For the past decade and since its inception in 2013 Fori has participated in Manufacturing Day (MFG Day) in Macomb County. But what is MFG Day and why is it so important to Fori and the communities throughout the nation?
Manufacturing Day is a national day where high school students learn about modern-day manufacturing career options and current technologies in manufacturing. Students visit local facilities and gain hands-on experience in a range of careers. MFG Day connects classroom learning to on-the-job skills. Careers in manufacturing today are much different than years ago. Today, the manufacturing industry utilizes automation and cutting-edge technology to create and build its products and produce solutions.
The Macomb Intermediate School District (MISD) in conjunction with the Macomb County Department of Planning and Economic Development (MCPED), works with local businesses and organizes MFG Day each year. For 2023 their goals were for 2,000 students from all 27 high schools in Macomb County to participate in MFG Day. Each year students are on-site for roughly two hours. MFG Day host sites, like Fori, welcome a group of chaperoned students and provide them a chance to see the industry in action by offering tours that showcase different processes as well as the careers involved. This year Fori welcomed Chippewa Valley High School whose students visited our machine shop, drove and demoed some of Fori’s Automated Guided Vehicles, and learned about 3D printing and how Fori incorporates 3D printing in our manufacturing processes.
Along with Fori local businesses like Kuka, Ascent Aerospace, BAE Systems, Paslin, and more opened their doors so students could take part in this educational opportunity.
Why is this day so important?
In Michigan and across the nation there is a trending manufacturing skills gap in the U.S. which could result in 2.1 million unfilled jobs by 2030, according to a new study by Deloitte and The Manufacturing Institute.
As an automation manufacturer, we believe it’s important to promote the value of manufacturing and skilled trades in our county, state, and country. While many people have a negative view of jobs in manufacturing many of us also know manufacturing offers fulfilling and rewarding careers. MFG Day encourages young minds to take a closer look at manufacturing and what this industry offers.
We are grateful to participate in this enriching program that promotes manufacturing and automation in Macomb County, Michigan, and across the United States.
This year Fori added some new faces to our intern roster and welcomed back a Fori internship pro.
Read on for our Q&A's with Ruess Rolloff discussing his first year interning with Fori and Nick McHugh who talks about his internship at Fori this time around.
Q: First things first, can you tell us your name, and which department you are interning in?
My name is Ruess Rolloff, and I am interning in the mechanical [engineering] department.
Q: What school are you attending and what is your major?
I currently attend the University of Michigan and I major in mechanical engineering.
Q: How did you come across the internship here at Fori?
I met someone at school who knew someone that works at Fori, and they set me up with an interview.
Q: What types of projects are you working on so far?
So far, I have been assisting with finishing up designs for an RGC and an AGV. In addition, I have been designing guarding for a portion of an assembly line in a factory. I also had the fun task of designing and 3D printing a business card holder modeled after an AGV.
Q: If you could do the internship again what would you change? Is there something you wanted to learn more about?
There is plenty that I would change, but that is just a part of the learning experience. I was unfamiliar with many of the processes early on which led to some simple mistakes in my work that I have since learned to fix. Although I ask plenty of questions, if I were to do it again, I would ask more questions about everything I was unsure about because it could have saved me time by going back and correcting my mistakes.
Q: Have you received training and support during your internship?
I have received plenty of support during my internship, but I do feel as though I received less than adequate training going into the internship. I was expecting a learning curve as is the case with any new job, but it was somewhat of a trial by fire the first few weeks.
Q: Does the workload match your expectations of the internship?
The workload does feel slightly heavier than average at times, but for the most part, is very manageable. The workload feeling heavier than average could potentially be attributed to not being familiar with procedures and falling behind while learning all the systems and processes.
Q: How would you describe the company culture here at Fori?
From what I have seen, I would describe the culture as friendly and relaxed. Everyone in the mechanical department seems to get along well and there are often jokes being cracked. Everyone is also quick to offer help if needed which is very appreciated.
Q: Why do you think internships are beneficial for students?
Internships are very beneficial to students because they give students actual relevant experience in their respective fields of study which goes far beyond what is learned in classes. They are also beneficial because they can help a student hone in on what field they would like to specialize in after graduation.
Q: What’s next for you, any exciting plans for the upcoming school year?
This upcoming school year is my senior year, so I plan on focusing on completing my final credits and soaking up as much information as can. I also plan on enjoying a great football season and spending lots of time with my friends before we graduate and go our separate ways.
Thanks, Ruess! We wish you continued success in the upcoming school year and wherever your career takes you.
Now let's check in with Nick McHugh who returned to Fori after completing an internship in 2022.
Q: Just to go over the basics again, what is your name, and what department are you interning in?
Nicholas McHugh, Controls Engineering Department
Q: What school are you attending and what is your major?
Q: What types of projects are you working on so far?
Automated Guided Vehicle Commissioning/Debugging for The Ford Box, Cab, and Chassis 123 AGVs.
I went to Ford RCP: Started updating AGVs (Automated Guided Vehicles) for the expansion, working with Pari at the plant, and cleaning up incorrect markings on the ground for RFID pucks.
Q: Have you received training and support during your internship?
Yes, any questions I have get answered. Sometimes I just have to find the right person or come to a different solution because software likes to break.
Q: Does the workload match your expectations of the internship?
Yep, the workload does match my expectations.
Q: How has this experience been, compared to your previous experience interning at Fori?
So far this year’s experience has been better than last year’s. The workload is comparable to last year for me. It was better because I know a lot of the people coming back and I got to go to Ford’s Rawsonville Plant. Going to the plant was cool because I got to see how the AGV’s are used in production. Other than that, it's essentially the same.
Q: Why do you think internships are beneficial for students?
Internships are beneficial because they provide an opportunity for students to gain experience in the field, create connections, and have a chance to learn if a certain career is something they want to do in the future.
Q: Why did you choose to come back and intern at Fori for a second year?
I came back to Fori for a second year because I enjoyed working on the AGVs and I feel like I have an amazing group of co-workers that are supportive and helpful.
Nick, we appreciate you taking the time to talk about your experience at Fori for the second year. Hopefully, we will see you again!
If you are interested in internships at Fori Automation, A Lincoln Electric Company contact our HR team at employement@foriauto.com. We are always happy to mentor and host aspiring talent.
It’s long been said children’s minds are the future. Little Inventors is a creative and educational organization that inspires imagination and takes this concept seriously. Born from creative minds in the United Kingdom Little Inventors creates free resources for institutions, teachers, and parents to encourage children to think up and draw innovative inventions. From these ideas, they promote challenges, events, and workshops. In addition to encouraging promising young inventors, they encourage skilled experts and makers, like Fori Automation, to work with local children to turn their ideas into reality. Making the fantastical practical.
Sa'Niya's original idea for the project.
This year MISD the Macomb County chapter of Little Inventors brought some of these great inventions to reality, with students from around southeast Michigan. Fori jumped at the opportunity to work on a design by New Baltimore student Sa’Niya. Sa’Niya’s brilliant idea tackles the problem of trash and asks people to take a harder look at what they are throwing away. Her design is called the Trash Monitor. The concept helps people discern if what they are throwing away is trash or if it can be reused or have another purpose.
To start this project the Fori team dove into the world of recycling. As an automation company, we had an idea of how we would bring Sa’Niya’s Trash Monitor invention off the page, but we needed to learn more about recycling and the materials the project would filter.
Many products and items that we throw away can easily have a second, third, or fourth life and we were excited to conceptualize this design which helps people identify items that are not – at first glance - trash.
After completing our recycling research, we moved on to sourcing the parts we would need for the Trash Monitor and creating the design. We had to find a trash receptacle we could modify and sensors to detect various items of materials that are commonly thrown away.
Sa’Niya’s idea for the trash monitor is when someone drops what they think is a piece of trash into the Trash Monitor receptacle, the sensors in the bin detect if the item is trash or if it can be reused or is a recyclable material. If the item can be recycled or reused it moves onto the conveyor and back to the user. If the item is truly trash it stays in the bin. Additionally, if an item is recyclable, a Trash Monitor alerts the user with a buzzing noise and the recycling symbol lights up bright green.
Many of the parts on the project such as the project logo, recycling logo, and conveyor could be 3D printed in our shop, here in Shelby Twp., Michigan. One of our mechanical engineers who specializes in 3D printing, created a design concept for the overall project using CAD software and designed the conveyor model as well.
Another final aspect of the Trash Monitor is the information panel on the front of the bin. A screen is attached to the receptible, this informational screen helps the user learn more about waste, recycling, and how we can all make small changes for a better community and world in relation to what we throw away.
Several Fori teams, including mechanical engineering, controls engineering, marketing, human resources, and the manufacturing shop came together to work on this project. Everyone involved truly enjoyed the opportunity to exercise their creative muscles and bring Sa’Niya's sensational invention to life.
In the images, you can see the final CAD design for the project along with one of our engineers wiring a board for the receptacle sensors. One of the reasons we liked this design was its practicality and how we can see it used today in many applications from a school hallway to an office complex or a bustling city center.
The 3D concept for the Trash Monitor project.
With the Trash Monitor complete, we were proud to showcase Sa’Niya’s design at the Macomb County Little Inventors banquet, along with other student inventors and makers. This project was truly an inspiration to Fori and our team. We hope all the Little Inventors continue to use their minds and imagination to create amazing inventions for a brighter and greener future.
In the dynamic landscape of corporate growth and business acquisitions, it is not uncommon to witness extraordinary alliances that bring together companies with complementary strengths and shared values. One such remarkable collaboration was seen when Lincoln Electric, a leader in welding technology, acquired Fori Automation, an automated manufacturing specialist with product offerings spanning automated material handling, assembly and automation systems, welding systems, and end-of-line testing.
This acquisition not only earned Lincoln Electric the coveted All-Star Deal of the Year Award by the Detroit Chapter for Corporate Growth (ACG Detroit), but it also solidified both organizations' reputations as inventive companies with similar cultures.
For years, Lincoln Electric has embodied the principles of hard work, innovation, and distinction, which have made it a revered name in the welding industry. Similarly, Fori Automation has established itself as a leader in automated manufacturing, maintaining a reputation for quality, reliability, and a strong commitment to its employees and community. The acquisition brought together two companies with parallel cultures, ensuring seamless integration and a shared vision for the future.
Leaders in their Respective Fields
Lincoln Electric's expertise in welding technology has propelled them to the forefront of the industry. Their commitment to producing high-quality welding equipment has made them a trusted partner for professionals around the world. Meanwhile, Fori Automation's specialization in automated manufacturing has allowed them to carve a niche as leaders in automation manufacturing and Automated Guided Vehicles (AGVs). Their advanced technologies and integrated systems have enabled efficient production processes for numerous industries.
Scope and Scale
The acquisition of Fori Automation by Lincoln Electric has significantly expanded the range and abilities of both companies. With the addition of Fori Automation, Lincoln Electric expands its automation integration offerings, and Fori Automation is now a part of the impressive network of Lincoln Electric Automation. Boasting a network of 32 facilities dedicated to automation, this expanded reach allows them to provide unparalleled service and support to their customers globally. Furthermore, the Lincoln Electric automation workforce includes over 2,000 employees, including Fori, who are skilled in the art of automation and dedicated to pushing the boundaries of industry standards.
Operational Competencies and Integrated Technology
Lincoln Electric and Fori Automation share a common commitment to operational competency and the integration of cutting-edge technology. Lincoln Electric's emphasis on continuous improvement, lean manufacturing practices, and operational excellence aligns perfectly with Fori Automation's dedication to providing efficient automated manufacturing solutions. The acquisition has allowed Lincoln Electric to leverage Fori Automation's expertise and technological advancements to further enhance its own product offerings.
A Global Force in Automation
With the acquisition of Fori Automation, Lincoln Electric has reinforced itself as a global force in automation. Their expanded facilities and skilled workforce enable them to deliver comprehensive solutions to customers across the globe. From installation to service, Lincoln Electric's commitment to the seamless integration of Fori Automation's capabilities positions them at the forefront of the automation industry.
This All-Star deal of the year has undoubtedly been a game-changer for both companies. Beyond the recognition of winning the award, this collaboration unites two companies with similar cultures and shared values. As Lincoln Electric continues to expand its global footprint, its enhanced capabilities in automation and dedication to operational excellence, and commitment to employee well-being ensure a promising future for Lincoln Electric, Fori Automation, and their customers.
This week as part ofNational EngineersWeekwe celebrated our makers, designers, developers, and tinkerers. Like every one of our integral teams at Fori, we wouldn't get far without our engineers and the important work they do.
When asked about their backgrounds, projects, and overall thoughts on engineering this is what some of them had to say.
"A unique part of being an engineer at Fori is the creative problem-solving used to update customer manufacturing operations. In recent operations we have been altering our designs to up-and-coming Models of EV automobiles, embarking us on a new era of automobiles and engineering. This is an exciting time with so much changing in the auto industry." - Jacob Landenberger, Mechanical Engineer
"What I love most about being an engineer at Fori Automation is the constant exposure to new projects, ideas, and technology. A recent project I was involved in here at Fori was designing a new torque tube that is mostly comprised of 3D-printed parts. I enjoyed getting to learn about additive manufacturing and seeing what role it can play in the future of automation and manufacturing. It’s rewarding to get to work for a company that is always trying to improve using the latest technology." - Jordan Zak, Mechanical Engineer
"The most exciting part of being an engineer at Fori Automation is the opportunity to work on so many unique projects. In the Sales Department, there are always new opportunities to learn, new jobs to work on, and the need of trying to come up with new ideas or ways of meeting our customer’s needs. Every day there are new applications and challenges with those applications that keep my job interesting. It is always a great feeling coming up with a new idea/concept design, proposing it to the customer, and them liking it enough to write a purchase order for Fori to complete the job." - Ryan York, Fori Automation Estimator/Process Engineer
In addition to testimonials, we were able to sit down with Cristiano Sarmento our Lead Controls R&D Engineer, and Martin Erni our Sales Director. We learned more about them, their backgrounds, and some of the projects they have worked on at Fori, providing solutions for customers through engineering.
Looking toward the future companies face many challenges, domestically and globally, and engineers will be needed to solve more and more complex problems. At Fori, we are grateful for our team of innovative engineers who consistently rise up and meet these challenges. To all young and upcoming engineers, “Sometimes it is the people who no one imagines anything of, who do the things that no one can imagine.” - Alan Turning. Happy National Engineers Week!
It’s not often you find someone like Mike Beck. A 25-year veteran of a manufacturing business, many of those years spent steering the ship as the GM, Vice President, and President of Fori Automation.
To quote Fori’s current President Paul Meloche,“Mike is a true leader. His integrity, open-minded demeanor, humble attitude, and commitment to well-being of Fori’s employees and customers was unparalleled. He’s also an incredible problem solver; I still believe he has a “sixth-sense” that allows him to predict issues before they happen. I was blessed to have him as my mentor for the past 20 years.”
Mike was born on the South Side of Chicago, after a few moves throughout the Midwest Mike’s family settled on Michigan’s west side, the best side one could argue. He received a Mechanical Engineering degree and shortly after that an MBA. A job with Detroit Diesel brought him to Metro-Detroit where he moved from engineering into manufacturing and saw projects come to life on the floor.
After nearly seven years with Detroit Diesel Mike was recruited into Chrysler for a joint venture power train program between Chrysler and BMW. With this new opportunity came new connections, one of those connections was Heinz Becker. Heinz an experienced manager working at Chrysler knew that Mike was potentially moving to Brazil as part of this joint venture, to start up a new engine factory. Before Mike headed south of the equator Heinz stepped in and introduced him to a gentleman named Arthur Koerner. Art as Mike would come to know him was the candid owner of Fori Automation, along with his son Bernd Koerner.
At the time, Arthur and Bernd were contemplating next steps and looking for someone to help run their growing business. When he met with Arthur and Bernd there were a lot of direct questions, which was Arthur’s style, followed by a couple of Warsteiner beers and a “When can you start?” Also, Arthur’s style. Mike told the Koerners he would think about it, as it was a career-altering decision.
“After two days, I accepted the offer.” And so, he was off to Fori Automation. Mike was hired at Fori as the Manufacturing Manager for the first year before he transitioned into the GM position. “I thought that was pretty exciting I didn’t have to move around the world to be in a General Manager leadership role.”
Big company politics didn’t interest Mike and the advantages of a smaller company where you can sit down with the owner and/or a few key people and agree if something makes sense appealed to him. “You have to live with your decisions, and you can’t blame anyone else, but you also have the ability to make a difference. You’re not part of a committee, there are not 20 people in the room. We didn’t always make the right decisions, but we learned from it.”
Mike’s first day at Fori he walked into the front office, no one at Fori knew or was expecting him except for Arthur. Arthur asked if he was ready to get started. “I am,” said Mike. So, Arthur asked the office admin to page all employees to the center of the building. “I walked with Arthur, and we get to the center of the manufacturing floor and he says, “I’d like to introduce you all to Mike Beck, he’s going to be the new Manufacturing Manager, Mike tell them what you’re going to do.”
“As a young guy, I was taken aback. I said some general words and realized quickly that was Arthur’s philosophy: sink or swim.” After that first day, Mike started to learn all about Fori and this business of customization in automation. "Arthur was a no-nonsense mentor and I respected him as he was the true entrepreneur that started the company," says Mike. There were roughly 110 employees at that time in 1998 and Fori was starting to go global.
Over several years Fori expanded into more regions. For Mike, it was gratifying to have been a part of hiring the general managers and teams in each new region. Supporting these regions and being a part of the international development and expansion was very exciting.
Along with the company's growth came a mission and vision to diversify. Diversify Fori’s global footprint, and its product portfolio with the introduction of new technology and its base of customers. Mike cites the ownership’s commitment and the strong engineering team that supported the diversification plan as the main reasons Fori thrived over the years and minimized some of the downturn cycles in the manufacturing industry; such as the recession in 2008 and the bankruptcy of some of the large automotive customers.
About six years after Mike started with Fori Arthur Koerner stepped back from the business and Bernd Koerner took over as the CEO. Mike describes these years as exhilarating but challenging. “I had a strong working relationship with Bernd and together we traveled often in the early years to support the international growth.” The business grew to more than 680 employees and advanced its global footprint to a total of seven international locations beyond its headquarters in Shelby Township, Michigan.
Speaking of his two-plus decades with Fori, Mike fondly remembers the challenges and the Fori team coming together to overcome them. “When we had some jobs that didn’t go as planned and had to jump on a plane or in a car whether it was to Auburn, Indiana, Kitchener, Ontario, or overseas, we would go into the field and spend days or weeks getting something back on track…I don’t miss the pressure or stress but the excitement of the team pulling it off and walking out of there knowing we were able to get it right is memorable.”
“Good companies have good people. I’m grateful people trusted that the ownership and the leadership team always had the employee’s and customers’ best interests in mind. As a machine tool company, you often get peaks and valleys, but Fori was always secure. We consistently experienced growth which was exciting. The global growth was quite an accomplishment for an organization of our size to create a global footprint and build stand-alone organizations in seven different regions was something. It was clearly a testament to the ownership’s commitment and the dedication of the international leadership and employees.” Says Mike.
Mike is confident Fori will continue to grow and succeed under the new ownership of Lincoln Electric and the leadership of Fori’s former Vice President and now President Paul Meloche. Paul has worked with Mike for nearly two decades as part of the Fori management team.
Speaking about his future, Mike said, “I’m ready to slow down for now. We have the right people in place, and I feel good about the hands that are taking over. I plan to spend time with family, maybe learn the guitar, spend time traveling; wake up in the morning look outside and have a cup of coffee without having to read a hundred emails or troubleshoot any issues. I feel that the timing and the way things landed this is the right time.”
Thank you, Mike, for helping take Fori to a level of distinction and credibility that can only be achieved through exceptional leadership. Thank you for fostering the right people and right customer relationships along the way. You truly helped shape Fori’s present and future. Enjoy your much-deserved retirement and as the saying goes, this isn’t farewell, it’s simply see you later.
Almost every organization wants employees who trust and have confidence in their employer. Nothing demonstrates that trust more than longevity. This past Friday, November 18th, we celebrated three Fori employees with who have been with the company more than several decades. Thank you to all who planned, attended and helped us celebrate these three exceptional individuals.
Calvin Visser celebrated 30 years with Fori Automation and was praised for his can-do attitude and his willingness to take risks.
Stojke Misovski who commonly goes by "Steve", a machinist and another 30-year veteran of Fori was credited with his ability to come in get the job done and his vast knowledge of the equipment. And, last but certainly not least Paul Schumann celebrated 20 years as part of the Fori team. Paul was commended on his dedication, capability and efficiency. A company is only as strong as its' workforce. We are proud to have such a solid and committed team.
