Background: In the manufacture of semiconductors, silicon wafers are transported from process to process within the fabricating plant by a transport robot. The robots run on a monorail and operate from battery power.

Project: Rapidly expanding business prompted an international robotics manufacturer to transfer assembly of the complex battery packs from its own plant to Product Resources. In the rush to production, our customer had produced only minimal drawings leaving much of the assembly detail in the minds of the production personnel.

The battery assembly incorporates cell temperature monitors and is very intricate, requiring great precision and care to achieve the dimensional, electrical, and thermal requirements. Product Resources engineers were given the responsibility of producing a new, comprehensive, unambiguous drawing package for the battery assembly. Manufacturing jigs and fixtures were designed and built, and full quality assurance procedures were developed.

Within only six weeks, Product Resources had achieved a quality level of better than 99% (much better than our customer was able to achieve in-house!). Production is currently running at around 100 units per week and generating supplier ratings of 100% quality and 100% on-time delivery from our customer.

Technologies: assembly jigs and fixtures, wire harnesses, hot melt adhesives, 100% functional testing

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