Next-Gen

Revolutionize your assembly line with innovative assembly automation solutions tailored for efficiency from AMS.

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Decades of experience in a range of industries

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Proven processes for smooth delivery

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Engineering and design expertise

Where Manufacturing Efficiency and Quality Meet

Of all the systems found in manufacturing plants, the automated machinery responsible for final product assembly is often the most critical. Up to the point of assembly, all the pieces that make up a final product are handled and fabricated independently, judged individually and not yet for how they will function altogether. Once these parts get into the assembly step of production, assembly automation systems now forge these separate pieces into a final product that can be evaluated as a whole for the first time. 

Clearly the assembly process is crucial to overall plant efficiency and quality assurance: Any parts rejected at this stage are a waste of all the preceding resources consumed. For these reasons, automated assembly solutions must be diligently selected, implemented, and managed, or else a plant’s efficiency and quality will be left wanting.

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Automated Manufacturing Assembly Methods and Technologies

To begin our stroll through assembly automation, let’s explore this quick list of common technologies used for assembling industrial manufactured parts:

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Where and How to Use Assembly Automation Systems

Even with an untrained eye, it doesn't take long to spot signs of automated manufacturing assembly methods out in the world. Common applications and their key assembly considerations include:

Automotive Parts Ultrasonic Welding - AMS

Automotive and transportation

Plastic joining techniques such as ultrasonic welding and staking are very popular in automotive and transportation applications, including the assembly of parts such as body panels, trim pieces, instrument clusters, headliners and upholstery. Automated assembly solutions for auto, truck, train and airplane parts tend to focus on lightweight, low-cost, long-life features.
Medical Equipment Sonic Welding - AMS

Medical devices and equipment

Ultra-clean, high-integrity assembly methods such as ultrasonic welding, hermetic sealing and adhesive bonding are great options for medical components and consumables, especially those with hygienic cleanability requirements. Assembly machinery for medical device applications should be equally hygienic and built with full machine cleaning in mind, as well as advanced onboard documentation recording for full traceability.
Electronics Ultrasonic Welding - AMS

Electronics

Electronic and electrical component assemblies are often produced using insertion, spot welding and staking techniques to manufacture parts such as circuit boards, sensing instruments, computing peripherals and networking hardware. For electronics, assembly methods are often selected specifically to avoid risk points such as static electricity, radiative heat and inconsistent waterproof sealing.

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Industrial components

Spare parts, tooling, personal protective equipment, consumables, replacement components and seal kits all use automated assembly techniques such as press fitting, adhesive bonding, spin welding and precision fastening. The industrial component market tends to focus on lower costs, reliability and high-volume assembly solutions to keep up with demand.

CPG Packaging Sonic Welding - AMS

Consumer goods

All types of consumer goods such as personal electronics, mobile phones, kitchenware, appliances and product packaging all rely on automated assembly solutions; adhesive bonding, precision screwdriving and ultrasonic welding are the most common. Assembly systems used on consumer goods seek to balance low cost and high reliability so that consumer confidence is maximized.
MRO (Maintenance, Repair and Operations) Parts

MRO (Maintenance, Repair and Operations) Parts

Motor guards, seal kits, retainer clip kits, service tools and all manner of plastic replacement parts. 

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Opportunities With Robotics

So far, we've described assembly automation systems that are traditionally designed using linear, rotation or servo motion control. All are proven solutions intent on serving the average component manufacturer. These systems offer high levels of efficiency at attractive capital investment costs and will serve most applications quite well.  

With that said, there are alternative robotic motion control options that some manufacturers pursue to meet their highest productivity targets. These options are finding their way into more and more systems even for low- and medium-scale operations. Robotics can unlock massive new functionality and efficiency in both new and existing systems alike.

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Providing manufacturers with new operational opportunities including:

  • Robotic multi-axis, free-motion positioners can easily replace existing or be provided new in place of linear motion actuators across practically any type of automated assembly system.

  • Robotic arms speed up overall cycle times by grabbing, moving, orienting and releasing parts in one swift motion as opposed to multiple successive actuator steps. 

  • Advanced robotics open up many possibilities for unique part orientations and machine layouts that can be optimized around travel path and distance parameters. 

  • In some systems, robotics can hold parts while tool processes are performed, reducing production steps and costs by eliminating separate fixturing needs. 

  • In addition, robots can perform additional tasks beyond just part motion. Robotic arms can be configured with all types of customized end-of-arm tooling (EOAT) options, providing even more flexibility and capabilities to assembly systems. 

  • As a universal opportunity for automated assembly systems and beyond, robotics help to free up humans from unergonomic, repetitive, unsafe or mundane tasks, allowing those employees to be reassigned to more important work.  

Automated Manufacturing Solutions for Advanced Part Assembly

With so many potential assembly solutions and customizations (including the addition of robotics), manufacturers typically prefer to configure their manufacturing lines with an intentional mix of manual, semi-automated and fully automated systems each dedicated to specific tool processes. Manufacturers will choose their desired levels of automation based on business factors such as labor availability, operating costs, efficiency thresholds, quality compliance requirements and customer expectations.  

From there, manufacturers work with integrators such as AMS to develop the ideal mix of systems that can fulfill these business needs, and all technical product needs as well. 

As an example of varying automation levels selected for different tool processes in the same manufacturing plant, here’s a quick lineup of systems we supplied on a recent project:

High-Volume Ultrasonic Plastic Welding

AMS’ PJ-401 Plastic Joining system is a high-volume ultrasonic plastic welding solution serving applications that require precise welding profiles and specifications, exact locations, high levels of error-proofing and repeatability to ensure consistent welding. The PJ-401 offers larger part sizes, higher volumes, shorter cycle times, advanced recipe-driven PLC controls and extensive data reporting.

Low-Entry Cost Precision Fastening

AMS’ PF-201 Precision Fastening system is a basic, low-entry-cost precision fastening machine, designed to solve ergonomic and consistency demands in single-tool, small-scale applications. The screwdriver is mounted onto a manually positioned tool balancer arm, with controller-managed torque and quick-change tool ends. Our PF-201 is a great selection for entry-level automation of low-volume, high-precision applications such as automotive and industrial component assembly.

PLC-Controlled Insertion

AMS’ PM-401 Semi-Automated Press system is a PLC-controlled, pneumatic cylinder-pressed insertion solution for higher production capacities and insertion forces. Designed with independent and customizable tooling plates, the PM-401 can fit large parts with multiple different insertion hardware positions. Additional features include built-in operator safety, error proofing, precise insertion depths to +/- 0.25mm, accurate repeatability and automatic reporting features.

Lock It Down With Next-Gen Assembly Automation

In modern manufacturing, the term “assembly processes” refers to such a wide array of technologies that no short list of systems could possibly describe all the options available. From this perspective, this post is just an introduction to the world of automated manufacturing assembly solutions. There is certainly much more to be discovered. 

If you’re looking to venture into your first automated assembly system, we encourage a direct discussion with a qualified OEM to make sure that the right technology is matched to the specific application (which should include physical product testing to confirm applicability).  

If you want to expand or upgrade existing assembly systems, a qualified OEM is again the best bet for assessing upgrade paths and feasibility. In all cases, automated assembly solutions should be carefully selected given their critical role in a manufacturer’s total plant efficiency and end-user satisfaction.  

Reach out to us today for a free application review. We’re happy to answer your questions.

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Surefire Automation Plan

  • Share your automation goals with one of our application engineers.
  • We’ll guide you through our proven process.
  • Sit back and enjoy the outstanding results.
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