Fori Automation, USA implemented a welding system for an SUV aluminum front suspension sub frame. The integration of weld scanning in North American automotive welding systems required an economical and robust concept to offer original equipment manufacturers (OEM's) European style weld verification and high system thru put. For this project Fori provided Robotic Aluminum MIG Welding, a Robotic Fori Weld Check System and In-line Inspect/Repair Stations.
Weld seam inspections for U.S. Automotive Structural Components are becoming a developing requirement to ensure critical welds are free of defects. Current weld seam inspection systems are not cost effective in North American markets due to high on-set costs and high levels of good part rejections that result in added production labor costs and lost production thru-put.
Current weld seam scanning inspection systems operate with extreme resolution to detect very small defects and weld bead profile conditions required to provide reliable weld certification. This results in high numbers of acceptable welds that are rejected due to the high accuracy image-processing requirement.
Fori Automation and a North American customer developed Weld Check as an alternative to high-resolution weld seam scanning systems. We combined low cost, high-speed 2D profile weld seam scanning and electronic data from the digital welders in a common database to provide reliable weld seam accept/reject capability. The combination provides customers with cost effective and truly efficient weld verification.
The solutions provided on this project offered high robot utilization and keyence profile scan and fronius weld database. Results eliminated part handling and the 100% weld check and allowed for 54 assembly jobs per hour (JPH) with a capacity of 40,000 lbs. or 18,181 kg. This weld project was successful due to the in-line robotic weld check system and the integrated sub-assemblies. To learn more about this project or Fori's welding systems check out our site.
The Manufacturing industry supports much of the U.S. economy. It's a backbone in Southeastern Michigan and pivotal to Macomb County but many in the manufacturing workforce are aging and retiring. Most schools no longer offer skilled trades, apprenticeships or promote manufacturing jobs as viable career paths. That's why Macomb County implemented Manufacturing Day more than ten years ago. The purpose of Macomb County's Manufacturing Day is to help students learn about modern-day manufacturing careers. Through Manufacturing Day students are able to visit local businesses that specialize in manufacturing and either learn more about careers they're familiar with or gain exposure to something new.
Today, careers in manufacturing are different from years past. Now, the manufacturing industry utilizes technology to create and build the latest and greatest products. And manufacturers need skilled workers who understand that technology. A skilled manufacturing team is essential to Fori's long term growth and the future of manufacturing in Southeastern Michigan. Fori's Vice President Paul Meloche gave his insight into Fori's experience with the event.
"Fori has been actively engaged in Manufacturing days since 2013, when County Executive Mark Hackle toured Fori with the media. We then attended a roundtable discussion with Mark and various local manufactures in an effort to raise awareness about the lack of young people entering the field of skilled trades. It was on that day that Manufacturing Day in Macomb County was established," said Paul.
In Macomb County Manufacturing Day has been around for almost a decade but the idea of this day isn't unique to Michigan. Manufacturing Day or MFG Day for short, is a national movement to inspire younger generations to take up careers in modern manufacturing. MFG Day is an initiative of The Manufacturing Institute, with the Fabricators & Manufacturers Association as a founding partner. Across the country cities, schools and businesses come together through a series of events to promote and educate students, parents and teachers on what careers in manufacturing can offer.
Manufacturing Day 2022
This year Fori hosted over 75 students on Friday, October 7th. The students were divided into groups and then rotated through five stations each on a different aspect of manufacturing. The students stopped by Fori's Machine Shop where they saw the machines used to create and fabricate parts.
They visited Fori's Quality Department where students learned about the various tools and systems needed to check the engineering specifications prior to assembly. The Fori Quality Team went over a Faro arm details inspection, a laser tracker demonstration and a Zeiss CMM running auto, all processes used to verify precision and accuracy.
Students also had a chance to drive an AGV (Automated Guided Vehicle) and learn about the use cases for different types of AGVs. They viewed a presentation from one of our sales engineers about the quoting process and even stopped by our 3D printing department.
Fori's focus on MFG Day is educating students that walk through the door. We want to showcase the engaging, challenging and lucrative careers that exist within manufacturing, what skills are required to succeed and a day in the life of the Fori team. We do all of this through hands on experience and our employees, who are passionate and proud to share their work with others. It's truly rewarding when our efforts pay off.
"By far my most memorable moment was not at Manufacturing Day itself but when a young man entered my office early one morning wearing a Manufacturing Day t-shirt, (Macomb County provides an MFG Day t-shirt to every student that participates.) He came into my office to introduce himself and thank me for hiring him and for hosting Manufacturing Day three years prior. That was his first day on the job at Fori and he was excited."
Paul Meloche, Fori Automation, Vice President
To learn more about Fori Automation check out our site. For more info about Macomb County's Manufacturing Day, find it here.
With eight global locations Fori Automation, Inc. is no stranger to meeting customer needs on an international level. A great example of this is shown through our Fori Korea team. In 2021, Fori Korea supplied a stable AGV system to an automotive manufacturer located in Andizon, Uzbekistan.
Fori Korea successfully installed a Body to Chassis Marriage system or BCM AGV system, as we like to call it, for an automotive manufacturer that made a major facility investment after converting another Uzbekistan automotive plant to a state-owned company. Fori Korea's BCM AGV System was selected because of our longstanding experience with body to chassis marriage systems. Fori Korea stabilized the facility in a short period of time and started mass production in September 2021.
The results consisted of four processes of sub-line and four processes of marriage line. The sub process is a go and stop method, and the marriage process is composed of a reflector and a smart camera, so that the vehicle body and AGV are synchronized to execute marriage. Annual production for line one is 180,000 units and line two is 150,000 units. Fori is a global leader in automotive chassis marriage systems and turnkey integration. Contact us to learn more about our offerings or head over to our website.
Internships are great opportunities for learning about industries you have never experienced and discovering new fields. This was the case for Fori intern Nick McHugh. Nick, an electrical engineering student at Michigan Tech in Houghton, Michigan joined the Fori team in early July. We spoke with him to learn more about his experience over the last few months, working at Fori and his plans for the remainder of the summer.
Q: How did you come across the internship here at Fori?
I applied to a bunch of internships. At my school they have a career fair every year and I applied to some internships through the career fair. I wasn’t hearing back from some of the places I applied, so, I started working my normal summer landscaping job. Then my dad told me someone from Fori reached out to him about Fori’s internship program. I’m really interested in circuits and circuit design and my dad suggested I check out other industries and places to see what other fields I might like. After that, I came in for an interview, did all that stuff. I wasn’t familiar with the work Fori does, but I was interested.
Q: So, that’s what you were doing with this internship learning about different industries?
Yea, I think it’s a good idea to try and figure out if circuit design is or isn’t what I want to do. I think that’s a good point of internships to learn if you like something or if you dislike it.
I totally agree. So, let’s get back to your experience at Fori.
Q: What types of projects did you work on while you were here?
I mainly worked on the AGVs for the Ford batteries. We worked with the Fori Flex Floor AGVs. We commissioned them. Me and Kerolless (the other Fori summer intern) also got a chance to wire some of the AGVs, after the commissioning work slowed down.
Kerolless explained to me what commissioning involves but can you explain the process?
Yea sure thing, the electrical and building departments build and wire the entire AGV. In the controls department we basically get the AGV without any software. We then have to add all the software to the AGV, configure the IP addresses and finally make sure everything is connecting and talking to each other. While we’re going through all these processes, we troubleshoot any errors we might find. It could be a miswiring or a control panel made by a supplier having issues, that sort of thing. You can’t notice the errors until the AGV is on and saying, “Oh there’s an issue here.” We did a little bit a work with the electricians as well, learning how to wire the AGVs. The electricians are responsible for wiring the AGV, building some smaller scale components and creating some smaller wires for the AGV.
Q: If you could do the internship over what would you change? Is there something you wanted to learn more about?
I would be interested in learning more about the engineering process from start to finish. Spending more time with each of the departments. Like, more time with the electricians, controls, blueprints and understanding the full process. If there was an issue with the AGV we were able to look at the blueprints and troubleshoot the issue, but it would have been fun to sit with some of the engineers and learn more about the design and build process. When I first got here there was also some line testing going on in the shop, it would have been nice to explore a little and learn more about that.
Q: Did you receive training and support during your internship?
I was given resources and I had a mentor for the first week or two. I could also ask all the other controls engineers or people working in the controls department for help or if I had questions. I was given a tour of the shop and shown the AGVs and the components. We talked about how it works and then we installed some software on the AGV together, then I was added to the team so I could start working.
Q: Did the work match your expectations of the internship?
I didn’t know what to expect, so I really didn’t come in thinking anything one way or another. I don’t know if what I did here will translate to my coursework, I’m heading into my fourth year at Michigan Tech and I’ve taken various electrical engineering courses and we have to complete a senior design project. Overall, the internship was a really good experience because it will allow me to build on the knowledge that I have gained from the last three years of college. In school, its theory based, we’re not doing much hands-on work, yet at least. I’m assuming when I get to more upper-level courses, I’ll start doing more practical stuff. Even just reading the blueprints during the internship was helpful because I get to see something that’s real and has a purpose. It’s not like coursework where they say, "Let’s throw as many wires and issues as we can to solve the problem."
Q: How would you describe the company culture here at Fori?
With working in controls everyone was very friendly. I liked the entire group of people. Knowledge wise there was not a lot of hand holding, we figured things out and then people were available as a resource.
So, what’s next for you, any exciting plans?
Right now, I’m really looking forward to my study abroad trip. I’m participating in a cultural program where I am going to Japan for two weeks. As far as engineering I still don’t know exactly what I want to do maybe I’ll want to do something completely different. Overall, I had a great time at the internship, I enjoyed it.
Fori provides internship opportunities for students interested in automation manufacturing. We offer internships in various departments and help students gain hands-on experience. If you want to learn more about our internship or apprenticeship programs, contact employment@foriauto.com
The summer season is coming to a close and with it the end of summer break. Soon we will be saying farewell to our interns as they head back to school. Kerolless Nasseef joined the Fori team on June, 7 as an engineering intern. He is a current senior at Wayne State University in Detroit, pursuing a bachelor’s degree in Electrical Engineering. We sat down with him to learn more about his experience working at Fori and his future career plans.
Hey Kerollees, thanks for taking some time to meet. Let’s start at the beginning.
Q: What motivated you to apply to the internship position with Fori?
Well, a lot of my colleagues in school recommended applying to an internship. I wasn’t sure of the specific field that I wanted, I was looking for controls and embedded systems with programming, those were kind of my interests. I applied to a couple internships and Fori responded right away. It’s close to my house so that helps too.
Q: Did you receive training and support during your internship?
When I started everything was well documented, as far as the processes for doing the job. A lot of it was learning the processes from the information provided and troubleshooting the systems. It was good because it forces you to understand things in a deeper way. And if I needed help with something I was able to ask one of the supervisors that are around to help us out.
Q: Can you explain what you did during your internship?
I was working on the AGVs, the smaller AGVs. Our role was to commission them. There are steps to configure the (AGV) networking to the software and the hardware configuration and then tuning the drives using separate software. There are a couple different software systems that we learned to use, to configure the scanners and magnetic sensors, since they are magnetic guided carts. Then we would take them on the track and test them. For example, we would run them for an hour make sure everything was working correctly then we would add heavy weight. I was surprised those small AGV carts can carry like a ton and a half. Once the weights were added using a crane, we run the carts for 20 hours to make sure everything works. I also got some exposure to the VMS (Vehicle Management System) which is the systems or the brains behind the AGV. I got a lot of exposure to the networking aspect of the system, which is how each piece of the system communicates with another. We also worked with WABs, which are the wireless access points. We would commission those as well. So, those are set up around the AGVs to communicate with all of them. We were given a router and we had to connect those systems to the power and ethernet cable, then connect those to a computer, then follow steps to configure the networking part of it. From there we had to set the specific IP address which allows the AGVs to communicate with the VMS. Through the VMS you can control the AGVs. We would upload ACE tables and those ACE tables are what gives the AGV commands based off a track. The track is designed then given an ACE table that can follow the magnetic sensor and then uploaded to the VMS and the VMS communicates that info to the AGVs. I got to work with a Fori employee and design a track and help create an ACE table which was cool.
Thanks for explaining that so clearly, it sounds like you learned a ton. Let’s change gears and talk about the culture within Fori.
Q:How would you describe our company culture?
I was surprised because I didn’t know what to expect. I thought I was going to be working in a much more managed environment and everyone I worked with was easy to get along with. They explained the processes and let you know what you needed to do to get the work done but no one is breathing down your neck about anything. There was a lot of hands-on experience, and I learned a lot. It was good to see what opportunities there are in this field. It helps too, to know what I should be working toward as far as what software types and what background and experience companies want.
Q:If you went through the internship process with Fori again is there anything you would change or like to learn more about?
I would like more experience with the VMS system, it seemed interesting and there weren’t a lot of opportunities to get involved with it. I think understanding the full system would have benefited me especially now after working on the AGVs in detail and the communication part of it.
Q: Do you think what you did here during your internship will translate to your coursework?
I do think what I learned will help with future coursework. I had to look at prints for the entire AGV, and you know in school you get all this work, but you don’t get to apply it to real world experience. So, seeing it in person helps with making the connection to the schoolwork. Getting exposed to the automation industry was really interesting to me. Some of the courses I have taken have been basic assembly code and I don’t think many companies program in that low level language, so it was nice to learn about the systems that are actually being used. In school they don’t really tell us what is being used in the industry, so it was good to learn. I’m interested in computer science, and it was great because the internship with Fori offered me some interaction with the CL programming language using the Siemens PLCs on the AGV systems. For controls engineers I learned I should know some programming too so that was good. I feel like programming is something that is really intriguing. I’m still trying to figure out what specific field I want to go into, but Fori gave me great exposure to what I can do with my skillset and degree in the future.
Fori provides internship opportunities for students to work in various departments and gain experience in all aspects of automation manufacturing. If you’re interested in our internship opportunities, contact employment@foriauto.com
For this post we are travelling across the globe to our China location. Fori China supplied 10 end of line testing systems for an automobile group, with an annual output of roughly 1.5 million passenger vehicles.
These systems allow the customer to complete 30 to 45 jobs per hour creating a more efficient process and workload for their teams. For this customer we increased their production rate, accommodated future production increases and created a flexible end of line equipment process for multiple wheelbases. The systems Fori China supplied are adaptable for testing fuel vehicles and electric vehicles and for testing of automatic driving function modules.
Fori Automation remains a global leader in the manufacturing of wheel alignment, headlamp aiming technology and ADAS calibration systems. Interested in how we can help with your next project? Drop us a line.
Assembly of peripheral equipment for Ocado. The final customer is O’Logistique, a food industry under constant pressure to increase efficiency and improve quality, automation becomes the most sought-after solution.
The Fori Spain Team has performed the assembly of decanting station equipment consisting of 8 integrated stations. The operator(s) load the food product bins which are then stored by the bots into a grid system.
Assembly of picking station equipment consisted of 12 stations, in which the bots bring the products directly from the grid system to the pick station where the operator(s) prepare the customer’s order.
Assembly of bot charger equipment included 23 charging stations, where the robots came to recharge their batteries. The new line was installed in the third quarter of 2021. A second phase is planned for the second quarter of 2022.
Fori Korea recently signed a contract to supply a Chassis Marriage System for a customer located in Jurong, Singapore.
Fori Korea is preparing to install the CMS system at in 2022.
The CMS equipment installation included (2) lifts, (1) auto tightening system, (4) auto marriage devices, (4) body holding devices, (4) hanger centering devices, (3) silent chain conveyors and (6) pallets.
The supplied equipment was designed for (2) vehicle models, the Ioniq 5 and GV60. The Ioniq 5 and GV60 are an electric compact SUV.
The Fori Korea chassis marriage equipment will be beginning the production vehicles during the 4th quarter of 2022.
Fori Automation recently installed a complex vehicle camera calibration and testing matched with high production requirements making new vehicle technology safe and effective. In an industry with constant pressure to boost efficiency and improve quality, automation becomes the key solution.
The FCM (Front Camera Module) Test System consists of specific targets to calibrate the Front Camera on vehicles with this option. The equipment included roof suspended calibration targets following the customers specifications in front of existing Fori alignment cells.
The FCM test system provides luminosity control, current (amps) monitoring, visual indication for failed lamp(s) and integration with the wheel alignment system(s) PLC to activate the system per vehicle options.
The FCM test system consisted of (6) FCM cells, each with 2 targets per wheel aligner with background luminosity protection. The FCM test systems also provide illuminance intensity metering for the maintenance team to validate the correct luminosity.
The new FCM test systems were installed during the last quarter of 2020 by the Fori Brasil Team.
In-floor headlamp aiming added to a wheel alignment machine with hi-resolution camera box provides accurate and repetitive means for adjusting vehicle headlamps for improved IIHS (Insurance Institute for Highway Safety) capability.
The (5) in-floor aiming systems provided for this project, were integrated to the existing Fori wheel alignment machines. Each system included the in-floor servo slide system for Y and Z automatic positioning to the vehicle headlamp, and a separate control panel with PC, Rockwell PLC and Rockwell servo motor drive components. The hi-resolution Fori-Vision camera box is mounted to the mast of the system. When automatically positioned to the headlamp center, the aiming process is initialized for finding the position of the lamp aiming point. The operator places the semi-automatic screwdriver on the lamp adjuster and the software sets the lamp to the required target.
The in-floor systems were used to provide better means of integrating to the existing wheel alignment machines versus the gantry systems. The gantry systems would have interfered with other existing overhead structures.
Upon installation of the systems, a more open environment was great for improved operator accessibility to adjust the headlamps. The latest hi-resolution aiming system has contributed to an improved headlamp aiming capability.
The 5 systems were installed over long holiday weekends and shutdown periods to not interfere with ongoing production.
RBT Modification kits with latest Emerson M Series Drive Controllers for improved torque measurement and control of test processes.
Modifications were requested for two existing Fori Roll and Brake testers to accommodate a new vehicle model “9-Speed Transmission Test Process”. The transmission features an increase in torque and acceleration. This required new servo motors and controllers that could accommodate the torque and acceleration throughout the test process.
Upon installation of the servomotor and drive kits, software was provided for the new transmission test process. The package included test curve displays, revised test screens, parameter selection menus and other enhancements for “Roll and Brake” test processes.
The new test screens displayed to the operator resulted in a very precise means of conducting the test process. Results of the test proved to be within the expected design criterion for the new 9-speed transmission.
The two systems were modified during a shutdown period and restart of production for existing and new product was made successfully.
High Capacity halogen free operator guided vehicles for the refurbishment of a Nuclear Power Plant have increased safety throughput.
The high capacity Fori operator guided vehicles have been designed to work within a nuclear power plant refurbishment project that runs 24 hours a day, 7 days a week, 365 days per year. The refurbishment is expected to take 12 years, the project started in 2016.
Initial refurbishment plans included a rail and carriage system. Through further investigation it was determined that operator guided vehicles would enable the end user to reduce infrastructures and increase flexibility. The vehicles were designed around the current plant infrastructure, this dictated the overall dimensions and capabilities of the system.
The vehicles allow for finite manual adjustment while handling the nuclear refurbishment equipment. The operator guided vehicles utilize a lithium ion battery, which allowed for a decreased footprint of the vehicle. The LiNMC battery also increased throughput due to the greater charge rate. The vehicles have reduced infrastructure costs, increased flexibility of the refurbishment plan and improved safety.
A high production capital welding system for large truck frames require efficient transfer and handling systems to maintain production thru-put. Close-coupled direct feed systems for major sub components (rails), and AGV’s integrated into end of line processes, help provide flexible facility configuration and efficient production flow.
Fori Automation recently supplied a high production robotic welding line with 150 robots (114 MIG welding and 36 transfer), inline inspect and repair stations, inline buffers, over aisle transfer conveyors, 8 AGV’s with frame positioner trunnions, 3 inspect/repair platform stations, and final frame stacking cell.
The weld system provided flexible tooling and welding processes for 35+ models of pickup and SUV frames with multiple wheelbase variations, and multiple drivetrain, body and box configurations. The AGV’s were built by Fori Automation, USA.
The complete welding system was built, runoff and delivered from Fori Automation de Mexico—Arteaga, Coahuila.
Increased demand for air ride suspension required a new system with higher capacity. Multiple canister weld cells are required due to the continuous welds for leak requirements, which feed into integrated final assembly and testing cells for consistent quality.
The robotic weld system consisted of six weld cells with ten aluminum MIG welding robots, two material handling robots, and four rotary welding stations for continuous pressure tank welds. Additionally, two final assembly welding stations for mounting brackets and two final assembly stations for pressure valves, fittings and labeling.
The mezzanine provides for overhead location of robot controllers, welders, and system control panels to reduce overall plant floor space.
