit our website.
Fori recently supplied a module assembly system that included the Fori Flex Rail conveyance system which utilized Rail Guided Carts (RGCs) and a drive-thru module aligner for the assembly and alignment of a rear suspension module.
Features:
Assembly Jobs Per Hour: 25 jobs per hour
Keys to Success: RGC conveyance, manual alignment backup
Results: Jobs per hour fulfillment, flexible assembly
The module assembly system had a unique set of design constraints. One example was that the floor space available within the plant for the required rear suspension module was limited, requiring a common unload area with an existing assembly line. Due to the oddly shaped footprint available for assembly and the mandated unload area, the end user utilized Fori’s RGC to accommodate their needs for a flexible material handling and assembly system.
The system utilized a standardized Siemens control architecture, including the RGC, traffic control, and aligners. The standardization of Siemens controls was customer requested in order to match their existing controls architecture. In matching the controls architecture between all of the equipment, Fori was able to offer seamless integration into the customer’s assembly plant.
The rear main assembly line was composed of 15 RGCs, seven operators, one automatic drive through alignment machine, and one manual backup alignment system.
https://www.youtube.com/watch?v=_vAiYKMojDU
For more information about Fori Automation's RGCs, assembly systems, and aligners, please visit our website.
Fori Automation specializes in module assembly & alignment systems. Modules include suspensions, corners, axle, instrument panels, coil over shock and many others.
Fori supplied a rear module suspension assembly line utilizing Fori Rail Guided Carts (RGC) as a conveyance and assembly method alongside two fully automatic drive-thru module alignment systems.
Drive-thru Suspension Module Aligner for Automotive Assembly
The assembly line consisted of (22) RGCs, two drive-thru aligners, (16) operators and various torque tools. The product for the rear suspension module varied between all-wheel drive and rear wheel drive vehicle variations. The build pallet on top of each RGC accommodated those variants and manipulated the ride height setting of the five link suspension by manually setting the ride height wheel in the correct position verified by a switch on the pallet.
https://www.youtube.com/watch?v=XX0VgCh6d9Y
A drive-thru aligner was also utilized within the system to help streamline the process. A lift and locate unit was located in each drive-thru aligner that would pick the pallet from the RGC and accurately present the suspension assembly for alignment.
https://www.youtube.com/watch?v=hximcPC65jE
Utilizing Fori’s RGCs allowed for a timelier changeover. The RGC system also provided long term flexibility supporting:
Accommodating future product changes that could add new stations.
Production increases that can affect station to station cycle times.
Production line shape if required.
Fori Rail Guided Carts (RGC) with Custom Tooling Pallet
For more information about Fori Automation's RGCs and assembly systems, please visit our website.
ean reduced ability to provide repeatable operator output. In an industry with constant pressure to boost efficiency and improve quality, automation becomes the solution most look for.
The suspension module assembly consisted of a heavily automated system. The equipment included a rear suspension module line, front suspension module line, front and rear combo module line and a front coil over shock assembly (FCOS).
spension assembly line consisted of (16) RGCs, a semi-automatic ride height and trending set machine that positioned the links within a slot. The equipment could be adjusted based on the tolerances provided by the OEM.
The rear suspension assembly line consisted of (37) RGCs, (2) automatic alignment systems, ride height set automatic torque cell and a robotic flip station.
The new RGC assembly line was installed during the first quarter of 2019.
hape it wants without major rework to the entire system.
Not all customer plants are built the same. With the ability to provide a Rockwell or Siemens control solution Fori is able to best fit our customer’s needs. In this case, the plant is utilizing a Rockwell based controls architecture, offering seamless integration into the assembly plant.
The engine assembly line is composed of (37) RGCs & (43) operators. The new RGC assembly line was installed in late October & was production ready early first quarter of 2020.
modate our customer’s need for a flexible 
hitecture for the end user and provided a seamless integration into the assembly plant.
The rear main assembly line was composed of (17) RGCs, (16) operators, (1) automatic drive through suspension module alignment machine & one semi-automatic backup alignment system.
The new RGC assembly line was installed early June of 2018 & was production capable in Fall of 2018.
The module assembly project consisted of a lean automated system. The commodities involved are FCOS assembly (both spring & air ride models).
The choice of automated conveyance for this project was the Fori’s 
system also included a large sequencing area. This “market place” style area worked directly with the customers manufacturing execution system (MES) to direct the RGC cart to the correct product storage position. Pick lights were activated to assist operators in the selection of the correct variant of spring, shock or air shock as requested by the OEM.
The new RGC assembly line was production capable in September of 2017.
The single loop style conveyor system consists of 13 RGCs to transport front brake corner and strut components (front 
For more information about Fori's 
The rear main assembly line was composed of 15 RGCs, seven operators, one automatic drive through alignment machine, and one manual backup alignment system.
https://www.youtube.com/watch?v=_vAiYKMojDU
For more information about Fori Automation's RGCs, assembly systems, and aligners, please visit our 
