Background & Challenges

In the increasingly competitive automotive industry, component manufacturers face multiple pressures:

• High output, fast cycle time: Meeting large-scale production plans often requires overtime, but relying on manual methods makes it difficult to ensure progress.
• Consistent & stable quality: Automotive components like headlamps demand high precision—small deviations may lead to significant issues during vehicle assembly.
• Rising automation requirements: Manufacturers aim to increase automation to enhance efficiency and reliability.
• Space & flexible design: With limited factory space, assembly lines must be designed for optimal utilization while remaining flexible for model changes.
• Integrated quality control: Monitoring tightening torque, pressing stroke, pressing force, etc., to ensure every product leaving the line meets strict standards.

Our client, an automotive parts manufacturer, wanted to implement automation in headlamp assembly to achieve production targets, improve quality, and reduce manufacturing risks.
 

ETEK Proposed Solution

ETEK approached the project by designing an automated assembly line with specialized modules tailored for each headlamp assembly stage—from lens pressing, reflector module installation, and screw fastening to final inspection. Key highlights include:
 

1. Dedicated module design

 

• Lens pressing machine: Equipped with a 6-axis robot and automatic tray feeder, shaping ABS/PP materials according to design with high precision.
• PBA & left/right reflector assembly machine: Robots combined with ETEK’s proprietary automatic screwdriving system to ensure accurate and consistent torque.
• Automatic LDM screw fastening station: Integrated with robots and parts feeding system, tightening screws in a pre-defined sequence.
• Semi-automatic & operator-assisted stations: Handling components that are difficult to fully automate, where operators assist with feeding, inspection, or fine adjustments.
• Quality inspection & monitoring system: Including vision cameras, leak detection sensors, and force measurement sensors, ensuring every product meets standards.

 

2. Integration & cycle time optimization

During implementation, ETEK focused on calculating the cycle time for each module to ensure synchronized operation across the entire line, preventing delays or bottlenecks. The intelligent control system manages communication between robots, feeders, and inspection devices, maintaining stable production rhythm. Meanwhile, the assembly line layout was carefully designed to optimize factory space usage, minimize redundant length, and reduce infrastructure costs for the client.
 

3. Project management & support

ETEK’s engineering team closely followed the project from survey and design to installation and trial operation, ensuring precision in every detail. On-site issues were resolved promptly, from design adjustments and component changes to system optimization based on real conditions. After handover, ETEK continues to support clients through maintenance services, technical assistance, and 24/7 operational monitoring, ensuring maximum performance of the assembly line.
 

Results & Benefits

 

• Outstanding productivity: Achieving ~145 seconds per product (~74,300 products/year).
• High OEE performance: Stable operation with OEE above 90%.
• Consistent & reliable quality: Every product passing inspection meets required standards, reducing defect rates.
• Reduced labor costs & error risks: Many manual processes were eliminated or minimized.
• Optimized space & flexible upgrades: Compact layout allows easy expansion or model change when needed.