In-line leak test stations provide verification of the finished product.
Fori Automation recently provided (2) High Capacity AGVs for the assembly of rockets for a large aerospace OEM.
The High Capacity AGVs can lift and transport up to 330,000 lbs. when used as a pair. Each AGV is capable of 165,000 lbs. when used in a single tool configuration. The system is designed to carry several different tools with varying lengths, widths, and total weights. The AGV system utilizes an optical coupler to communicate between the AGVs to coordinate motion and safety.
Each AGV includes (4) servo lift arbors, (6) suspended drive wheel assemblies and (8) suspended caster assemblies. The AGV chassis was custom designed to accommodate all of the different use cases. Each system included (3) different guidance methods for the various use cases within the plant. Currently, the system utilizes semi-automated control, with the ability to be upgraded to fully automated in the future.
The system can repeatedly locate within +/- 1.5mm at pick and drop stations. While driving the vehicle must maintain +/- 10 mm at slower speed. Improved accuracy and repeatability are accomplished through the use of Siemens servo motors and drives. The system is based on a high voltage DC Architecture, with a DC-DC converter to run the high voltage servo motors and drives.
The AGV solution reduced reliance on overhead cranes and other manual material handling methods for moving tooling and product through the plant. The AGVs will improve production flow and improve safety and repeatability for the assembly processes moving forward.
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.
The latest precision 3D wheel alignment provides for the high accuracy of toe and camber measurement as well as the best auditing of caster with the sweeping proves. Latest features of the Fori 3D technology prevent influence of temperature and have reduced the complexity of the electrical interface for PC top camera communication.
The specialized tooling for automatic front toe, camber-caster set and secure removes one operator from the pit, while providing the most accurate means for controlling alignment capability.
The specialized tooling for rear automation provides the capability to adjust and secure a small percentage of rear toe and camber on rear suspension modules. The tooling provides for a means of automatically adjusting the toe and camber once it is loaded on the suspension links and activated by operator to begin the adjust and secure cycle.
The headlamp aim audit system can be integrated with the production headlamp aimer. It is used to measure exact position of the location of the headlamp in reference to the bulb center. It can be used for verifying lamps are being aimed to tolerance and to assist with setting up new lamp models. It includes a high resolution camera to process and measure headlamps at 25 feet, a whiteboard that headlamps are projected onto, and a separate PC system for processing the lamps image.
In an industry with constant pressure to boost efficiency, improve quality and flexibility, automation becomes the solution most look for.
The Electric Power Pack (EPP) assembly from Fori Automation consisted of multiple pieces of equipment. Everything from lift assists and secure tooling to a servo controlled half shaft press fixture.
Automatic Guided Vehicles (AGV’s) were provided for conveyance of the product down the assembly line. This allowed operators full 360 degree accessibility around the power pack assembly.
The AGV’s were not only used for the assembly process but were also used as the transportation device to get the EPP to the line side location to complete the vehicle assembly.
The EPP assembly line was installed during the first quarter of 2020.
What does a typical day look like for you? I will get a line up from the Project Engineer and we will go through the quote and discuss what direction we want to go with the design. Then I will start designing the machine and we will have customer reviews and then finalize it, release it, and eventually get to see everything working properly on the floor.
What’s your favorite part about working for Fori? My favorite part about Fori is probably seeing the growth in the company. They are always trying to expand, try new things, and take on a variety of new jobs. It is also nice to see everything come together. A design starts off from just words on paper and then finally getting to see the machine functioning on the floor is really cool.
What has been the most exciting or important innovation at Fori you’ve witnessed? Well, I haven’t been here too long but from what I have seen, probably an Aluminum Ingot Transfer AGV that had to carry 250,000 pounds. It had to move aluminum ingots from station to station across the plant.
What is your proudest moment working at Fori? I don’t necessarily have a proudest moment, but I really enjoy working on the FEA’s - the stress analysis. We can take the machine, put it in the software, and replicate the working conditions and can see all of the stresses and deflections that are happening on the machine. We take that information and make it better and stronger. Then when we design something similar in the future we can take what we learned from that and avoid any problems.
What advice would you give someone who is thinking about a career at Fori Automation? I think it’s a great company with great people. It’s nice to work for a company that’s thinking about the future – always trying to expand and try new things. Since I’ve been here the last couple years, we’ve built a new facility across the street. And I hear we’re expanding globally. It’s always good to see a company trying to expand.
What is something most people don’t know about you? I don’t drink coffee!
What have you gained from working at Fori? I’ve gained a lot of knowledge on the manufacturing industry as a whole and just how everything works. The process behind everything going from a quote, to a design, to an approval, to a final build. Finally seeing it come to life is pretty cool.
How would you define success? Success to me is learning from your past mistakes or successes and building off of that and constantly pushing yourself to be the best you can.
When you’re not at work, what are you most likely doing? I am most likely golfing, snowboarding, or spending time with friends and family.
Fori Automation recently provided (2) high capacity Aerospace AGVs for the automated transport of a Mobile Paint System for aircraft painting and sealant.
The (2) high capacity AGVs are utilized as mobile platforms for the transport of a mobile paint system. The paint system is for painting and sealant applications within the general assembly area. The mobile paint system seals to the outside of the aircraft fuselage, allowing for paint and sealant activities in the general assembly area of the plant.
The AGVs were developed for the transport and staging of this system. Each AGV includes (4) powered drive wheels, (4) lifters and (8) suspended swivel casters. Once the AGV moves the system into position, the AGV and system are lifted and leveled. The mobile paint system is leveled in order to maintain a proper seal to the fuselage section for pressurization. After the paint and/or sealant apply is complete, the AGV retracts the lifts to lower the mobile paint system. Once lowered, the AGV and paint system are transported to the home position to wait for the next fuselage section to be loaded into the work position.
Each of the AGVs is outfitted with (4) powered drive wheels. The powered drive wheels enable omni-directional travel and fine positioning. The AGV is required to locate within +/- 5 mm at final position. The lifters are fully adjustable, including 6” of total stroke. The suspended swivel casters were provided in order to overcome the +/- 19 mm of floor variation in the plant. Suspended swivel casters also improve weight distribution across the entire AGV system.
Control of the AGVs & mobile paint system is completed via Siemens tethered HMI. The positioning, lift and level is completed automatically via preprogrammed sequences.
Can you tell us about your role at Fori? I started at Fori in the mechanical engineering department. Being new to this particular position and industry, I started out as a detailer, progressed to a designer and as of recent have taken on the role of Project Engineer.
What does a typical day look like for you? A typical day consists of overseeing multiple projects. Coordinating designs directly with our customers as well as working closely internally throughout various other departments to ensure the project runs smoothly. It is a very hands on position which I really enjoy! What is your favorite part about working for Fori? For me, it is seeing a project start as a concept/idea, watching it progress through the design phase in 3d cad, then going through the manufacturing process on our floor before finally being delivered to the customer. It is a rewarding experience seeing our final product in the production environment.
What has been the most exciting/important innovation at Fori that you have witnessed? In my time at Fori, the most exciting innovations have been our AGV (automated guided vehicles) systems and technology. Each one is unique per customer request and requirements from automotive to aerospace. It really gives you a glimpse of the future of manufacturing and automation.
Describe some of your favorite projects completed at Fori or your proudest moment? My favorite projects are the ones that require creative solutions. In particular, one of my proudest moments was when we were experiencing complications on a machine in the field and I was able to identify the issue and provide a quick solution.
What advice would you give someone who is thinking about a career at Fori Automation? Fori is a fast paced environment where you can challenge yourself, innovate and advance your career.
What does true leadership mean to you? Working side by side, encouraging and inspiring others. It is providing the tools to maximize success and goals on an individual or team level. What is something most people don’t know about you? I don’t drink coffee.
What have you gained from working at Fori? I have gained many new skillsets in my time at Fori. Most notably, looking at challenges from a different perspective and thinking outside the box. No one project is the same and has its own set of challenges and roadblocks to overcome.
How do you define success? I see success as accomplishing personal goals, challenges or tasks you set out to do. If you can set your mind to something and work to your full potential to achieve that goal, then that is true success - the goal itself is subjective.
When you’re not at work, what are you most likely doing? Mountain biking or planning my next trip out west.
Fori China recently designed, built and integrated a super pallet and associated modifications for a final assembly line for a customer at their plant in China.
Fori China was responsible for designing, building and integrating (4) different final assembly line retrofits to accommodate an additional (3) vehicle platforms on an existing assembly line.
In order to support the super pallet modifications and the additional vehicle platforms, there were (4) different line modifications required for the equipment. The final assembly line retrofits included:
• Super pallet modifications for new vehicle powertrain
• Addition of new load bar for different powertrain
• Updated tooling for hub tightening
• Robotic auto-tightening for battery package
The most unique portion of the modification project was the integration of an auto-tightening station for the battery electric vehicle (BEV) battery. The auto-tightening was completed with (4) fastening robots.
Fori China recently designed, built and integrated a Chassis Marriage system for a customer in Germany.
Fori China was responsible for supplying the Rail Guided Vehicles (RGVs), associated track, overhead loader and PLC control system that controls the loop.
The Chassis Marriage RGVs are based on Fori’s long standing mechanical design and controls architecture. Each RGV includes (2) Fori patented servo controlled chain lifts for the synchronized lift and locate of the front and rear pallet. Each Fori chain lift includes a floating table for alignment to the vehicle chassis that is transferred via overhead rail system.
The RGV is focused on maintainability and simplicity for the end user. The system utilizes a variety of off the shelf components and Fori standard product. The RGVs have been a robust solution for many years, pushing Fori to become a global leader in Chassis Marriage systems.
Fori also offers induction based rail guided vehicles and automated guided vehicles (AGVs) for chassis marriage that utilize a combination of induction and battery power.
Fori Germany recently designed, manufactured and supplied a new rear suspension adjustment stand for the Audi Brussels plant.
The rear axle is delivered by an existing conveyor system and automatically raised to the setting position. Once located, the suspension is clamped and the measurement of the camber takes place without contact. After the suspension is located the installed vehicle force is applied to the module, force displacement is included within the equipment to simulate vehicle loading.
Once the measurement is complete, the required adjustment is completed automatically by appropriate torque units. After completing the adjustment process, the rear axle is placed back on the tool carrier and extended out of the protected area of the adjustment cell.
Consists of the following components:
• Protective safety fencing
• Rear suspension adjustment system
• Contactless measurement device
• Auto-torque for adjustment
• Device to simulate actual vehicle weight during adjustment
Fori Mexico recently provided an automated bushing press system for a Martinrea production plant in Queretaro, Mexico.
The bushing press system includes two tooling modules, one to produce left hand modules and one to produce right hand modules. The system includes a single press in the center of the equipment to product either configuration of product. The press system supplied utilizes a Fori servo controlled press system that is capable of 50 kN of force.
An operator loads the busing into a product fixture, which is automatically loaded into the press system via automatic indexing slides. The press moves to the work position via servo controlled slide and performs the insertion of the bushings.
Start of production for the equipment was during the 1st quarters of 2019. The system provided improved production rate versus more manual methods of bushing insertion.
Fori recently supplied (2) automated Tugger AGVs for Aerospace composite tooling cart transport.
The Fori Tugger AGVs were supplied to transport a variety of composite tooling parts with total transfer weight up to 30,000 lbs. The Tugger AGV system included auto docking to the product carts. The purpose of the auto docking is to eliminate the need for operator intervention to couple to the carts and transfer them through the assembly plant.
The Fori Tugger AGV is utilized in two configurations, first as a Tugger pulling tooling carts in a single direction. The Tugger AGV is also used as a Dock N’ Lock. In the Dock N’ Lock configuration, the AGV automatically connects to the tooling cart and pulls it against the bumpers (shown in bottom picture). The attachment allows the tooling cart to rotate with the Tugger AGV and back it into work stations as required by the process.
The Tugger AGVs were commissioned to ensure safe and reliable product transfer. Previously, this transfer was completed with fork lifts or manned tow vehicles. The AGVs eliminated non-value added material handling and provided a hands off system for transporting product through the assembly process.
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.
The Fori assembly system sequences and processes multiple variants utilizing Fori Flex Rail System assembly solution.
Integration of manufacturing execution systems (MES) with the Flex Rail System allows the value added assembler the means to create multiple variants of suspension systems. The product is sequenced and assembled as requested by the end user and ready for installation into the vehicle. Flexible configurations allow for the most cost effective utilization of plant floor and personnel when handling large volumes and variables of product.
The loop style conveyance system consists of (57) rail guided carts (RGCs) to transport suspension module components from incoming material dunnage thru the various assembly processes including:
Front & rear brake corner assembly system:
• Automatic hub bearing & rotor lateral runout test and assembly.
• Robotic assembly of knuckle to hub bearing and caliper to knuckle with vision inspection.
Front vertical assembly system:
• Automatic Front Coil over Shock assembly.
Rear suspension module assembly system:
• Automatic setting of camber and toe.
• Simultaneous auto-torque of all links in (5) link suspension with vision inspection.
• Robotic unload of completed module to shipping container.
Fori recently supplied (7) wheel alignment systems with integrated headlamp aim (HLA) and driver assist for a customer.
The wheel aligners and headlamp aimers feature the latest 3-D camera and digital headlamp aiming camera system that Fori offers.
Each wheel aligners can accommodate various tire styles and tread-width variations. The wheel base adjustment allows the machines to handle all of the different truck cab styles.
A gantry style target board system aligns the vehicle adaptive cruise control (ACC) module, lane departure warning (LDW) camera and several other onboard vehicle sensors.
The Fori wheel aligners supplied during this project are not the “typical” systems supplied in the past. Fori’s strong engineering group and past experience enabled us to take on these requirements and successfully implement them into the equipment.
Adaptive Driver Assist Safety (ADAS) centering cells are stand alone and can be placed in any audit or production facility.
The stand-alone ADAS cell was developed for the Faraday future electric vehicles that are eventually moving to a total autonomous Level 5 stage.
The project required the calibration of the vehicles long range Radar sensor, corner Radar sensors, front camera, (stereo vision) and surround view camera. Headlamp aiming (HLA) was integrated into this platform to best utilize the operator’s process time.
The ADAS system was developed using lower cost solutions for:
• HLA with the hi-resolution Fori camera box and manual positioning gantry
• Pneumatic “auto” positioning of the LRR aluminum target for Bosch Gen 5 radar sensor
• Pneumatic drop down positioning of the LDW target
• Fixed stanchions with corner reflectors for the corner radar calibration
• Pneumatic centering platform for a wheelbase range of 500mm.
• A self-contained control system with Siemens based s7-1200 series PLC for conducting all positioning and the adjust sequence.
• PC and software to interface with other plant provided systems that communicated to the vehicle OBDII.
Fori has further improved on its standard Tugger AGV design by doubling the overall towing capacity.Fori Tugger AGVs have been used for a variety of material handling applications within the automotive industry. Most recently Fori was enlisted to supply a derivative of the standard Tugger product line that is capable of nearly double the capacity of the original vehicle. The driver of this increase was the transport of (3) carts, carrying axle assemblies for a large automotive OEM.
The Fori Tugger capacity allowed more product to be transferred during each move, further increasing the return on investment to the end user and decreasing the number of required vehicles. The Tugger AGVs were commissioned to replace non-value added material handling tasks within the assembly process. The most important process consideration was safety and reliable delivery of product.
Further improvement of the safety and reliability of the material handling system was the integration of a Fori Vehicle Management System (VMS). Vehicle scheduling of moves, tracking and traffic control is coordinated through the Fori VMS. The Fori Tugger is a proven and robust product that can be applied to a variety of material handling applications.
Fixed Audit Headlamp Aiming (HLA) systems are stand alone and can be integrated within any existing wheel alignment machine, pneumatic centering platform, or other centering system.
The dual camera fixed audit headlamp aimer was developed for a customer and installed in 2018. The HLA system included a fixed gantry frame with the (2) high resolution camera boxes, a whiteboard that was collapsible for easy storage and a PC control panel.
The HLA application was used to perform headlamp aiming audits on various GM vehicles from the car and truck platforms. A simple manual cent
ering system and leveling plates were included to provide a low cost method for centering the vehicle during the audit process.
The (2) high resolution cameras provide an accurate method of finding the true headlamp center and headlamp aim position, to accommodate requirements set forth by the latest IIHS standard.
Fori USA recently designed, built, and integrated a wheel alignment system with headlamp aiming (HLA) and wheelbase adjust for a customer.
The End of Line system included: non-contact wheel alignment and automatic headlamp aiming. Wheel base adjust was also included in order to handle a variety of vehicle wheel bases.
The wheel alignment machine is designed for automatic measuring of toe and camber. Feedback is supplied to the operator, who completed a manual adjustment of the vehicle parameters. The wheel alignment equipment is designed for a wide range of wheel bases and tire tread width sizes.
An integrated headlamp aimer (HLA) measures the vehicle headlight intensity and positions the aimer automatically to guide the operator to the correct adjustment necessary. The “Fori Vision” aiming unit utilizes a 2.3 megapixel camera based system to measure the intensity and position of the headlight.
The latest hi resolution camera box was also included for improving the headlamp aiming resolution and accuracy required by the latest IIHS standards.
Highly flexible, automated robotic MIG welding assembly cells, consists of (3) similar lines that accommodated customers (9) different model variations.
The rear suspension cradle satisfies approximately 90% of the vehicles in this family, with its model output accurately controlled and monitored throughout each robotic weld line.
Each line possesses (21) MIG welding robots, (3) material handling robots and utilizes a minimum number of operators. The current assembly system runs consistently between 181 seconds and 150 seconds depending on which model is being processed. After completion of the robotic welding, the critical component characteristics are machined with a pair of precision, custom machining centers.
The integration of the MIG welding and material handling robots has decreased cycle time and increased throughput. Utilizing highly accurate machining stations and a repeatable process has also reduced waste and the quality of the final product has been greatly increased
The Axle Assembly System sequences and processes multiple product variants utilizing Fori's Automated Guided Cart (AGC) assembly solution.
Fori Automation's integration of manufacturing execution systems with the AGC system allows the value added assembler the means to create multiple variants of Axle Assemblies.
The single loop style conveyor system consists of (12) AGCs to transport Axle Assemblies from incoming material dunnage through the various assembly processes and (2) off-line turntables including:
• Automatic positioning of Axle housings for various fill and drain plugs, using (2) trunnions on a turntable.
• Robotic transfer from plug turntable to dowel weld turntable to AGC load.
• Semi-auto dowel welding
• Robotic sealant apply to a variety of Axle housing carrier shapes.
• Leak test while manual start of carrier bolts.
• Manual final torque of carrier bolts.
• Manual loading with assist of various Axle shafts.
Utilizing experienced resources, Fori developed a viable process, engineered the system, manufactured the equipment and integrated the assembly line at the end user.
Fixed audit Headlamp Aiming (HLA) systems stand alone and can be integrated within existing wheel alignment machine, pneumatic centering platform or other centering system.
The heavy duty 3D wheel alignment system was developed by Fori Automation for a facility to accommodate the heavy truck loads and 110” wheelbase ranges of various truck models.
The equipment was developed to improve the wear capability of machine load components such as the floating plates and sliding access plates for accommodating the high throughput of the heavy duty truck models. Additionally, telescoping machine covers were provided to accommodate the long wheelbase adjustment range of 120-210”.
The machine included other special features for measuring and tracking underbody points with laser displacement modules during the truck’s suspension adjustment cycle. The machine also performed audit checks for caster measurement using the caster sweep audit process.
For HLA an above floor gantry system was provided with Y and Z servo motor positioning and the latest high resolution camera box for improving the HLA resolution and accuracy required by the latest IIHS standards.
Hi-Speed Stand Alone Headlamp and ADAS Auditing with Pneumatic Centering Platform.
The high speed audit headlamp system utilizes an automatic Y and Z positioning gantry similar to what is used on production machines. Combined with the pneumatic centering platform, it provides for a means of auditing a wide variation of vehicle model headlamps with the Fori high resolution camera system. The high speed audit system provides improved throughput compared to manual headlamp audit systems.
High speed headlamp audit applications require the platform be mounted to the plant floor, so an entrance ramp is included for pulling into the platform, and backing off.
The system also provided the means for adding floor targets for a calibration check of the surround view camera system. The equipment can be utilized for adding other ADAS calibration devices in the future.
End of Line pneumatic centering platform for ADAS calibration process.
(2) Pneumatic centering platforms were provided for centering the vehicle during the ADAS calibration process. The centering actuators also included integrated string encoders to track the actual position of the vehicle for verifying centering within tolerance as required by the customer ADAS specifications.
The project required the platform be mounted to the plant floor, so entrance and ramps were included for pulling into the platform and driving off. Heavy duty roller saddles were included for this system to handle the high throughput of the heaviest vehicles.
