Tier-1 EGR cooler assembly line — 60 ppm, full traceability
Cell-based assembly with leak test, servo press, laser marker, and per-unit data capture for IATF 16949 compliance.
- Client
- Confidential — Tier-1 Powertrain
- Location
- Indiana, USA
- Capabilities
- Turnkey Line Build · Process Engineering · Machine Vision
The challenge
Customer awarded a new program with strict per-unit traceability and a 60 ppm cycle target. Their existing manual assembly cell ran 35 ppm and traceability lived in spreadsheets.
What we built
Eight-station rotary cell with servo press, helium leak tester, laser marker, and a vision read of the laser-marked DMC. Each station's data writes to an MES via OPC UA. Statistical process control charts run live on the cell HMI.
Key equipment
- Promess servo press
- ATEQ helium leak tester
- Keyence MD-X laser marker
- Cognex DataMan 470
From the floor
Illustrative image — representative of project scope; customer-identifying details have been removed.
Results
Cell hit 60 ppm at PPAP, traceability is 100% per-unit through final assembly, and PPAP was approved on the first submission.
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