📋 Case Study
Automotive Tier-1 Supplier: Robotic Deburring Cell ROI
High manual labor cost ($38/hr) and inconsistent surface finish causing 12% rework
🏗️ Project Overview
Implementation of collaborative robot cell for aluminum chassis components
🎯 Challenge
High manual labor cost ($38/hr) and inconsistent surface finish causing 12% rework
🔧 Design Approach
UR10e cobot with force-sensing end effector, vision-guided path planning, and integrated metrology feedback loop
📐 Design Diagram
AI-generated project design illustration
📐 Key Calculations
Labor Cost Offset
2 operators × $38/hr × 2,000 hrs/yr
Result: $152,000/yr
Direct operational savings
Rework Avoidance ROI
12% scrap × $220 avg. part value × 180k units/yr
Result: $475,200/yr
Quality-driven margin recovery
📊 Results
Payback: 14.2 months; NPV @ 8%: $1.24M over 5 years; OEE increased from 68% to 89%💡 Lessons Learned
- •Force control calibration reduced tool wear by 40%
- •Vision-guided teaching cut programming time by 70%
- •Cross-training maintenance staff was critical for uptime
✅ Key Takeaways
- 1Force control calibration reduced tool wear by 40%
- 2Vision-guided teaching cut programming time by 70%
- 3Cross-training maintenance staff was critical for uptime
📐 Prerequisites
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🔗 Engineering Applications
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