The system also provided the means for adding floor targets, for a calibration of the surround view camera system. Additional ADAS devices were also integrated with the supplied centering system.
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.
Fori Automation has further improved on its standard Tugger AGV design by incorporating a Fori chain lift and pallet tooling for lithium ion battery decking.
Fori AGVs have been used for a variety of material handling applications within the automotive industry. Most recently Fori was enlisted to supply a derivative of the standard Tugger product line that has a built in electric lift and pallet tooling to be used for marrying the electric vehicle battery to the chassis.
The AGV was required to synchronize with the vehicle chassis in the overhead carrier. The synchronization was a challenge in itself as there was no physical tracking arm. All of the vehicle synchronization for battery decking was completed utilizing tracking cameras and encoder positioning. The most important process consideration was the safe and reliable positioning of the product for the operators.
Further improvement was the integration of a Fori Vehicle Management System (VMS). The Fori VMS allows for vehicle scheduling, charging, vehicle status information and traffic control. The Fori battery decking AGV platform partnered with the Fori VMS is a proven and robust product that can be applied to a variety of material handling applications.
Cost effective, flexible AGV solutions have allowed automotive companies to implement a safe, reliable and repeatable material handling solution within their build processes.
The Dock N’ Lock AGVs were built to fit within existing plants and each plants respective material handling strategy. The AGVs were commissioned to replace non-value added material handling tasks. Specifically as a direct replacement for all of the fork lifts, creating a “fork free” environment. The Dock N’ Lock AGVs are responsible for auto-docking to the pictured companion carts. Previous methodology utilizing fork lifts was not a safe or reliable option, the Dock N’ Lock AGVs solved this problem.
The automated locking feature is what differentiates the Dock N’ Lock AGVs from standard Tuggers. The AGVs were required to auto-couple to newly developed racks, doing so removed the need for operator interface and allowed the end user to relocate operators to value added activities. The vehicles were required to repeatedly locate within +/- 10mm and travel at speeds up to 200 feet per minute.
A fully integrated, automated Vehicle Management System (VMS) was also provided. The VMS handles the traffic routing between the 19+ vehicles that are currently operating within the system. The VMS has the ability to track and store faults, monitor battery consumption and ensure safe operation by monitoring all safety devices.
Fori Automation Designed & Built (3) automated static alignment cells. This is a pallet pass through system that adjusts camber & toe. The aligner handles (2) vehicle models that have different geometry.
The project challenges included:
• Packaging additional tooling
• Limited module tryout
Providing customized equipment such as this starts with a concept design phase. Fori engineering was requested to provide a detailed engineering study. Upon completion of engineering and feasibility study, it was determined that the (2) new models could be ran together. Through the design, process and simulation, Fori was able to fit multiple tooling features for the (2) new models with different geometry.
The suspension module aligner knows which model is in the station based on a broadcast from the OEM, as well as position sensors placed in the machine, automatically initiating the correct tooling combinations.
A challenging portion for any project is the ability to debug and tryout the process. The key to success was analyzing every failure mode with precision in order to correct and provide results that would normally require more debug time.
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 Tugger AGVs were supplied to transport a variety of composite tooling parts with total transfer weight up to 30,000 lbs. The Tugger AGV system included auto docking to the product carts. The purpose of the auto docking is to eliminate the need for operator intervention to couple to the carts and transfer them through the assembly plant.
The Fori Tugger AGV is utilized in two configurations, first as a Tugger pulling tooling carts in a single direction. The Tugger AGV is also used as a Dock N’ Lock. In the Dock N’ Lock configuration, the AGV automatically connects to the tooling cart and pulls it against the bumpers (shown in bottom picture). The attachment allows the tooling cart to rotate with the Tugger AGV and back it into work stations as required by the process.
The Tugger AGVs were commissioned to ensure safe and reliable product transfer. Previously this transfer was completed with fork lifts or manned tow vehicles. The AGVs eliminated non-value added material handling and provided a hands off system for transporting product through the assembly process.
Fori Automation de Mexico facility was completed in 2019 and offers more than 90,000 square feet of manufacturing and office space.
The new facility was built to support the continued growth of Fori Automation de Mexico. Fori Mexico has been an intricate part of the continued growth of Fori Automation globally. The new facility will enable Fori Mexico to take on larger projects and support our domestic and global customer base. Below is an interactive tour and company overview for Fori Automation de Mexico.
https://www.youtube.com/watch?v=JscRbXVu7L8
Fori Mexico currently has over 50 employees and a plan is in place to hire over 20 more within the next three years. Pictures of the new facility and start of the project can be found below. The new facility is located in Coahuila, Mexico.
Fori Automation de Mexico HeadquartersRobotic Welding System for Automotive Frame Assembly
Fori Automation recently supplied a number of powered drive wheel systems for an automotive Tier 1 supplier. The drive wheels were integrated into a customer supplied tooling cart providing automated movement of product through the automotive assembly process.
Automotive Assembly with Powered Drive Wheel System on Assembly Cart
The Fori powered drive wheel systems include modular drive wheel units that are mounted to new or existing assembly carts. Once mounted the drive wheels automate the transfer of materials through the manufacturing facility. The drive wheel systems provide the same capability as an off the shelf Automated Guided Carts (AGCs). The powered drive wheel systems can be manually moved by the operator or can be supplied with an integrated vehicle management system (VMS) or traffic control to automatically control movement from station to station.
The key benefits of a powered drive wheel system include:
Reduced reliance on fork lifts or manned Tuggers.
Improve ergonomics, reduction in injuries in relation to pushing or pulling assembly or kit carts.
Repeatable, reliable delivery of goods and consistent line pulse for assembly operations.
Ability to integrate into manufacturing execution system (MES) for data analysis and production streamlining.
Safe transfer of goods through the use of onboard Safety PLC and associated safety devices.
Accurate positioning of carts and goods, standard station positioning is +/- 10 mm when utilizing a Fori provided vehicle management system (VMS).
Drive wheel systems include their own self-contained power supply, control panel, collision avoidance devices, guidance hardware and tethered (or wireless) pendant for manual control. Power supplies include sealed lead acid batteries and lithium ion product offerings. The controls architecture is safety PLC based and available in Siemens or Rockwell. Guidance or navigation options available include optical, magnetic or natural feature utilizing the onboard safety scanners.
Powered Drive Wheel System with Safety Scanner, Alarm & Lights, E-Stops & HMI
Total carrying capacity of the powered drive wheel systems is accommodated by a variety of standard drive wheel sizes. Capacities can be increased by up-sizing the drive wheel and motor combination or adding more of the smaller drive wheel units. Drive wheel systems can also be configured to allow for different levels of maneuverability. The maneuverability ranges from uni-directional, loop based systems, up to omni-directional systems for complex material handling or assembly systems with the integration of two or more drive wheels.
The drive wheel systems are structured for current or future automation with the ability to retrofit the assembly cart later in the production cycle. The assembly cart can be designed to accommodate mounting of the drive wheels and required equipment at a later date. For existing carts, our design team will work with the production team to define the required changes for addition of the powered drive wheel system. The ability to add automation as production increases, decreases the initial capital expenditures, allowing production rates to increase before adding the automation required for automated or manual transport through the assembly process.
Powered Drive Wheel System with Single Powered Drive Wheel & Support Casters for Assembly Cart & Product Transport through Automotive Assembly Process
Overall the powered drive wheel system provides a flexible, safe and reliable material handling and assembly solution for the a wide range of industries and processes.
To learn more about Fori's available products please visit our website or contact us at sales@foriauto.com.
Fori Automation recently supplied a number of powered drive wheel systems for an automotive Tier 1 supplier. The drive wheels were integrated into a customer supplied tooling cart providing automated movement of product through the automotive assembly process.
Automotive Assembly with Powered Drive Wheel System on Assembly Cart
The Fori powered drive wheel systems include modular drive wheel units that are mounted to new or existing assembly carts. Once mounted the drive wheels automate the transfer of materials through the manufacturing facility. The drive wheel systems provide the same capability as an off the shelf Automated Guided Carts (AGCs). The powered drive wheel systems can be manually moved by the operator or can be supplied with an integrated vehicle management system (VMS) or traffic control to automatically control movement from station to station.
The key benefits of a powered drive wheel system include:
Reduced reliance on fork lifts or manned Tuggers.
Improve ergonomics, reduction in injuries in relation to pushing or pulling assembly or kit carts.
Repeatable, reliable delivery of goods and consistent line pulse for assembly operations.
Ability to integrate into manufacturing execution system (MES) for data analysis and production streamlining.
Safe transfer of goods through the use of onboard Safety PLC and associated safety devices.
Accurate positioning of carts and goods, standard station positioning is +/- 10 mm when utilizing a Fori provided vehicle management system (VMS).
Drive wheel systems include their own self-contained power supply, control panel, collision avoidance devices, guidance hardware and tethered (or wireless) pendant for manual control. Power supplies include sealed lead acid batteries and lithium ion product offerings. The controls architecture is safety PLC based and available in Siemens or Rockwell. Guidance or navigation options available include optical, magnetic or natural feature utilizing the onboard safety scanners.
Powered Drive Wheel System with Safety Scanner, Alarm & Lights, E-Stops & HMI
Total carrying capacity of the powered drive wheel systems is accommodated by a variety of standard drive wheel sizes. Capacities can be increased by up-sizing the drive wheel and motor combination or adding more of the smaller drive wheel units. Drive wheel systems can also be configured to allow for different levels of maneuverability. The maneuverability ranges from uni-directional, loop based systems, up to omni-directional systems for complex material handling or assembly systems with the integration of two or more drive wheels.
The drive wheel systems are structured for current or future automation with the ability to retrofit the assembly cart later in the production cycle. The assembly cart can be designed to accommodate mounting of the drive wheels and required equipment at a later date. For existing carts, our design team will work with the production team to define the required changes for addition of the powered drive wheel system. The ability to add automation as production increases, decreases the initial capital expenditures, allowing production rates to increase before adding the automation required for automated or manual transport through the assembly process.
Powered Drive Wheel System with Single Powered Drive Wheel & Support Casters for Assembly Cart & Product Transport through Automotive Assembly Process
Overall the powered drive wheel system provides a flexible, safe and reliable material handling and assembly solution for the a wide range of industries and processes.
To learn more about Fori's available products please visit our website or contact us at sales@foriauto.com.
Fori Automation is proud to announce that we have been selected as a Top System Integrator Giant for 2020.
Fori Automation has been selected as a Top 5 System Integrator Giant for 2020. The selection of System Integrator Giants is based on each respective companies revenue that is attributed to system integration. For more information on System Integrator Giants, please visit the Control Engineering webpage.
The System Integrator Giants announcement can be found here.
Fori Automation privately held and U.S. owned and operated since 1984, specializes in the custom design, build and integration of automated material handling, assembly, testing and welding systems for the automotive and non-automotive industries.
Our equipment and systems include:
Fori has supplied equipment across the globe for a variety of Automotive & Non-Automotive OEMs and Tier 1's. Customer verticals served include the Aerospace, Automotive, Defense, Nuclear, Recreational Vehicle and Construction industries. With over 30 years of experience and seven locations across four continents, Fori is positioned to support its customers around the globe.
For more information on Fori Automation, please visit our website.
Crain's Detroit Business has listed Fori as number 25 on their Fast 50 list for 2019. This list is compiled to highlight the fastest growing companies in Southeast Michigan.
https://www.youtube.com/watch?v=k3MGrg7W9hA
25. Fori Automation Inc.
Revenue 2015: $164,000,000 | Revenue 2018: $240,000,000
Three-year percentage change: 46
What it does: Design and build of automated material handling, assembly, testing and welding systems for the automotive, aerospace, agriculture, recreational vehicle and alternative energy industries.
How it grew: Diversification strategies that include investing in new product development for assembly, testing, welding and material handling systems. The company began focusing on automotive opportunities outside of its traditional assembly equipment in 2008, including welding systems, material handling systems and automation systems for both global automotive car manufacturers and tier one suppliers. Fori has also expanded into aerospace, military, recreation vehicle, construction and agriculture, heavy metals and alternative energy industries. The company also expanded globally, with design and build facilities in China, Korea, India, Germany, Brazil, Mexico and Spain.
To check out the rest of the list, visit Crain's website. To find out more about how Fori has expanded to meet your automation needs, please visit our website.
Fori China designed, built and integrated an end of line testing system for an automotive manufacturer.
Features:
Jobs Per Hour: 65 jobs
Testing Completed:wheel alignment, headlamp aiming, roll and brake
Results: Increased production rate, reduced labor, improved quality
https://www.youtube.com/watch?v=uO3VIb39Ubc&t
The end of line testing system included: non-contact wheel alignment, automatic headlamp aiming and roll and brake testing.
The wheel alignment machine is designed for automatic measuring and manual adjustment of the vehicle parameters. The system was designed to measure toe and camber. The system is designed for a wide range of wheel bases and wheel tread width and tire sizes.
An integrated headlamp aimer measures the vehicle headlight intensity and position automatically and guide the operator to adjust the lamp position semi-automated. The “Fori Vision” aiming unit utilizes a camera based system to measure the intensity and position of the headlight.
Roll and brake testing is also completed on the end of line system, which includes testing for acceleration, cruise control, transmission, rear gear, dynamic braking and engine.
For more information about Fori Automation's end of line testing solutions, please visit our website.
The battery powered chassis marriage AGV with dual independent lifters is capable of lifting and transporting up to 4,000 pounds (1,818 kilograms) in order to install the front and rear suspension and drivetrain modules.
This AGV was developed to support the end users lean, automated, manufacturing methodology. Not only will the AGV enable the end user to reduce their hardware investment, there will be significant flexibility in the assembly process. The guidance system and reduced plant infrastructure allows the AGV to easily interact with other systems and processes. The AGV is also outfitted with multiple safety measures that ensure collision avoidance.
The chassis marriage AGV is responsible for accurate and repeatable location of a part within the station for a reliable chassis marriage process. The AGV will provide increased flexibility, safety, and decreased product damage, thus increasing profitability within the manufacturing process for the end user.
Fori China recently designed, built and integrated a cockpit assembly line in Shanghai.
Features:
Jobs Per Hour: 60 jobs
Results: Increased production rate, reduced labor, decreased injury concerns
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The Fori China project aimed to improve the productivity and ease of assembly for a cockpit. The manipulators were attached to a steel structure that is used for assisting the operator while installing the cockpit assembly into the vehicle. After the cockpit is attached to the manipulator, it is conveyed to the install location, the goal is to reduce potential of damage to the workpiece. Once the workpiece is located within the vehicle, the manipulator holds the panel until tightening of the bolts is completed.
The manipulator has improved production efficiency, reduced product damage, and most importantly improve safety for the operators. For more information about Fori's aerospace tooling, please visit our website.
https://www.youtube.com/watch?v=lehMe10Vx9g&t=
Fori Germany supplied 16 AGVs for a body shop project that were custom designed around the customer’s process. The total capacity required for each AGV was 1,100 pounds (500 kilograms). The AGV was responsible for carrying a car chassis between various assembly stations.
Each vehicle consisted of two fixed drive wheels, an integrated scissor lift, and a 24 volt lithium ion battery to power the vehicle. The system was based on an open controls architecture, utilizing a Siemens PLC for the vehicle control. In addition, each vehicle is equipped with a camera based guidance system that follows colored tape or paint. The optical guidance system provides a flexible, reliable and cost effective solution for guiding the vehicles throughout the assembly plant.
The vehicle included a custom scissor lift to accommodate the vertical lift stroke and capacity required for the process. Each vehicle is capable of lifting 1,100 pounds (500 kilograms), and the scissor lift is capable of 21 inches of total stroke with a collapsed height of 11 inches. The custom 24 volt 67 ampere hour lithium ion battery was designed to fit within the available footprint on the vehicle. The system allowed for quick charging at the designated opportunity charge stations. Utilization of a lithium ion battery reduced the required charging infrastructure.
For more information about Fori Automation's AGVs, please visit our website.
Fori China designed, built and integrated a chassis marriage system for a automotive manufacturer located in Slovenia.
Features:
Jobs Per Hour: 45 jobs
Results: Increased production rate, reduced labor, decreased injury concerns
https://www.youtube.com/watch?time_continue=29&v=3_u1UGkP928
The marriage line is a sub-set of the trim and chassis final assembly system that delivers the completed front and rear modules to the marriage line after being assembled. The overall project is based on the green field sit to provide the delivery conveyance of the completed sub-assembly from the tunnels to the marriage line automatically where the complete chassis assembly will be automatically married and secured to the car chassis.
The body carrier and frame are powered into the stations via asynchronous conveyors. The spindles index and begin securing the front module, differential cradle, and rear module. All 14 fasteners must be torqued at the same time. There will be three wheel base variations that have a common front module and center cradle positions.
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An inspection station was supplied with the system. The station will provide positive verification that the details match the corresponding configuration of the vehicle sequencing through the assembly process. The vision inspection is completed at a stop station.
The marriage station includes an electro-mechanical hook style body clamping device for models that require holding the body during the marriage process. An external actuator in the station is used to clamp the body to the pallet. Once married the overhead carrier drive is disengaged allowing the pallet conveyor to the move pallet/carrier assembly down the line. Future non-related products may be introduced by either pallet redesign or through additional pallets and a future pallet storage system.
For more information about Fori Automation's body and chassis marriage systems, please visit our website.
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 Mexico was involved in the relocation of an existing hot stamping line during production from Detroit, MI to Ramos, Mexico.
https://www.youtube.com/watch?v=k3MGrg7W9hA
Timing for this project was critical, because it was going to take place during production. The customer was required to build a bank of stampings for production while the equipment was being relocated.
The existing hot stamping line in Detroit was a singular process. The customer requested that a new process in Mexico be a parallel process to improve the output of the system. Fori was responsible for engineering the new process. Fori developed the new system layout and completed all the robotic simulations with offline programming to verify the performance of the new parallel process system. The customer requested that Fori use as much existing capital as possible to help control costs, therefore anything that was not available for reuse had to be built by Fori, including the controls of the new system.
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Once the engineering was completed and signed off, Fori Mexico managed the installation, integration, and run off of the new parallel process. Fori USA was responsible for project management, engineering, and quotation.
For more information about Fori Automation's products, please visit our website.
https://www.youtube.com/watch?v=YPEvwHyMXD0
Fori Korea was contracted to replace an existing Chassis Marriage system. The system consisted of 14 Chassis Marriage carts, two chain lifts, and associated tooling plates to accommodate the three different vehicles assembled within the process. The system was built to meet a production capacity of 60 jobs per hour.
The Chassis Marriage cart was unique due to the ability to move the wheel base for the front and rear pallet separately in order to accommodate the vehicle variations. Doing so allowed the Chassis Marriage system to meet the various engine decking points within the limited hanger pitch.
The chassis marriage RGV system consisted of a single traffic control panel for the 14 vehicles. The main control panel ensured proper vehicle pitch and synchronization through the chassis marriage process.
In order to ensure a smooth installation and buyoff at the customer facility, the entire chassis marriage was setup, debugged and bought off on Fori Korea’s floor.
For more information about Fori Automation's chassis marriage capabilities, please visit our website.
Fori India recently designed, built and integrated a Rail Guided Vehicle (RGV) style engine decking system to an automotive manufacturer near Pune, Maharashtra.
Features:
Jobs Per Hour: 25 jobs
Features: Engine dress conveyor and pallets, overhead hoist and rail system for loading engine on pallet
Results: Increased production rate, improved decking process
The system was supplied for accommodating the customer's new vehicle model. The system was integrated into an existing assembly shop and was designed for 25 jobs per hour. The decking system supplied runs cross-car to the underbody conveyor line. The decking for the engine assembly is completed in a static position.
The RGV movement was completed with a friction drive wheel. A hydraulic scissor lift was provided for vertical movement of the pallet and engine. The control architecture for the system was Allen Bradley PLC based.
The decking system also included the engine dress up conveyor and pallets, as well as a buffer conveyor with overhead hoist and rail system for loading the product on the pallet.
For more information about Fori Automation's automotive capabilities, please visit our website.
https://www.youtube.com/watch?v=lehMe10Vx9g&t=
Fori Germany supplied 31 AGVs for a front end assembly line. The AGVS are used to transport the workpiece carriers that are mounted on the carrier plate of the AGV.
The total capacity required for each AGV was 1,100 pounds in order to support the pallet and associated product. The carrier plate used for locating the product was mounted onto a trunnion to provide better ergonomics and accessibility for the operator completing the assembly.
Each vehicle consisted of two fixed drive wheels, an integrated trunnion, and a 24 volt lithium ion battery to power the vehicle. The system was based on an open controls architecture, utilizing a Siemens PLC for the vehicle control.
