Semi-Automated Door Hinge Press-Fit Cell

Overview

Redesigned the press-fit operation for a Toyota door hinge line, where operators manually used an arbor press to install a rubber cap into a stamped hinge component. The repetitive manual force required led to operator fatigue and progressively longer cycle times over the course of a shift. Designed a semi-automated solution that combined multiple operations into a single station while maintaining production requirements.

Objective

Eliminate the ergonomic and productivity limitations of the manual press-fit process by automating the pressing operation and incorporating a second, similar press-fit process through a tool changeover. The new cell needed to maintain required yearly throughput without overloading the station while remaining practical to manufacture, operate, and maintain.

Approach

Designed the complete tooling and fixture system within the standardized cell architecture, including the part fixtures, press tooling, actuator selection, sensor placement, and changeover mechanism. Developed CAD models and engineering drawings, selected materials and off-the-shelf components, and worked with tooling engineers to ensure manufacturability. Consulted technicians to design the changeover and route sensor wiring through the subsystem without interference or tangling. The operator loads the hinge components and rubber cap into the fixture, after which the cell detects part placement and verifies that the operator has cleared the guarded area. The automated actuator then performs the press-fit operation before the fixture rotates and deposits the completed parts into a collection bin. The changeover system allows the same station to perform a second press-fit operation without requiring a separate dedicated cell. Calculated maximum annual throughput prior to implementation to verify that the combined operations would remain within the station's production capacity.

Results

• —Replaced a repetitive manual arbor-press operation with a semi-automated press-fit process, reducing operator fatigue and eliminating the effect of fatigue on cycle time
• —Increased production capacity from 1 part per cycle to 5 parts per cycle
• —Integrated a second press-fit operation through a tool changeover, eliminating the need for a separate station
• —Reduced required operator count by 50% while improving overall process efficiency
• —Designed the tooling and fixtures from concept through engineering drawings and manufacturability review
• —Verified maximum yearly throughput to ensure the combined operations would not exceed station capacity
• —Improved part cycle time by approximately 2.5×

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