Assembly Line with Integrated Jig Return

The Challenge:

Five operators assemble products on fixtures known as jigs. Once testing is complete, the product is removed and the empty jig must be returned to the start of the line. Each jig weighs approximately 20 to 30 kg. Carrying it back by hand added a repeated task to every cycle and placed a physical burden on the operators.

Proposed Solution:

ADAPTIV proposed a closed loop for the jigs. They move through assembly and, after testing, transfer to a separate inclined roller return. The empty jigs travel back to the beginning of the line, ready for the next assembly cycle without being carried back by an operator.

Design:

The design connects the operator stations, testing area and return path in one continuous system. Turning tables guide the jigs around corners, while stoppers and separators control their movement and spacing. Adjustable monitor and keyboard mounts, together with scanners, are planned for the operator stations. This allows work information to be available at the point of use and supports the client’s move toward paperless operations.

Expected Benefits:

The planned return path is designed to eliminate the need to repeatedly carry jigs weighing 20 to 30 kg and is intended to reduce physical strain on operators. It also returns the fixtures in a controlled flow for their next use. At the same time, the workstation equipment provides a foundation for digital work instructions at the line. Any time savings will be measured after commissioning.

Project Status:

The system is currently under construction. The design views on the following pages show the planned solution. Installation photos, measured results and customer feedback can be added after commissioning.