Each vehicle utilizes a camera based guidance system that follows colored tape or paint. The optical guidance system provides a flexible, reliable and cost effective solution for guiding the vehicles throughout the assembly plant.
The system was supplied with a Siemens based Vehicle Management System (VMS) to schedule and coordinate vehicle moves, communicate with the plant and for monitoring of the vehicles.
For more information about Fori Automations' AGVs, please visit our website.
Fori China recently designed, built and integrated an end of line system for an automotive manufacturer.
Features:
Jobs Per Hour: 15 jobs
Testing Completed: Wheel alignment, headlamp aiming, roll and brake
Results: Increased production rate, reduced labor, improved quality
The end of line system was included: non-contact wheel alignment, automatic headlamp aiming, and roll and brake testing.
The Wheel Alignment machine is designed for automatic measuring and manual adjustment of the vehicle parameters. The system was designed to measure Toe & Camber with a wide range of wheel bases, tread width, and tire sizes.
An integrated headlamp aimer measures the vehicle headlight intensity and position automatically and guides the operator to adjust the lamp position semi-automated. The “Fori Vision” aiming unit utilizes a camera based system to measure the intensity and position of the headlight.
Roll and brake testing is also completed on the end of line system, which includes testing for acceleration, cruise control, transmission, rear gear, dynamic braking and engine.
For more information about Fori Automation's end of line systems, please visit our website.
Fori supplied a cost effective solution for setting the front suspension caster and camber alignment prior to the end of line equipment.
https://www.youtube.com/watch?v=WcFVxdwJ4BA
Features:
Safety: Safety scanners, system interlocks
Controls: Allen Bradley
Keys to Success: Highly accurate and repeatable, fully automatic with manual override functionality.
Results: Increased production rate, reduced personnel injuries
The Caster Camber fixtures (primary and back up) were built to fit within the existing assembly plant. The system proved to be a challenge in the already congested twin strand pedestal conveyor. The fixture itself hangs from an overhead rail system and is capable of locating and tracking with the vehicle frame as it passes beneath.
The fixture lowers itself onto the vehicle frame, and then pins and clamps to the frame which establishes the control datum points to locate to. The machine's two pivot arms swing in and clamp the upper and lower control arm ball joints. DC Nutrunners loosen the lower control arm fasteners. Servo motors position the X and Y location of the lower control arm. DC nutrunners secure the lower control arm into the correct location. The fixture then un-clamps and lifts off of the frame. At that point the fixture drives itself back to it's home position ready to accept the next unit.
The system consists of a fully integrated Safety PLC. The PLC has the ability to track and store faults, monitor and record positional and setting information as well as monitor all safety devices.
For more information about Fori Automation's automotive assembly capabilities, please visit our website.
Fori Mexico provided a robotic MIG and projection welding system for a sub frame line for an automotive manufacturer.
Features:
Assembly Cycle Time: 54 seconds
Keys to Success: Integrated robots and custom designed turn tables, custom precision welding
Results: Decreased cycle time, increased quality
https://www.youtube.com/watch?time_continue=120&v=yKQiLvi-SyU
The front sub-frame line has a total capacity of 292,000 units with a cycle time of 54 seconds. The assembly consists of MIG welding, projection welding and clinch studs. Fori processed this with dial tables mounted to the customer's base system for ease of installation.
The assembly line consists of 22 MIG welding robots and ten material handling robots. MIG welding is the main process completed, but the line also has Vitronic cameras to scan welds for quality control, post welding pierce stations, and machining centers for key attachment points and a map vision system to verify dimensional accuracy.
Fori USA was responsible for project management and engineering for the program. Fori Mexico was responsible for building the line, debug and run off on their floor. The robotic welding system proved to be a successful collaboration between Fori USA and Fori Mexico. The ability to support the setup, buyoff and installation near the customer plant was of great value to the end user.
For more information about Fori Automation's welding systems, please visit our website.
Fori Korea supplied an Advanced Driving Assistance System (ADAS) to accommodate several vehicle platforms and test a variety of safety features.
Features:
Safety Testing: Lane departure warning, automatic headlights, over speed prevention, traffic signal recognition, distance warning
Results: Decreased infrastructure, increased production rate, accommodation of future vehicle models
ADAS test benches certify the operation of the vehicle cameras related to Lane Departure Warning (LDW), Automatic Head Lights (AHL), Over Speed Prevention (OSP), Traffic Signal Recognition (TSR) and Distance Warning (DW).
The ADAS system also validates functionality of the vehicles radar system which detects the moving elements in front of the vehicle from a significant speed and the operation of the vehicle. Examples include Adaptive Cruise Control (ACC), Advanced Emergency Braking System (AEBS) and Forward Collision Warning (FCW).
Another test completed by the ADAS is the AVM (Around View Monitor). This process is completed with four cameras (front, rear, two for side mirrors) and then displays the image captured by the cameras to the operator in their cones of vision (e.g., help for the blind spots, help for the car parking).
The ADAS system has reduced the infrastructure required for the various sensor testing that is completed on production vehicles. The system allows multiple tests to be completed in one station.
For more information about Fori Automation's end of line testing products, please visit our website.
Fori India designed, built, and integrated a chassis marriage Rail Guided Vehicle (RGV) system for front and rear assemblies.
Features:
Electro-Hydraulic Scissor Lifts
Friction drive wheel
Wheel base adjustment
Results: Increased production rate
The Rail Guided Vehicle system supplied was comprised of a Fori standard friction wheel drive for the required forward and reverse movement. The vehicle included two separate electro-hydraulic scissor lifts that are used for decking the front module and rear axle assembly. The system also included wheel base adjustment that was required to accommodate multiple models for the rear axle assembly.
The RGV was designed to be user friendly and simple to use. An example of this methodology is the within the control System which was designed to be very simple for the end user, utilizing a relay based logic.
For more information about rail guided vehicles, please visit our website.
Fori Germany supplied 21 work piece carriers for a front end assembly line. The work piece carriers were integrated with an existing automated guided vehicle (AGV) system, and are mounted directly to the AGVs.
The purpose of the work piece carriers is to provide a repeatable solution for locating the parts to the pallet for assembly. The work piece carrier also provides a process to the operator for adjusting the part location and orientation. Adjustment is completed through a powered trunnion.
The carrier trunnion has an integrated motor in order to tilt (the system has four automatic tilt angles) the fixture both automatically and manually. The carrier utilizes the power available on the AGV and communicates with the it to provide confirmation of the correct position. Upon completion of the front end module, the carrier returns to the home position and the module is unloaded via a lift assist.
The system supplied provided a simple technique for locating the front end module for the operator. The design considerations were based on a high level of reliability and minimal maintenance.
To learn more about Fori Automation's AGVs and assembly capabilities, please visit our website.
Fori China designed, built and integrated an end of line system for an automotive manufacturer.
Features:
Jobs Per Hour: 30 jobs per hour
Testing Completed: Wheel alignment, headlamp aiming, roll and brake
Results: Increased production rate, reduced labor, improved quality
https://youtu.be/_GJYOmV-Ekc
The end of line testing system was integrated for a two vehicle inspection line. Testing completed included: non-contact wheel alignment, automatic headlamp aiming, roll and brake testing, and various other sensors.
The wheel alignment machine is designed for automatic measuring and manual adjustment of the vehicle parameters. The system was designed to measure toe and camber for a wide range of wheel bases, tread width, and tire sizes.
An integrated headlamp aiming system measures the vehicle headlight intensity and position automatically which guides the operator to adjust the lamp position with semi-automation. The “Fori Vision” aiming unit utilizes a camera based system to measure the intensity and position of the headlight.
https://www.youtube.com/watch?v=uO3VIb39Ubc
Roll and brake testing is also included in the end of line system which consists of testing for acceleration, cruise control, transmission, rear gear, dynamic braking, and engine.
For more information about Fori Automation's end of line 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.
Solutions: Vehicle synchronization, auto-leveling, vehicle management system
The six high capacity AGVs, capable of auto-leveling and synchronized transport of tooling up to 40,000 pounds have been designed to accommodate projected wing production. The AGV system is required to be synchronized during the lift of the tooling and product, as well as synchronization of the three AGVs during transport. The system includes an auto-leveling feature that dynamically levels the tooling during travel to ensure a level plane is maintained during transport between stations. The Fori AGVs will be the primary method of transporting the tooling and product through the assembly process. Traditional assembly systems rely heavily on overhead crane utilization, whereas the AGV based solution eliminates the reliance on cranes.
The AGVs were developed to support the customer's lean automated manufacturing methodology. The goal of the project was to automate the entire material handling process for the assembly of the stringers (specifically the load and unload of the autoclaves used for curing the composite wing stringers). The loading of the autoclave is completed utilizing a natural feature guidance system. Then the AGV uses the walls of the loaded autoclave for the guidance in and out, while still maintaining +/- 5mm accuracy.
The design intent was to build a vehicle that was modular and interchangeable. The AGV system is required to transport many tools of different lengths and weights. The AGV system needs to be able to accommodate synchronization of up to three AGVs during the lift and transport from assembly stations.
Each of the AGVs is outfitted with two servo based lifters and a laser alignment system which provides measurement feedback to the onboard PLC for the dynamic leveling of the tooling during transport. The system must maintain levelness within +/- 1/8” from each end of the tool.
A Fori Vehicle Management System (VMS) has been provided to monitor system I/O, communication between the AGVs, tooling and automated assembly stations. Scheduling of moves also occurs at the Fori VMS.
For more information about Fori Automation's Aerospace AGV products, please visit our website.
During extensive layout and process reviews, all areas that required rework were identified so a plan could be developed to add field kits which consisted of new portions of assembly line. In order to be flexible and to accommodate the heavy variation in product, a number of robotic torque applications were added each with a common trombone torque tool to be utilized on all module complexity types.
In order to accommodate the new product, two additional aligners were reworked from another customer plant and installed on a new conveyor section of the assembly line.
https://www.youtube.com/watch?v=usiSOJZkGnA&t=3s
For more information about Fori Automation's assembly products, please visit our website.
Controls: Rockwell open architecture, vehicle management system (VMS)
Keys to Success: Vehicle synchronization, custom designed chassis, high capacity lifts
Results: Improved flexibility, decreased infrastructure, elimination of batteries and chargers
Chassis marriage has traditionally been completed with a Rail Guided Vehicle (RGV) and in floor track. The system has been a longstanding robust and reliable solution; however some customers require additional flexibility to support their process.
The chassis marriage AGV looks to improve on the RGV technique by utilizing induction power. Using induction provides a limitless power source and magnetic guidance which is a proven guidance technique for AGVs providing a high level of reliability and accuracy.
One of the main design considerations for the chassis marriage AGV development was flexibility and infrastructure reduction. Utilization of an in floor induction wire and magnetic bar will decrease the cost and time associated with the installation of Chassis Marriage systems. The ease of layout changes supports the added flexibility requested by the end users of these systems.
In floor induction wire.
A Vehicle Management System (VMS) is supplied with the vehicles to manage communication with the overhead conveyor, synchronization of vehicles and system diagnostics required by the end user. This inductive chassis marriage AGV can be designed to use the proven and reliable patented Fori electric chain lift or other suitable lift devices.
For more information about Fori's AGVs or Chassis Marriage systems, please visit our website.
Fori has further improved on its standard Tugger AGV design by doubling the overall towing capacity.
https://www.youtube.com/watch?v=TdX5-JNfPsw
Features:
Guidance Technology: Inertial with pencil magnets, bi-directional, capable of 0 degree turn
Capacity: 35,000 lbs./15,909 kg.
Safety: Scanners and bumpers
Controls: Siemens Open Architecture
Keys to Success: Highly accurate and repeatable
Results: Increased production rate, reduced personnel injuries, decreased infrastructure
Fori was enlisted to supply a derivative of the standard Tugger AGV product line that is capable of nearly double the capacity of the original design. The driver of this increase was the goal of being able to transport three carts carrying axle assemblies for a large automotive OEM.
Due to the capacity, more product was transferred during each move which further increased the return on investment while decreasing the total number of required vehicles. The Tugger AGVs were commissioned to replace non-value added material handling tasks within the assembly process. The most important process consideration was safety and reliable delivery of product.
Integration of a Fori Vehicle Management System (VMS) introduced further improvements to safety and reliability. Vehicle scheduling of moves, tracking and traffic control is coordinated through the Fori VMS. The Fori Tugger is a proven and robust product that can be applied to a variety of material handling applications.
For more information about Fori's Tuggers and other material handling systems, please visit our website.
Fori recently supplied a module assembly line for axle assembly. The production line consisted of a Fori twin strand conveyance system with manual assembly stations, automatic Lateral Run Out (LRO) and automatic end of line robotic vision system for inspection.
Features:
Assembly Jobs Per Hour: 81 jobs
Keys to Success: Inverted assembly process, integrated robots for vision inspection, lateral run out with WSS testing
Results: High build efficiency, reduction in rejected parts
https://www.youtube.com/watch?v=MySCkX35R6I
The required equipment was met with a few unique challenges and aspects:
Inverted assembly and unloading of the vehicle side up
Unique LRO testing and retry methodology
Inverted robotic vision verification
Minimal area available for assembly line
Robotic vision verification
Prior to testing the LRO, the hub and rotor must be assembled on a test fixture complete with constant velocity. The joint and hub fasteners are then tightened according to production standard and are able to withstand an axial load of 100 kN. In order to accomplish these items the equipment had to lift the axle from the pallet prior to being secured.
https://youtu.be/fZ15gTgPO60
Due to the rotors being unable to be retained flat against the hub, the equipment could not guarantee "non-contamination" that could potentially produce a fault during LRO. In order to correct this the “retry method” of the equipment was to remove the rotor, index to the next rotary present pattern and reinstall the rotor to the hub prior to LRO testing.
For more information regarding Fori Automation's assembly or end of line systems, please visit our website.
Fori has traditionally supplied Rail Guided Vehicles (RGVs) for automotive Chassis Marriage, but over the past five years Fori has leveraged its AGV experience to transfer existing automated vehicle technologies to its Chassis Marriage systems. The automated vehicle technology provides a Chassis Marriage system that decreases the required plant infrastructure. Whereas the traditional RGV based system requires an in floor track and power transfer system. The AGV system removes this requirement by utilizing an on board, battery based power supply and magnetic tape or bar guidance for vehicle tracking and positioning. Overall these improvements decrease facility work and associated cost, and allow for decreased installation times and provide long term flexibility for changing production needs.
The battery powered Chassis Marriage AGV includes dual independent Fori patented chain lifts capable of lifting and transporting 4,000 pounds in order to install the front and rear suspension and drive train modules to the vehicle Chassis. The battery based Chassis Marriage AGV was developed to support the end users lean automated manufacturing methodology, decreasing the total in plant infrastructure required for the system. Not only will the AGV enable the end user to reduce their plant hardware investment, there will be significant long term flexibility in the assembly process. The guidance system of the AGV and reduced plant infrastructure allow the AGV to easily interact with other systems and processes.
The AGV is outfitted with multiple safety measures that ensure collision avoidance. Safety scanners are included on the front and rear of the vehicle that will slow down and stop the vehicle as objects enter the scanning field. The Chassis Marriage AGV also includes indicator lights in each corner, (4) e-stops, safety pressure bumpers on the perimeter of the AGV and an on board HMI for vehicle status and diagnostics.
Automated Guided Vehicle (AGV) for Chassis Marriage utilizing Magnetic Tape Guidance
The Chassis Marriage AGV is responsible for accurate and repeatable location of product in station for a reliable chassis marriage process. The AGV will provide increased flexibility, safety and decreased product damage, thus increasing profitability within the project for the end user.
For more information on Fori's Chassis Marriage AGVs, please visit our website.
Fori recently designed and built a Tunnel AGV to support its global customers. The Tunnel AGVs are utilized for transporting product and dunnage throughout the production process.
The Tunnel AGV pictures includes a Roller Conveyor companion cart for Pallet Transfer.
Features:
Guidance Technology: Magnetic bar, inertial with pencil magnets
Capacity: Up to 10,000 lbs./4,545 kg. (can be increased upon request)
Safety: Safety scanners and bumpers, Siemens safety PLC, system interlocks
Controls: Siemens open architecture, vehicle management system
Keys to Success: Custom designed chassis, highly accurate and repeatable
Results: Improved flexibility
The Fori Tunnel AGVs are capable of automated docking and transport of companion carts carrying up to 10,000 pounds. The design intent was to build a vehicle that was modular and interchangeable. In order to increase process flexibility the Tunnel AGVs are capable of docking to various companion carts, each serving a unique purpose.
Applications include pallet transfer via roller conveyors, lift tables and powered trunnions. Automated docking to the companion carts is completed with two docking or hitch pins. The docking pins ensure proper alignment to the companion cart for repeatable pick and drop.
The Tunnel AGV was designed to provide a high capacity material handling solution in the smallest footprint possible. The vehicle is comprised of two fixed drive wheels allowing for bi-directional travel and zero turn capability.
A Fori Vehicle Management System (VMS) is utilized for scheduling of vehicles and traffic management of the system. The vehicle controls are based on an open architecture utilizing a Siemens safety PLC, eliminating the black box technology that is commonly used across the industry. The Tunnel AGV has proven to be a cost effective and reliable material handling system for a variety of applications.
For more information on Fori's automated material handling products, please visit our website.
Fori recently supplied an assembly system for an american motorcycle manufacturer. The system comprised of manual push pallets on a vertical conveyor system consisting of a main build line and two vertical lift support stands.
Features:
Assembly Units Per Day: 500 units / 2 shifts
Keys to Success: Operator ergonomics, flexible tooling, loop configuration, modular sections for line expansion
Results: Quality built assemblies, on time turnkey install
Not all projects require high levels of automated equipment in order to meet the end users production requirements. This project is a great example of how Fori took a powered vertical conveyor system and redesigned it to a manual push pallet system based on cycle times and customer budget requirements. The updated design provided the customer increased flexibility for their long term build process. The line was designed in modular sections for future expansion of increased production as required based on customer demand.
The ability to be flexible with the pallet provided the ability to use the vertical conveyor for more than current parts or model changes. Overhead support for tooling was a jib boom that bolted to the floor to remove the assembly to dunnage.
For more information about Fori's assembly solutions, please visit our website.
Fori recently provided six high capacity Aerospace Tugger AGVs for the automated transport of tooling, supporting the horizontal build line for wing assembly.
https://www.youtube.com/watch?v=XMOAJ_BuOEQ
Features:
Guidance Technology: Magnetic bar, inertial with pencil magnets, natural feature and laser contour
Capacity: 120,000 lbs./54,545 kg.
Safety: Safety scanners and bumpers, Siemens safety PLC, system interlocks
Controls: Siemens open architecture, vehicle management system (VMS)
Keys to Success: Vehicle synchronization, custom designed chassis, highly accurate and repeatable.
The six high capacity Tugger AGVs (capable of automated docking and transport of tooling up to 120,000 pounds) have been designed to accommodate projected production. The AGVs will be the primary method of transporting the tooling and product through the assembly process.
The AGVs were developed to support a lean automated manufacturing methodology. The design intent was to build a vehicle that was modular and interchangeable. The AGV system is required to transport nine different tools, all with different weights and footprints. Due to tools exceeding lengths of 100 feet, the AGVs are required to dock at each end of the tool and move in tandem.
The automated docking utilizes a natural feature and camera based guidance system, which accommodates unexpected movement of the tooling. The system measures the surface of the tooling to generate angular offsets and utilizes a SICK camera and reflector based system for final location. Once positioned, servo driven couplers automatically pin spring loaded receivers mounted to the tooling. The tooling is also outfitted with safety scanners powered and controlled by the AGV.
Responsibilities of the AGVs include: automated docking, tooling identification and transport throughout the facility. A Fori Vehicle Management System (VMS) has been provided to monitor system I/O, communication between the AGVs, tooling, and automated assembly stations. Scheduling of moves also occurs between the vehicle Siemens Mobile Panel and the Fori VMS.
For more information about Fori Automation's aerospace products, please visit our website.
The Robotic MIG Welding system contains resistance spot welding, projection welding, drawn arc welding and a sealer application.
https://www.youtube.com/watch?v=yKQiLvi-SyU
Features:
Assembly Cycle Time: 54 seconds
Keys to Success: Integrated robots, custom designed turn tables, custom precision welding
Results: Decreased cycle time and increased quality
The robotic weld system provided accommodates for multiple structural end item assemblies that consisted of resistance spot welding, projection welding, drawn arc welding, as well as a sealer application. The system contained multiple welding cells with a total of (50) robots.
The end item assemblies within this program were Load Beams, Rear Quarter Inner, Rear Closure Inner Assembly, Dash Assembly, Cowl Side, Center Floor Pan Assembly and Sill Outer.
Dial indexers where integrated into a number of the weld cells to improve the efficiency of the robots. Within the process some robots carried weld guns while others were material handling robots that moved the assemblies through pedestal welders (spot, projection and drawn arc) or pedestal sealers.
Fori USA was responsible for Project Management, Engineering, Assembly and Integration. All cells were setup and run off at Fori's global headquarters in Shelby Township, MI. Fori Mexico was responsible for installation and buy off at the end user's production facility.
For more information on Fori Automation's weld lines, please visit our website.
The (3) high capacity automated guided vehicles (AGVs) were supplied to replace a legacy system that was over 20 years old. The Fori AGVs will be the primary method of transporting the aluminum ingots through the finishing process. Traditional handling systems rely heavily on overhead crane utilization, but the AGV based solution reduces reliance on cranes.
https://www.youtube.com/watch?v=lehMe10Vx9g
The AGVs were designed to fit within the existing plant and process. One of the biggest challenges on the project was packaging eight drive wheels and (2) 100 ton capacity lifts within the existing vehicle footprint. Each drive wheel was outfitted with a suspension system to ensure proper radial loading and equal load distribution between the (8) drive wheels. Another improvement on the Fori system was ball screw based lift jacks that included integrated load cells for measuring fore/aft and side to side loading of the ingot. If the ingot is loaded outside of an acceptable range, the AGV stops immediately and sets down the ingot.
The Fori AGV utilizes a 72VDC sealed lead acid battery as a power supply. The vehicles utilize PMAC motors that provide improved control and efficiency over the previous system which utilized DC brushed motors. Each vehicle had a safety bumper front and rear, as well as six safety scanners around the perimeter of the vehicle to provide added safety coverage.
A Fori Vehicle Management System has been provided to monitor system I/O, manage communication between the AGVs and scheduling of moves for production.
For more information about Fori Automation's high capacity AGV capabilities, please visit our website.
Guidance Technology: Magnetic bar, natural feature/laser contour
Capacity: 40,000 lbs./18,181 kg.
Safety: Safety scanners and bumpers, Siemens safety PLC, system interlocks
Controls: Siemens open architecture
Keys to Success: Custom designed chassis, highly accurate and repeatable
Results: Improved flexibility
The two high capacity AGVs (transporting mobile robotic platforms with weights up to 40,000 pounds) have been designed to accommodate projected production. The Fori AGVs will be the primary method of transporting the mobile robots between each of the necessary drilling stations.
The AGVs were developed to increase system automation, flexibility, and remove the traditional monuments that are generally required for automated drilling applications. The design intent was to build a vehicle that was modular and interchangeable. The AGVs were designed to accommodate multiple mobile robots, the software is modular, and simplifies the communication between the Fori AGV and mobile robot.
The Fori AGV is required to locate within +/- 5mm to an existing fuselage transporter. The Fori system utilizes a natural feature and camera based guidance system, which accommodates unexpected location of the transporter. The Fori system overcomes the variability of the fuselage transporters accuracy by measuring the surface of the transporter to generate angular offsets and utilizes a SICK camera and reflector based system for final location. Once positioned, the mobile robot automatically docks to the transporter for power, communication, and pneumatics.
Automated movement is handled through the tethered Siemens Mobil Panel. The operators are able to select drill positions on either the Fori HMI or robot HMI. Once selected the Fori AGV is responsible for safely and accurately lifting and transporting the two mobile robots between 16 different drill positions.
For more information about our drilling platform AGVs, please visit our website.
Robot Active Safety Cell Systems are completely stand alone and can be integrated within existing wheel alignment systems.
Features:
Fanuc 35iA CR collaborative robot
Auto tool change out
Results: Reduced personnel injuries, decreased infrastructure and installation time.
The Robot Active Safety Cell system (RASC) features the new Fanuc 35iA collaborative robot for positioning various targets that are used for Long Range Radar (LRR), Night Vision Calibration (NV), Headlamp Aim Box, and other devices used for End of Line testing.
When more than one device is required, an automatic tool change between the target, NV target, and headlamp aiming camera is included. The flexibility of the collaborative robot has enabled Fori to remove the conventional overhead gantry or in floor positioning systems that had previously been used throughout the industry for headlamp aiming and driver assist safety devices.
The Integration of collaborative robots has reduced the complexity of equipment required for calibrating “Driver Assist Safety” devices, and headlamp aiming. They also provide flexibility for integrating new “Driver Assist” devices for future vehicle platforms. It also provides for an open architecture, allowing more space for walk through areas, and for a better safe working environment.
For more information about Fori's End of Line Systems, please visit our website.
The automated dynamic alignment cell is a drive through system that adjusts Camber and Toe. The Fori module aligner handles (2) vehicle models that have different geometry.
Providing customized equipment such as this starts with a concept design phase. Fori Germany was requested to complete a thorough engineering review in order to accommodate the rear axle assembly of the (3) vehicles.
A challenging portion to any project is the ability to debug and tryout the process. This project had limited time of debug. The key to success was analyzing every failure mode with precision in order to correct and provide results that would normally require more debug time.
The system was comprised of an axle gripping unit that is used for locating and lifting the axle. An alignment unit is also utilized in order to increase repetition. The adjustment and torque is completed with SEW drives and a special gear head.
This new drive alignment cell was integrated during the 3rd quarter of 2017. Initial production started during December of 2017.
For more information about Fori Automation's module assembly products, please visit our website.
Fori China recently designed, built and integrated a Chassis Marriage system for a Germany Plant.
https://www.youtube.com/watch?v=YPEvwHyMXD0
Features:
80 jobs per hour (JPH)
Increased production rate
Reduced labor
Decreased injury concerns
Fori China was responsible for supplying the Chassis Marriage Rail Guided Vehicles (RGVs), associated track, overhead loader and PLC control system that controls the loop.
The Chassis Marriage RGVs are based on Fori’s long standing design and architecture. Each RGV includes two Fori patented servo controlled chain lifts for the synchronized lift and locate of the front and rear pallet.
The Fori RGV is focused on maintainability and simplicity for the end user. The system has been a robust solution for many years, pushing Fori to become a leader in Chassis Marriage systems.
The integrated system was a great success for the end user. Installation was completed during the 3rd quarter of 2017, with initial production beginning in August of 2017.
For more information about Fori Automation's body and chassis marriage products, please visit our website.
Automated Guided Vehicles (AGVs) for Aerospace Wing Assembly Systems
Fori recently provided seven high capacity Aerospace AGVs for the automated transport of tooling for spar assembly, supporting the production of composite wing assemblies.
Features:
Guidance Technology: Magnetic bar, inertial with pencil magnets, natural feature/laser contour
Capacity: 120,000 lbs./54,545 kg.
Safety: Safety scanners and bumpers, Siemens safety PLC, system interlocks
Controls: Siemens open architecture, vehicle management system
Keys to Success: Vehicle synchronization, custom designed chassis, and highly accurate and repeatable.
Results: Improved flexibility and decreased crane usage
The seven high capacity AGVs, capable of auto-leveling and synchronized transport of tooling up to 120,000 pounds have been designed to accommodate projected wing production. The Fori AGVs will be the primary method of transporting the tooling and product through the assembly process. Traditional assembly systems rely heavily on overhead crane utilization, the AGV based solution eliminates the reliance on cranes.
https://www.youtube.com/watch?v=lehMe10Vx9g
The AGVs were developed to support a lean, automated manufacturing methodology. The goal of the project was to automate the entire material handling process for the assembly of the spars. Notably, the load and unload of the autoclaves used for curing the composite wing spars. The loading of the autoclave is completed utilizing a natural feature guidance system, the AGV uses the walls of the autoclave for the guidance in and out, while still maintaining +/- five mm accuracy.
The design intent was to build a vehicle that was modular and interchangeable. The AGV system is required to transport many tools of different lengths and weights. The AGV system needs to be able to accommodate synchronization of up to three AGVs during the lift and transport from assembly stations.
Each of the AGVs is outfitted with four servo based lifters and a laser alignment system which provides measurement feedback to the on-board PLC for the dynamic leveling of the tooling during transport. The system must maintain levelness within +/- 1/8” from each end of the tool.
A Fori Vehicle Management System has been provided to monitor system I/O, communication between the AGVs, tooling and automated assembly stations. Scheduling of moves also occurs at the Fori VMS.
For more information about Fori Automation's aerospace assembly products, please visit our website.
Fori Mexico recently broke ground on a new headquarters that provides over 70,000 square feet of production space. The new facility includes manufacturing and office space to support the continued growth of Fori Automation.
The new facility was built to support the continued growth of Fori Mexico. Over the past 3 years Fori has experienced a substantial amount of growth within its Fori Mexico division.
Fori Automation broke ground on the new Fori Mexico facility in January of 2019.
Fori Mexico currently has over 50 employees and a plan is in place to hire over 20 more within the next three years. Pictures of the new facility and start of the project can be found below. The new facility is located in Coahuila, Mexico.
The new facility will support the continued growth of Fori Mexico.
Fori Automation is a global designer and builder of Material Handling, Assembly, Testing and Welding Systems. For more information on Fori Automation's products and locations, please visit our website.
Fori Automation is proud to announce that we have been selected as a Top System Integrator Giant for 2019.
Fori Automation has been selected as a Top 5 System Integrator Giant for 2019. The selection of System Integrator Giants is based on each respective companies revenue that is attributed to system integration. For more information on System Integrator Giants, please visit the Control Engineering webpage.
The System Integrator Giants announcement can be found here.
Fori Automation privately held and U.S. owned and operated since 1984, specializes in the custom design, build and integration of automated material handling, assembly, testing and welding systems for the automotive and non-automotive industries.
Our equipment and systems include:
Automotive Robotic Welding System for SUV & Truck Frame
Fori has supplied equipment across the globe for a variety of Automotive & Non-Automotive OEMs and Tier 1's. Customer verticals served include the Aerospace, Automotive, Defense, Nuclear, Recreational Vehicle and Construction industries. With over 30 years of experience and seven locations across four continents, Fori is positioned to support its customers around the globe.
For more information on Fori Automation, please visit our website.
Fori Automation Flex Floor Product Line for Flexible Assembly and Material Handling Systems.
Fori Automation, a global leader in the design, build and integration of material handling, assembly, testing and welding systems has further expanded its assembly and material handling product lines. Fori has added a new material handling platform to its ever growing product line to help facilitate material flow through today's manufacturing facilities.
The Fori Flex Floor product line is a flexible material handling and assembly system that is designed to fit around the customer process and product, whereas many of the other material handling products on the market require the customer process and product to fit around the material handling system. The Flex Floor platform includes a variety of vehicles based on the same architecture that have varying levels of capability depending on the end users specific needs.
The Fori Flex Floor utilizes a heavy duty extrusion style frame that enables the footprint of each style vehicle to be modified to fit the product being assembled or the materials being moved. The Flex Floor platform utilizes commercially available drive wheels, casters, batteries, controls components and guidance. The Flex Floor platform is based on a Siemens Safety PLC based architecture, providing the end user an open architecture. Many of the other products on the market include a “black box”, requiring the user to enlist support from the equipment supplier. Each assembly and material handling system can be supplied with a Fori Vehicle Management System (VMS), enabling the system to be fully autonomous, only requiring input for scheduling of moves either from the user or from the plant production system, the Fori VMS takes care of the rest. The Flex Floor vehicles are outfitted with the latest safety components available on the market. At a minimum the vehicles are supplied with perimeter Safety Scanners, Indicator Lights, Alarms and E-stops. The Safety Scanners provide collision avoidance for the end user to ensure safety for the operator and that no damage occurs to the product or part. Additionally, each vehicle is designed to be user friendly and virtually maintenance free for the end user.
Example of Fori Flex Floor - Rail Guided Cart (RGC) utilized for a Corner Module Assembly LineFlex Floor – RGC: Flex Floor Rail Guided Carts (RGCs) are a direct replacement for traditional, monument based conveyor systems that are typically utilized in assembly processes. Fori RGCs utilize a low profile, floor mounted rail for tracking and a single, suspended drive wheel to propel the vehicle through the assembly process.
Flex Floor 1.0: Flex Floor 1.0 is a cost effective, scalable Automated Guided Cart (AGC) that is used for a variety of applications, including assembly and material transport. The vehicle includes a single drive wheel, perfect for loop style assembly and material handling systems.
Flex Floor 2.0: Flex Floor 2.0 is based on the same platform as the Flex Floor 1.0, but provides more capability by utilizing dual drive wheels. The results are a vehicle with double the capacity and Omni-directional capability. The vehicle is capable of spinning on its center and moving laterally, resulting improved layout flexibility and the capability to transport larger assemblies, such as large truck frames.
Flex Floor 2.0T: Flex Floor 2.0T is a Tunnel style AGC that utilizes the same architecture as the Flex Floor 2.0, but also includes (2) electric hitch pins that are utilized for transportation of companion carts. These companion carts are utilized for material transport and can include a variety of attachments, including roller conveyor, lift tables and powered trunnions.
Fori Automation, Inc. privately held and U.S. owned and operated since 1984, specializes in the custom design, build and integration of automated material handling, assembly, testing and welding systems for the automotive and non-automotive industries. With over 30 years of experience and seven locations across four continents, we are positioned to support our customers around the globe.
Fori Automation specializes in the design, build and integration of automated assembly systems for the automotive & non-automotive industries. Fori has supplied systems for axle, battery pack, cockpit, engine dress, headliner, seat, motorcycle and recreational vehicles.
Fori Automation specializes in the custom design, build and integration of automated assembly lines for a variety of industries and products. Fori has supplied assembly lines for the automotive, construction and recreational vehicle industries.
Our dedicated assembly and automation group has the experience to process a wide range of assembly systems across nearly any industry. Our assembly systems include: Axle, battery pack, bullet manufacturing, cockpit, door, electric stator, engine dress, glass roof, headliner, seat, motorcycle front end & saddle pack, electric scooter and many others.
https://www.youtube.com/watch?v=zzAw5dgQn9U
Fori's main system verticals which include, automated assembly, material handling, robotic welding and testing, enable us to be a one stop equipment supplier for the entire assembly system. Within the main system verticals, include vast experience with error proofing, data collection, MES integration, lift assists, auto-torquing and robotic handling.
Our latest material handling systems, such as our Rail Guided Carts (RGCs) or Automated Guided Carts (AGCs) have been a differentiator for our Tier 1 and OEM customers from a flexibility and scalability perspective versus a traditional conveyor system.
RGCs and AGCs improve tear down and setup times and also allow the end user to scale their material handling system based on projected production rates. The ability to re-utilize their capital expenditure on future programs through a simple tooling change is another long term benefit. Below is a success story where one of automotive Tier 1 customers utilized a fully automated assembly line with RGCs for their assembly system.
https://www.youtube.com/watch?v=Bd3bIlIrjfk
For more information on Fori Automation's available products and automated systems, please visit our website.
Fori Automation has added a variety of automated material handling options to its product portfolio, including automated tuggers, powered drive wheels, high capacity AGVs and multiple AGV synchronization for tooling transport.
We are proud to announce that we have added (4) automated material handling platforms to help facilitate material flow through today's manufacturing facilities.
These developments include Automated Tuggers, Powered Drive Wheel Systems, High Capacity AGVs and Synchronization of automated vehicles for the transport of large tooling.
The systems are designed to increase safety, throughput and accuracy and are supplied to replace traditional material handling methods such as fork lifts, manned Tuggers and overhead cranes. The systems are fully configurable to vary the level of automation depending on the requirements of the end user. The AGV control can be as simple as utilizing a control pendant to manually move the vehicle, all the way up to the highest level of automation which includes a Fori Vehicle Management System (VMS) or Traffic Control. A VMS allows the system to be fully autonomous, only requiring input for scheduling of moves, the VMS takes care of the rest.
Fori’s software is based on a Siemens Safety PLC for the vehicle control, providing an open architecture for the end user. Utilization of the Safety PLC based system eliminates the “black box” supplied by many of the AGV companies in the industry. All Fori AGVs are outfitted with the latest safety components available on the market. At a minimum the vehicles are supplied with perimeter Safety Scanners, Indicator Lights, Alarms and E-stops. The Safety Scanners provide collision avoidance for the end user to ensure safety for the operator and that no damage occurs to the product. Additionally, each vehicle is designed to be user friendly and virtually maintenance free for the end user.
Automated Tuggers:Tuggers are a direct replacement for Fork Lifts. The vehicles are utilized for transporting carts, kits and various product throughout the manufacturing process.
https://www.youtube.com/watch?v=TdX5-JNfPsw&t=28s
Powered Drive Wheels: Powered Drive Wheels are modular drive wheel sets that are mounted to mobile tooling or operator platforms for automated mobilization. The systems utilize a standard control architecture that is expandable to support added powered drive wheels in order to increase capacities.
Fori offers a variety of Powered Drive Wheels with a wide range of capacities that can be mounted to tooling or operator platforms for automated guidance.High Capacity AGV: AGVs are used for a variety of applications that are traditionally completed with an overhead crane. Fori AGV capacities are upwards of 250,000 lbs.
https://youtu.be/FTCMlcp9AEQ
Synchronized AGVs: When required multiple vehicles can be synchronized to move large tooling, this methodology allows a single, modular vehicle design to be provided to the end user, but multiples of two or three vehicles can be used for lift and carry of various tools.
https://www.youtube.com/watch?v=MnJJ5vnQ6NM
Fori Automation, Inc. privately held and U.S. owned and operated since 1984, specializes in the custom design, build and integration of automated material handling, assembly, testing and welding systems for the automotive and non-automotive industries. With over 30 years of experience and seven locations across four continents, we are positioned to support our customers around the globe.
For more information of Fori Automation's products and capabilities, please visit our website.
Fori Automation recently expanded its Global Headquarters with the addition of a new 50,000 square foot facility. The new facility includes manufacturing and office space to support the continued growth of Fori Automation.
The new facility was built to support the Welding Business Unit and its customers. Over the past 3 years Fori has experienced a substantial amount of growth within its Robotic Welding Business Unit. The Welding Business Unit focuses on Automated MIG, Projection and Spot Welding for the Automotive Industry.
Fori Welding Business Unit Team
Thanks to the addition of 55 new employees during 2017 and the added manufacturing space we will be able to better support our global customers. With the addition of 55 new hires in 2017, Fori USA now has over 260 employees at its Global Headquarters and over 650 globally. Fori is continuing to add members to the team in order to support the growth of the organization, to view open positions click here.
Robotic Welding System for a Large Truck Frame
The new facility is located across the street from Fori Automation's Global Headquarters in Shelby Township, MI.
Fori Automation's New 50,000 Square Foot Robotic Welding Facility
Fori Automation is a global designer and builder of Material Handling, Assembly, Testing and Welding Systems. For more information on Fori Automation's products and locations, please visit our website.
Fori China, founded in late 2007 recently celebrated their 10 year reunion.
Fori Automation is proud to announce the 10 year anniversary of Fori China located in Beijing, China. Fori China’s turnkey design and build capabilities have been instrumental in supporting Fori Automation’s customers in Asia and around the world.
The five original Fori China employees receive recognition for their 10 years of service.
With over 250 employees, Fori China has proven themselves to be a prominent turnkey design and build system integrator. Fori China specializes in End of Line Testing equipment, Chassis Marriage Systems and Assembly Systems for the Automotive Industry.
Fori Automation is a global designer and builder of Material Handling, Assembly, Testing and Welding Systems. Headquartered in Shelby Township, MI.
For more information on the full product portfolio and global locations, please visit our website.
Fori Automation is proud to announce that we have been selected as a Top System Integrator Giant for 2018.
Fori Automation has been selected as a Top 5 System Integrator Giant for 2018. The selection of System Integrator Giants is based on each respective companies revenue that is attributed to system integration. For more information on System Integrator Giants, please visit the Control Engineering webpage.
The System Integrator Giants announcement can be found here.
Fori Automation privately held and U.S. owned and operated since 1984, specializes in the custom design, build and integration of automated material handling, assembly, testing and welding systems for the automotive and non-automotive industries.
Our equipment and systems include:
Fori Rail Guided Cart (RGC) Module Assembly System with Module Aligner
Fori has supplied equipment across the globe for a variety of Automotive & Non-Automotive OEMs and Tier 1's. Customer verticals served include the Aerospace, Automotive, Defense, Nuclear, Recreational Vehicle and Construction industries. With over 30 years of experience and seven locations across four continents, Fori is positioned to support its customers around the globe.
For more information on Fori Automation, please visit our website.
Fori Germany recently hosted a customer open house exhibition. The visitors were able to see Fori Germany latest and greatest products which were highlighted by two new styles of automated guided carts for the automotive industry.
Fori Automation's German Headquarters recently hosted an in-house exhibition to feature some of their latest and greatest products.
Products and projects presented included Automated Guided Carts (AGCs) for Automotive applications such as body shops and front end pre-assembly, as well as rear axle adjustment stations for axle alignment.
Fori AGCs for Automotive Module Assembly Systems
Pictured above is an example of an AGC utilized for module assembly within the automotive industry. The vehicle will transport the work piece carriers in the front end pre-assembly line. The assembly system was comprised of over (30) vehicles.
Low Profile AGC for Automotive Body Shop Applications
Fori Germany also developed a low profile AGC that is capable of lifting over 500 kg. and providing a total lift stroke of 350 mm for transport of car frames through a body shop. The system utilized the latest lithium ion battery technology and an optical guidance system which increased flexibility for the end user.
Fori Germany Headquarters in Merzig, Germany
The open house exhibition was a great success for Fori Germany. Over the last year Fori Germany has supplied a number of innovative products. For more information on Fori Automation's global locations and our products, please visit our website.
Fori Korea recently installed (3) complete End of Line Test systems for a large automotive OEM with a plant residing in Mexico.
The Fori End of Line System included three wheel aligners, headlamp aimers, roll and brake test stations and an under body test station.
Fori Wheel Aligner with 3-D Measuring Head
One of the unique design features was the vehicle measurement system, which resides on the wheel aligner. Sixteen weight measurement transducers are integrated into the four floating plates to equally measure the distributed load of the vehicle during the alignment process. Doing so eliminates the need for a separate weight measurement station.
(3) End of Line Test Systems were Designed and Built at Fori Korea and Shipped to Mexico for Final Installation and Buy-Off
The facility, capable of producing over 300,000 vehicles per year opened in 2016. The facility produces small cars for Mexico and South American countries.
For more information on Fori End of Line Systems, please visit our website.
Fori recently supplied a custom designed Chassis Marriage Automated Guided Vehicle (AGV) for an electric vehicle manufacturer.
Over the past twenty years, Fori automation has been a leader in Automotive Chassis Marriage. Chassis Marriage, the process of bringing the car body and chassis together, has been primarily completed with the use of Rail Guided Vehicles (RGVs).
The Chassis Marriage process is completed utilizing integrated lifts and custom tooling pallets to support various chassis depending on the model of vehicle being manufactured. The Chassis Marriage process is completed once the operator does a final torque of fasteners, bringing the car body and chassis together.
Fori Automated Guided Vehicles (AGVs) provide increased flexibility and reduced infrastructure versus traditional Chassis Marriage methods.
The utilization of Automated Guided Vehicles (AGVs) for Chassis Marriage has increased flexibility for the end user by removing the monuments that are required on RGV based Chassis Marriage systems. The Chassis Marriage AGVs utilize a number of different power sources and guidance methods. Power sources include both lead acid and lithium ion batteries, induction and some cases a combination of both battery and induction power. Guidance can be completed in a number of ways, the guidance systems utilized most frequently are magnetic guidance, induction or optical.
Each Chassis Marriage AGV includes (2) integrated Fori electric lifts that are used for raising the drive train of the vehicle to the body. Each lift is capable of lifting up 2,500 kg. and upon request can reach lift strokes of up to 52" depending on the project requirements.
Utilization of AGVs within Chassis Marriage has resulted in increased system flexibility, decreased plant infrastructure for the end user and has provided a scalable solution allowing for addition of vehicles based on expected production rates.
For more information on Fori Chassis Marriage AGVs, please visit our website.
The central pillar of the partnership is the continued integration of Siemens Factory Automation hardware and software within Fori's Material Handling and Automation Equipment. Fori Automation will have one of their Automated Guided Vehicles (AGVs) for automated material handling on display.
Fori Automated Guided Vehicles (AGVs) with Siemens Controls for Flexible, Safe and Reliable Assembly and Material Handling Automation
Fori Material Handling equipment is utilized within the Aerospace, Automotive and Defense industries. Fori equipment has capacities as low as 500 lbs. to over 250,000 lbs.
The AeroDef takes place on March 7th and 8th at the Fort Worth Convention Center in Fort Worth, Texas.
Please visit us at booth #526 or contact us at sales@foriauto.com for more information!
Manufacturing Day is an annual event where high school students can learn about modern-day manufacturing and career options available. The event takes place this Friday, October 6th and Fori Automation will be participating in Manufacturing Day for the 4th consecutive year.
Manufacturing Day is a great opportunity for students to connect with organizations looking for future hires. There is a labor shortage for skilled trades within the Manufacturing industry and the hope is to raise awareness of the great career opportunities available within the Manufacturing field.
A video of success stories was recently produced which includes students from the Macomb County area who are working for local manufacturers. The video of these success stories can be found on the Manufacture My Future website.
https://www.youtube.com/watch?v=2SKxhozpV6w
There are a total of 2,466 events scheduled for MFG Day 2017. For more information on Manufacturing Day and how you can participate please visit the MFG Day website.
Fori recently supplied a highly flexible, automated robotic MIG welding assembly system. The system consisted of three similar lines that were able to accommodate nine different vehicle model variations.
The rear suspension cradle for the project satisfied approximately 90% of the vehicles in the family. There was a high level of importance on ensuring process control, the product had to be accurately controlled and monitored throughout each robotic weld line.
Each automated weld line possesses (21) MIG welding robots and (3) material handling robots. The current assembly system runs between 150 and 181 seconds depending on which model is being processed. After completion of the robotic welding, the critical component characteristics are machined with a pair of precision, custom machining centers.
Automated Robotic MIG Welding System
The integration of the MIG welding and material handling robots has decreased cycle time and increased system throughput. Utilizing highly accurate machining stations and a repeatable process has also reduced waste and the quality of the final product has been increased.
The system resulted in the following benefits to the end user:
Decrease in total cycle time
Reduced infrastructure to handle product variations
Increase in product quality
Main keys to success included the integrated robots, custom designed turn tables and the custom, precision machining centers.
For more information on Fori's available equipment, please visit our website or contact us at sales@foriauto.com.
Fori recently supplied two automated alignment cells that were required to adjust toe, camber and caster simultaneously, while ensuring the balanced marker for the drive train for 4WD models is properly positioned for ease of vehicle assembly at OEM.
The required changes for the 2016 model year were accompanied by many challenges:
Jobs per hour (JPH) increases
Minimal downtime for system installation
Product complexity
Change in model geometry
Rework of three current alignment machines
Fori was able to provide a solution that added two additional alignment cells each with a re-sequencing stand & integrated robot. In order to keep the flexibility of maintaining these machines, keeping sequence of the modules being built and quality, additional logic and hardware had to be developed.
Suspension Module Aligner for Toe, Caster and Camber Adjustment
Modules are picked on a first come, first serve basis. After alignment the robot places the completed module in its sequence stand. From there another robot on a track extending parallel to the conveyor line will pick and place the module to the pallet it was picked from.
The Fori supplied module alignment system improved throughput for the system. The pre alignment of modules reduces alignment at final assembly and ensures proper assembly.
For more information on Fori's available equipment, please visit our website.
Fori recently integrated a flexible assembly system for a scooter assembly line. The line currently utilizes a scalable manufacturing methodology, enabling the end user to increase automation as production requirements increase.
The assembly system is made up of a single assembly loop and two offline stations. The two offline stations consist of a battery assembly area, along with a tire & wheel assembly area.
A unique characteristic about this assembly loop is the manual carts are tied into a track that resides on the floor similar to the Fori Flex Rail system that utilizes Rail Guided Carts (RGCs).
The unique equipment provided includes:
Flexible production tooling pallets
Bushing press
Heavy duty torque tube for front fork attachment
Robotic sealant dispensing cell
Automotive Assembly System - Automated Sealant Apply
Implementation of these types of scalable assembly systems allow the end user to minimize upfront expenditure and utilize a cash flow structure which supports increased automation as throughput requirements increase.
For more information on Fori's available equipment, please visit our website.
Fori recently provided a drive-thru Automated Dynamic Alignment cell that adjusts camber and toe. The unique aligner handles two vehicle models with different geometry.
A summary of the challenges faced include:
Space constraints
Additional tooling requirements
Limited tryout parts & debug time
Providing customized module alignment equipment such as this begins with a concept engineering phase. A detailed engineering study is conducted to determine if the existing vehicle model could be aligned in the same aligner as the two new vehicle models. Once feasibility was determined, it was determined that the three models could not be run together. The result was a design, process and simulation that accommodated the two new models.
Outside of the space constraints on the project, which are always a challenge. Our engineering team was tasked with supporting two different modules within the same machine, which resulted in a substantial amount of investigation and engineering.
Delivery times are becoming more and more compressed, which reduces available debug time. The key to success on the project was analyzing every failure mode with precision in order to correct & provide results that would normally take substantially more debug time.Fori - Automated Module Alignment Equipment
Each module is aligned as it enters the station. The aligner knows which model is in the station based on a broadcast from the OEM, as well as position sensors placed in the machine, automatically initiating the correct tooling combinations.
The Fori module aligner is outfitted with unique per the vehicle frame locators, which aid in securing the part and ensuring proper adjustment of the toe & camber.
For more information on Fori's available equipment, please visit our website.
Fori recently provided two custom designed, high capacity Automated Guided Vehicles (AGVs) for a large Aerospace OEM. The AGVs were utilized for component material handling and assembly.
Over the past decade, there has been a strong push in the Aerospace industry to increase Automation. Main drivers for this initiative include decreased crane utilization, process control, improved safety and reduction in product damage and waste.
The AGVs supplied required a customized frame design in order to mimic the footprint of the transported tooling. The project team had specific requirements on the length, width and height of the vehicle, as well as deflection requirements for the AGV frame while transporting the part and tooling. These requirements required a substantial engineering effort through the utilization of Finite Element Analysis (FEA) to ensure the final design would meet all the design requirements.
Fori Aerospace Automated Guided Vehicle (AGV) for Aircraft Component Assembly
Fori AGVs are Siemens safety PLC based, providing an open controls architecture, eliminating the "black box" provided by many material handling suppliers. The AGV system is outfitted with the latest and greatest safety devices available. The AGVs provided include perimeter safety bumpers and 360º SICK safety scanner coverage to ensure collision avoidance.
Responsibilities of the AGVs include:
Lift & Transport up to 90,000 lbs.
Minimize tooling & part deflection
Accurate and repeatable tool placement
Fully automated order scheduling & completion
Utilization of AGVs has resulted in decreased reliance on overhead cranes, providing a reduction in product damage and an increase in system efficiency and most importantly safety.
For more information on Fori AGVs, please visit our website.
Manual drill & fill has been a topic of conversation within the Aerospace industry due to the health and safety concerns. Utilization of automated drill & fill systems with a mobile platform has helped alleviate these concerns.
Fori recently supplied a custom Automated Guided Vehicle (AGV) for automated drill & fill. The automated drill & fill system is used for the side panel of a large commercial aircraft.
The AGV is required to auto-lift and level the platform upon arrival in each production station. The AGV must be positioned within +/- .005" and level within +/- .16 degrees. This is accomplished through the utilization of inclinometer feedback and precision servo motion control.
Fori Aerospace Automated Guided Vehicle (AGV) for Automated Drill & Fill Tooling Transport
Strict requirements were placed on the actual AGV frame design and the allowable deflection while traveling. The frame was designed to deflect less than .03" during transport of the drill & fill system from station to station.
AGVs within the Aerospace industry will enable the automated tooling to move to the part versus traditional systems where the part has always moved to the tool or machine station. The results will include minimized part handling and a substantial reduction in crane utilization.
Long term, the automated drill & fill system will minimize safety and health concerns, while increasing throughput.
For more information on Fori Aerospace AGVs, please visit our website or contact us at sales@foriauto.com.
Fori recently supplied two high capacity, halogen free Automated Guided Vehicles (AGVs) for a nuclear power plant refurbishment project. The AGVs will result in decreased total infrastructure and long term flexibility for the project team.
Two different high capacity Fori AGVs were designed and built to meet a number of different design requirements. The requirements included specific accuracy, repeatability, dimensions and total load capacities.
The AGV system was designed to support a refurbishment project that runs 24 hours a day, 7 days a week, 365 days a year.
Each of the vehicles had unique requirements, supporting different dimensional and capacity requirements for safe and reliable operation within the work area.
The first vehicle included strict height, width and length requirements, while still providing the capability of transporting up to 18,000 lbs.
Fori Automated Guided Vehicle for Nuclear Power Plant Refurbishment - 18,000 lbs. Capacity
A larger vehicle was also required for the project that was rated to carry up to 70,000 lbs.
Fori Automated Guided Vehicle for Nuclear Power Plant Refurbishment - 70,000 lbs. Capacity
The Fori AGVs were required to locate within +/- 5mm and allow for finite manual adjustment while handling equipment for the project. A Siemens MP277 Wireless Mobile Panel was provided to the operators for manual adjustment and control.
Due to the 24/7/365 project requirement a lithium ion battery system was utilized, the lithium ion system provided a more reliable power source, that will result in an increased total life of the battery pack and less overall charge time. The system is designed to facilitate charging during load and unload of equipment, minimizing production downtime.
The vehicles have reduced total plant infrastructure for the project, improved safety and increased long term flexibility.
Fori has supplied over 1,000 automated vehicles over the last twenty years, for more information please visit our website.
Fori recently designed, built and integrated two new robotic wheel aligners with integrated dual mast headlamp aimers.
A total of four robots with Toe set gear heads are utilized for setting Toe within +/- 0.03 degrees from nominal. Front Toe is set by adjusting the tie rod with a Fori patented socket gear head which is driven by a nut runner. The Rear Toe is set by adjusting a cam bolt with a Servo driven gear head.
The equipment needed the ability to align three different vehicle models with uniquely different suspension configurations.
To achieve the cycle time requested Fori utilized a system called "predictor mode" for virtual real time toe and camber measurement. Once the initial tire run out is performed and mapped, all subsequent measurements are predicted based upon the known run out.
Elimination of the typical three second update time required after an adjustment is made, resulted in an average of ten seconds per machine cycle. Fori Robotic Toe Set System
Fori the first time, Fori implemented an auto tooling changeover system. Based upon the vehicle model identified prior to the alignment station, the robots will automatically disconnect and set the existing gear heads into fixture holding stands. The time required for this process simultaneously occurs while the current vehicle is driven off and the next vehicle is driven into the alignment station.
Fori has been supplying End of Line Testing equipment for over thirty years, for more information please visit our website or contact:
Fori recently supplied five wheel alignment systems with integrated single mast headlamp aim and semi-automatic front toe set.
Fori has been a leader in End of Line Testing equipment for more than 30 years. Supplying End of Line systems across the globe. End of Line Testing systems include, but are not limited to the following:
The Fori wheel aligners and headlamp aimers consisted of the following major assemblies: semi-automated front toe set with Fori patented dual socket gear heads to accommodate two different size tie rods. A semi-automated rear toe and camber secure tooling, caster sweep audit capability and ride height measurement capability were also included in the system.
The Fori system provided the ability for headlamp aiming with a headlamp aimer box and integrated light source. Auto-tilt positioning was provided for measuring and manually aligning the vehicle adaptive cruise control module.
Fori End of Line Testing Systems - Wheel Alignment, Headlamp Aim, Toe Set
Wheel aligners with the level of automation outlined above are not the "typical" systems supplied in the past. A strong engineering group and past experience ensured that the project would be a success.
For more information on Fori End of Line Testing systems, please visit our website.
Fori recently supplied an automated assembly and robotic weld cell that processes a complicated cradle assembly consisting of numerous parts and sub-assembly components.
Each line supplied utilizes 10+ MIG welding robots and additional robots for material handling. The system goal was to utilize a minimum number of operators. The current assembly system include a strict cycle time. Due to the complexity of the assembly, Fori was required to utilize excessive processing skills and use "outside of the box" thinking to develop a complete solution.
Fully Automated Robotic Weld and Material Handling System
After completion of the robotic welding, the critical component characteristics are formed with precision hydraulic pierce units and is followed up with a dual station machining center. Once assembled, the assembly enters a CNC validation and deburring station, followed by a vision inspection system to verify and track part quality. A video on Fori Cradle Welding Systems can be found here.
Through the utilization of experienced resources, Fori was able to develop a viable process. The utilization of the MIG welding and material handling robots has decreased the total cycle time, increased throughput and ensured consistent product quality.
For more information on Fori welding systems please visit our website.
A Fori Flex Rail system, utilizing Rail Guided Carts (RGCs) was recently supplied for a rear suspension module build. The system consisted of a main build line, two module alignment machines and a final assembly build line.
The utilization of a Flex Rail System and Rail Guided Carts provides the utmost flexibility for those customers who need to be able to accommodate change easily. The ability to be flexible in the automotive world means less downtime, cost and reduced infrastructure during installation.
Rail Guided Cart based assembly systems are becoming the norm on Fori's Automotive Assembly Systems. The systems can be modified easily, whether it be adding a station or even accommodating fluctuations in throughput requirements.
Fori Flex Rail System - Rail Guided Cart Assembly System with Integrated Robots
Each Rail Guided Cart is a stand along unit with an integrated Siemens Safety PLC and Wireless Client. Utilization of the PLC based system, results in an open architecture to the end user. Each of the carts are outfitted with safety bumpers and collision avoidance laser scanners to ensure the safety of the operators. A video of the Fori Rail Guided Cart can be found here.
Overhead support to the operators for tooling in most cases are simple jib booms and inverted "L" posts that are bolted to the floor to promote flexibility of the system. In instances where sequence and repeatability are critical, a robot is integrated for final torquing and the load and unload of assemblies.
Benefits of the Fori Flex Rail Systems utilizing Rail Guided Carts include:
Increased safety
Improved part and assembly access
Decreased plant infrastructure
Reusable for future programs
Scalable solution - add or remove carts for production fluctuations
For more information on Fori Rail Guided Carts please visit our website or contact us at sales@foriauto.com.
Cost effective, flexible Automated Guided Vehicle (AGV) solutions have allowed automotive companies to implement a flexible, safe, reliable and repeatable material handling solution within their assembly processes.
The Fori Dock' N Lock AGVs were built to fit within existing plants and each plants respective material handling strategy. The AGVs were commissioned to replace non-value added material handling tasks. Specifically as a direct replacement for majority of fork lift traffic, creating a "fork free" environment.
Fori Automation - Dock N' Lock AGV for Automated Material Handling
The Dock N' Lock AGVs are responsible for auto-docking to the companion carts pictured above. The previous methodology utilizing fork lifts and pallets resulted in injury and product damage concerns. Utilization of the repeatable and accurate guidance, along with integrated safety has solved this problem.
The automated locking feature and cart interface design is what differentiates the Dock N' Lock AGV from standard Tuggers. The ability to automatically connect to the carts removes the need for operator interface and cart staging. The cart and Dock N' Lock design also allows the AGVs to be bi-directional, which results in greater long term layout flexibility. An overview video of the Fori Dock N' Lock and Tugger AGV can be found here.
A fully integrated Fori Vehicle Management System (VMS) is also provided with the system. The Fori VMS acts a traffic cop for the AGVs and manages the routing of 20+ AGVs in some cases. The VMS has the ability to track and store faults, monitor battery status and communication with automated work cells.
Fori more information on Fori's Automated Material Handling equipment please visit our website.
Fori Automation, Inc. designs, builds and integrates custom assembly and material handling systems for the Aerospace industry. Fori recently provided a turnkey Automated Guided Vehicle (AGV) system for a large Aerospace OEM. The assembly system utilized a moving line methodology.
Fori Automation Automated Guided Vehicle (AGV) for Aircraft Assembly and Material Handling
There were a number of design considerations for the AGVs provided. The AGVs were built with an emphasis on operator access and ease of use. The AGVs included integrated scissor lifts for cockpit assembly, as well as other operator platforms that aided in the assembly of the aircraft. The vehicles were required to move at very slow speeds, sometimes as slow as 20″ per hour. The system utilized a high voltage servo based controls architecture in order to meet the accuracy and speed requirements for the project.
A total of (18) Fori Aerospace AGVs were supplied for the system. A video outlining the manufacturing and assembly methods used for the aircraft assembly can be viewed here.
For more information please visit Fori Automation’s website.
he equipment. The final assembly line retrofits included:
• Super pallet modifications for new vehicle powertrain
• Addition of new load bar for different powertrain
• Updated tooling for hub tightening
• Robotic auto-tightening for battery package
The most unique portion of the modification project was the integration of an auto-tightening station for the battery electric vehicle (BEV) battery. The auto-tightening was completed with (4) fastening robots.
raised to the setting position. Once located, the suspension is clamped and the measurement of the camber takes place without contact. After the suspension is located the installed vehicle force is applied to the module, force displacement is included within the equipment to simulate vehicle loading.
Once the measurement is complete, the required adjustment is completed automatically by appropriate torque units. After completing the adjustment 
process, the rear axle is placed back on the tool carrier and extended out of the protected area of the adjustment cell.
Consists of the following components:
• Protective safety fencing
• Rear suspension adjustment system
• Contactless measurement device
• Auto-torque for adjustment
• Device to simulate actual vehicle weight during adjustment
The bushing press system includes two tooling modules, one to produce left hand modules and one to produce right hand modules. The system includes a single press in the center of the equipment to product either configuration of product. The press system supplied utilizes a 
bushings.
Start of production for the equipment was during the 1st quarters of 2019. The system provided improved production rate versus more manual methods of bushing insertion.
pace composite tooling cart transport.
The 
hment allows the tooling cart to rotate with the Tugger AGV and back it into work stations as required by the process.
The Tugger AGVs were commissioned to ensure safe and reliable product transfer. Previously, this transfer was completed with fork lifts or manned tow vehicles. The AGVs eliminated non-value added material handling and provided a hands off system for transporting product through the assembly process.
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.
ctive utilization of plant floor and personnel when handling large volumes and variables of product.
The loop style conveyance system consists of (57) rail guided carts 
• Automatic Front Coil over Shock assembly.
Rear suspension module assembly system:
• Automatic setting of camber and toe.
• Simultaneous auto-torque of all links in (5) link suspension with vision inspection.
• Robotic unload of completed module to shipping container.
l aligners and headlamp aimers feature the latest 3-D camera and digital headlamp aiming camera system that Fori offers.
Each wheel aligners can accommodate various tire styles and tread-width variations. The wheel base adjustment allows the machines to handle all of the different truck cab styles.
A gantry style target board system aligns the vehicle adaptive cruise control (ACC) module, lane departure warning (LDW) camera and several ot
her onboard vehicle sensors.
The 
tereo vision) and surround view camera. Headlamp aiming (HLA) was integrated into this platform to best utilize the operator’s process time.
The ADAS system was developed using lower cost solutions for:
• HLA with the hi-resolution Fori camera box and manual positioning gantry
• Pneumatic “auto” positioning of the LRR aluminum target for Bosch Gen 5 radar sensor 
• Pneumatic drop down positioning of the LDW target
• Fixed stanchions with corner reflectors for the corner radar calibration
• Pneumatic centering platform for a wheelbase range of 500mm.
• A self-contained control system with Siemens based s7-1200 series PLC for conducting all positioning and the adjust sequence.
• PC and software to interface with other plant provided systems that communicated to the vehicle OBDII.
andling applications within the automotive industry. Most recently Fori was enlisted to supply a derivative of the standard Tugger product line that is capable of nearly double the capacity of the original vehicle. The driver of this increase was the transport of (3) carts, carrying axle assemblies for a large automotive OEM.
The Fori Tugger capacity allowed more product to be transferred during each move, further increasing the return on investment to the end user and decreasing the number of required vehicles. The Tugger AGVs were commissioned to replace non-value added material handling tasks within the assembly process. The most important process consideration was safety and reliable
delivery of product.
Further improvement of the safety and reliability of the material handling system was the integration of a Fori Vehicle Management System (VMS). Vehicle scheduling of moves, tracking and traffic control is coordinated through the Fori VMS. The Fori Tugger is a proven and robust product that can be applied to a variety of material handling applications.
latform, or other centering system.
The dual camera fixed audit headlamp aimer was developed for a customer and installed in 2018. The HLA system included a fixed gantry frame with the (2) high resolution camera boxes, a whiteboard that was collapsible for easy storage and a PC control panel.
The HLA application was used to perform headlamp aiming audits on various GM vehicles from the car and truck platforms. A simple manual cent
ering system and leveling plates were included to provide a low cost method for centering the vehicle during the audit process.
The (2) high resolution cameras provide an accurate method of finding the true headlamp center and headlamp aim position, to accommodate requirements set forth by the latest IIHS standard.
.
The wheel alignment machine is designed for automatic measuring of toe and camber. Feedback is supplied to the operator, who completed a manual adjustment of the vehicle parameters. The wheel alignment equipment is designed for a wide range of wheel bases and tire tread width sizes.
An integrated headlamp aimer (HLA) measures the vehicle headlight intensity and positions the aimer automatically to guide the operator to the correct adjustment necessary. The “Fori Vision” aiming unit utilizes a 2.3 megapixel camera based system to me
asure the intensity and position of the headlight.
The latest hi resolution camera box was also included for improving the headlamp aiming resolution and accuracy required by the latest IIHS standards.
Each line possesses (21) MIG welding robots, (3) material handling robots and utilizes a minimum number of operators. The current assembly system runs consistently between 181 seconds and 150 seconds depending on which model is being processed. After completion of the robotic welding, the critical component 
characteristics are machined with a pair of precision, custom machining centers.
The integration of the 
er shapes.
• Leak test while manual start of carrier bolts.
• Manual final torque of carrier bolts.
• Manual loading with assist of various Axle shafts.
was developed to improve the wear capability of machine load components such as the floating plates and sliding access plates for accommodating the high throughput of the heavy duty truck models. Additionally, telescoping machine covers were provided to accommodate the long wheelbase adjustment range of 120-210”.
The machine included other special features for measuring and tracking underbody points with laser displacement modules during the truck’s suspension adjustment cycle. The machine also performed audit checks for caster measurement using the caster sweep audit process.
For HLA an above floor gantry system was provided with Y and Z servo motor positioning and the latest high resolution camera box for improving the HLA resolution and accuracy required by the latest IIHS standards.
tems.
High speed headlamp audit applications require the platform be mounted to the plant floor, so an entrance ramp is included for pulling into the platform, and backing off.
The system also provided the means for adding floor targets for a calibration check of the surround view camera system. The equipment can be utilized for adding other 
ncoders to track the actual position of the vehicle for verifying centering within tolerance as required by the customer ADAS specifications.
The project required the platform be mounted to the plant floor, so entrance and ramps were included for pulling into the platform and driving off. Heavy duty roller saddles were included for this system to handle the high throughput of the heaviest vehicles.
The system also provided the means for adding floor targets, for a calibration of the surround view camera system. Additional ADAS devices were also integrated with the supplied centering system.
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.
hassis.
The AGV was required to synchronize with the vehicle chassis in the overhead carrier. The synchronization was a challenge in itself as there was no physical tracking arm. All of the vehicle synchronization for battery decking was completed utilizing tracking cameras and encoder positioning. The most important process consideration was the safe and reliable positioning of the product for the operators.
Further improvement was the integration of a Fori Vehicle Management System (VMS). The Fori VMS allows for vehicle scheduling, charging, vehicle status information and traffic control. The Fori battery decking AGV platform partnered with the Fori VMS is a proven and robust product that can be applied to a variety of material handling applications.
methodology utilizing fork lifts was not a safe or reliable option, the Dock N’ Lock AGVs solved this problem.
The automated locking feature is what differentiates the Dock N’ Lock AGVs from standard Tuggers. The AGVs were required to auto-couple to newly developed racks, doing so removed the need for operator interface and allowed the end user to relocate operators to value added activities. The vehicles were required to repeatedly locate within +/- 10mm and travel at speeds up to 200 feet per minute.
A fully integrated, automated Vehicle Management System (VMS) was also provided. The VMS handles the traffic routing between the 19+ vehicles that are currently operating within the system. The VMS has the ability to track and store faults, monitor battery consumption and ensure safe operation by monitoring all safety devices.
together. Through the design, process and simulation, Fori was able to fit multiple tooling features for the (2) new models with different geometry.
The suspension module aligner knows which model is in the station based on a broadcast from the OEM, as well as position sensors placed in the machine, automatically initiating the correct tooling combinations.
A challenging portion for any project is the ability to debug and tryout the process. The key to success was analyzing every failure mode with precision in order to correct and provide results that would normally require more debug time.
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 Fori Tugger AGV is utilized in two configurations, first as a Tugger pulling tooling carts in a single direction. The Tugger AGV is also used as a Dock N’ Lock. In the Dock N’ Lock configuration, the AGV automatically connects to the tooling cart and pulls it against the bumpers (shown in bottom picture). The attachment allows the tooling cart to rotate with the Tugger AGV and back it into work stations as required by the process.
The Tugger AGVs were commissioned to ensure safe and reliable product transfer. Previously this transfer was completed with fork lifts or manned tow vehicles. The AGVs eliminated non-value added material handling and provided a hands off system for transporting product through the assembly process.
The System Integrator Giants announcement can be found 
An integrated 
For more information about Fori Automation's end of line testing solutions, please visit our 
The vehicle included a custom scissor lift to accommodate the vertical lift stroke and capacity required for the process. Each vehicle is capable of lifting 1,100 pounds (500 kilograms), and the scissor lift is capable of 21 inches of total stroke with a collapsed height of 11 inches. The custom 24 volt 67 ampere hour lithium ion battery was designed to fit within the available footprint on the vehicle. The system allowed for quick charging at the designated opportunity charge stations. Utilization of a lithium ion battery reduced the required charging infrastructure.
For more information about Fori Automation's AGVs, please visit our 
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 existing hot stamping line in Detroit was a singular process. The customer requested that a new process in Mexico be a parallel process to improve the output of the system. Fori was responsible for engineering the new process. Fori developed the new system layout and completed all the robotic simulations with offline programming to verify the performance of the new parallel process system. The customer requested that Fori use as much existing capital as possible to help control costs, therefore anything that was not available for reuse had to be built by Fori, including the controls of the new system.
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Once the engineering was completed and signed off, Fori Mexico managed the installation, integration, and run off of the new parallel process. 
The chassis marriage RGV system consisted of a single traffic control panel for the 14 vehicles. The main control panel ensured proper vehicle pitch and synchronization through the chassis marriage process.
In order to ensure a smooth installation and buyoff at the customer facility, the entire chassis marriage was setup, debugged and bought off on Fori Korea’s floor.
For more information about Fori Automation's chassis marriage capabilities, please visit our 
The system was supplied for accommodating the customer's new vehicle model. The system was integrated into an existing assembly shop and was designed for 25 jobs per hour. The decking system supplied runs cross-car to the underbody conveyor line. The decking for the engine assembly is completed in a static position.
The 
The decking system also included the engine dress up conveyor and pallets, as well as a buffer conveyor with overhead hoist and rail system for loading the product on the pallet.
For more information about Fori Automation's automotive capabilities, please visit our 
Each vehicle consisted of two fixed drive wheels, an integrated trunnion, and a 24 volt lithium ion battery to power the vehicle. The system was based on an open controls architecture, utilizing a Siemens PLC for the vehicle control.
Each vehicle utilizes a camera based guidance system that follows colored tape or paint. The optical guidance system provides a flexible, reliable and cost effective solution for guiding the vehicles throughout the assembly plant.
The system was supplied with a Siemens based Vehicle Management System (VMS) to schedule and coordinate vehicle moves, communicate with the plant and for monitoring of the vehicles.
For more information about Fori Automations' AGVs, please visit our 
The end of line system was included: non-contact wheel alignment, automatic headlamp aiming, and roll and brake testing.
The 
The fixture lowers itself onto the vehicle frame, and then pins and clamps to the frame which establishes the control datum points to locate to. The machine's two pivot arms swing in and clamp the upper and lower control arm ball joints. DC Nutrunners loosen the lower control arm fasteners. Servo motors position the X and Y location of the lower control arm. DC nutrunners secure the lower control arm into the correct location. The fixture then un-clamps and lifts off of the frame. At that point the fixture drives itself back to it's home position ready to accept the next unit.
The system consists of a fully integrated Safety PLC. The PLC has the ability to track and store faults, monitor and record positional and setting information as well as monitor all safety devices.
For more information about Fori Automation's automotive assembly capabilities, please visit our 
The assembly line consists of 22 MIG welding robots and ten material handling robots. MIG welding is the main process completed, but the line also has 
Fori USA was responsible for project management and engineering for the program. 
ADAS test benches certify the operation of the vehicle cameras related to Lane Departure Warning (LDW), Automatic Head Lights (AHL), Over Speed Prevention (OSP), Traffic Signal Recognition (TSR) and Distance Warning (DW).
The 
The
Fori Germany supplied 21 work piece carriers for a front end assembly line. The work piece carriers were integrated with an existing 
The purpose of the work piece carriers is to provide a repeatable solution for locating the parts to the pallet for assembly. The work piece carrier also provides a process to the operator for adjusting the part location and orientation. Adjustment is completed through a powered trunnion.
The carrier trunnion has an integrated motor in order to tilt (the system has four automatic tilt angles) the fixture both automatically and manually. The carrier utilizes the power available on the AGV and communicates with the it to provide confirmation of the correct position. Upon completion of the front end module, the carrier returns to the home position and the module is unloaded via a 
The system supplied provided a simple technique for locating the front end module for the operator. The design considerations were based on a high level of reliability and minimal maintenance.
To learn more about Fori Automation's AGVs and assembly capabilities, please visit our website.
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 
The AGVs were developed to support the customer's lean automated manufacturing methodology. The goal of the project was to automate the entire material handling process for the assembly of the stringers (specifically the load and unload of the autoclaves used for curing the composite wing stringers). The loading of the autoclave is completed utilizing a natural feature guidance system. Then the AGV uses the walls of the loaded autoclave for the guidance in and out, while still maintaining +/- 5mm accuracy.
The design intent was to build a vehicle that was modular and interchangeable. The AGV system is required to transport many tools of different lengths and weights. The AGV system needs to be able to accommodate synchronization of up to three AGVs during the lift and transport from assembly stations.
Each of the AGVs is outfitted with two servo based lifters and a laser alignment system which provides measurement feedback to the onboard PLC for the dynamic leveling of the tooling during transport. The system must maintain levelness within +/- 1/8” from each end of the tool.
A Fori Vehicle Management System (VMS) has been provided to monitor system I/O, communication between the AGVs, tooling and automated assembly stations. Scheduling of moves also occurs at the Fori VMS.
For more information about Fori Automation's Aerospace AGV products, please visit our 
The required changes to the existing front 
For more information about Fori's AGVs or 
Fori was enlisted to supply a derivative of the standard Tugger AGV product line that is capable of nearly double the capacity of the original design. The driver of this increase was the goal of being able to transport three carts carrying axle assemblies for a large automotive OEM.
Due to the capacity, more product was transferred during each move which further increased the return on investment while decreasing the total number of required vehicles. The Tugger AGVs were commissioned to replace non-value added material handling tasks within the assembly process. The most important process consideration was safety and reliable delivery of product.
Integration of a Fori Vehicle Management System (VMS) introduced further improvements to safety and reliability. Vehicle scheduling of moves, tracking and traffic control is coordinated through the Fori VMS. The Fori Tugger is a proven and robust product that can be applied to a variety of material handling applications.
For more information about Fori's Tuggers and other material handling systems, please visit our 
A Fori Vehicle Management System (VMS) is utilized for scheduling of vehicles and traffic management of the system. The vehicle controls are based on an open architecture utilizing a Siemens safety PLC, eliminating the black box technology that is commonly used across the industry. The Tunnel AGV has proven to be a cost effective and reliable material handling system for a variety of applications.
For more information on Fori's automated material handling products, please visit our 
The ability to be flexible with the pallet provided the ability to use the vertical conveyor for more than current parts or model changes. Overhead support for tooling was a jib boom that bolted to the floor to remove the assembly to dunnage.
For more information about Fori's assembly solutions, please visit our 
The AGVs were developed to support a lean automated manufacturing methodology. The design intent was to build a vehicle that was modular and interchangeable. The AGV system is required to transport nine different tools, all with different weights and footprints. Due to tools exceeding lengths of 100 feet, the AGVs are required to dock at each end of the tool and move in tandem.
The automated docking utilizes a natural feature and camera based guidance system, which accommodates unexpected movement of the tooling. The system measures the surface of the tooling to generate angular offsets and utilizes a SICK camera and reflector based system for final location. Once positioned, servo driven couplers automatically pin spring loaded receivers mounted to the tooling. The tooling is also outfitted with safety scanners powered and controlled by the AGV.
Responsibilities of the AGVs include: automated docking, tooling identification and transport throughout the facility. A Fori Vehicle Management System (VMS) has been provided to monitor system I/O, communication between the AGVs, tooling, and automated assembly stations. Scheduling of moves also occurs between the vehicle Siemens Mobile Panel and the Fori VMS.
For more information about Fori Automation's aerospace products, please visit our 
Fori USA was responsible for Project Management, Engineering, Assembly and Integration. All cells were setup and run off at Fori's global headquarters in Shelby Township, MI. Fori Mexico was responsible for installation and buy off at the end user's production facility.
For more information on Fori Automation's weld lines, please visit our 
The Fori AGV utilizes a 72VDC sealed lead acid battery as a power supply. The vehicles utilize PMAC motors that provide improved control and efficiency over the previous system which utilized DC brushed motors. Each vehicle had a safety bumper front and rear, as well as six safety scanners around the perimeter of the vehicle to provide added safety coverage.
A Fori Vehicle Management System has been provided to monitor system I/O, manage communication between the AGVs and scheduling of moves for production.
For more information about Fori Automation's high capacity AGV capabilities, please visit our 
The Fori AGV is required to locate within +/- 5mm to an existing fuselage transporter. The Fori system utilizes a natural feature and camera based guidance system, which accommodates unexpected location of the transporter. The Fori system overcomes the variability of the fuselage transporters accuracy by measuring the surface of the transporter to generate angular offsets and utilizes a SICK camera and reflector based system for final location. Once positioned, the mobile robot automatically docks to the transporter for power, communication, and pneumatics.
Automated movement is handled through the tethered Siemens Mobil Panel. The operators are able to select drill positions on either the Fori HMI or robot HMI. Once selected the Fori AGV is responsible for safely and accurately lifting and transporting the two mobile robots between 16 different drill positions.
For more information about our drilling platform AGVs, please visit our 
For more information about Fori's End of Line Systems, please visit our 
Providing customized equipment such as this starts with a concept design phase. 
The Chassis Marriage RGVs are based on Fori’s long standing design and architecture. Each RGV includes two Fori patented servo controlled chain lifts for the synchronized lift and locate of the front and rear pallet.
The Fori RGV is focused on maintainability and simplicity for the end user. The system has been a robust solution for many years, pushing Fori to become a leader in Chassis Marriage systems.
The integrated system was a great success for the end user. Installation was completed during the 3rd quarter of 2017, with initial production beginning in August of 2017.
For more information about Fori Automation's body and chassis marriage products, please visit 
For more information about Fori Automation's aerospace assembly products, please visit 
The Fori Flex Floor utilizes a heavy duty extrusion style frame that enables the footprint of each style vehicle to be modified to fit the product being assembled or the materials being moved. The Flex Floor platform utilizes commercially available drive wheels, casters, batteries, controls components and guidance. The Flex Floor platform is based on a Siemens Safety PLC based architecture, providing the end user an open architecture. Many of the other products on the market include a “black box”, requiring the user to enlist support from the equipment supplier. Each assembly and material handling system can be supplied with a Fori Vehicle Management System (VMS), enabling the system to be fully autonomous, only requiring input for scheduling of moves either from the user or from the plant production system, the Fori VMS takes care of the rest. The Flex Floor vehicles are outfitted with the latest safety components available on the market. At a minimum the vehicles are supplied with perimeter Safety Scanners, Indicator Lights, Alarms and E-stops. The Safety Scanners provide collision avoidance for the end user to ensure safety for the operator and that no damage occurs to the product or part. Additionally, each vehicle is designed to be user friendly and virtually maintenance free for the end user.
Flex Floor 1.0: Flex Floor 1.0 is a cost effective, scalable Automated Guided Cart (AGC) that is used for a variety of applications, including assembly and material transport. The vehicle includes a single drive wheel, perfect for loop style assembly and material handling systems.
Flex Floor 2.0: Flex Floor 2.0 is based on the same platform as the Flex Floor 1.0, but provides more capability by utilizing dual drive wheels. The results are a vehicle with double the capacity and Omni-directional capability. The vehicle is capable of spinning on its center and moving laterally, resulting improved layout flexibility and the capability to transport larger assemblies, such as large truck frames.
Flex Floor 2.0T: Flex Floor 2.0T is a Tunnel style AGC that utilizes the same architecture as the Flex Floor 2.0, but also includes (2) electric hitch pins that are utilized for transportation of companion carts. These companion carts are utilized for material transport and can include a variety of attachments, including roller conveyor, lift tables and powered trunnions.
Manufacturing Day is a great opportunity for students to connect with organizations looking for future hires. There is a labor shortage for skilled trades within the Manufacturing industry and the hope is to raise awareness of the great career opportunities available within the Manufacturing field.
A video of success stories was recently produced which includes students from the Macomb County area who are working for local manufacturers. The video of these success stories can be found on the 
