Collaborative Pick and Place Station – Automotive Electronics Production

Client Overview

 
The client is a global manufacturer specializing in the development and production of electronic components and modules, with a strong focus on inductive technologies and customized solutions for demanding applications.

Its Romanian production operations support a wider European manufacturing network and serve multiple industries, with a particularly strong presence in automotive and industrial electronics.

With extensive experience in high-quality component manufacturing, the company places strong emphasis on production efficiency, precision, consistent quality, and continuous process improvement, making automation an important part of its manufacturing strategy.

Initial Situation
 

The production process required an operator to manually pick a component from the conveyor and place it into the processing machine for each production cycle.

This task was highly repetitive and physically demanding, requiring the operator to perform the same movement continuously throughout the shift. Over time, fatigue could affect the operator’s pace and consistency, while the manual handling process also contributed to a longer overall cycle time.

The client was therefore looking for a solution that could automate the repetitive loading process, improve cycle time, and reduce the physical workload on operators while maintaining consistent production flow.

Solution Implemented
 

To automate the process, the client was provided with a JAKA Zu5 collaborative robot, featuring a 5 kg payload and 954 mm reach, integrated into a complete pick-and-place solution.

The robot was equipped with a dedicated gripper to securely pick the components from the conveyor and place them into the processing machine. Presence sensors installed at the conveyor detect when a component reaches the designated pick-up position, allowing the robot to automatically identify when a new part is ready to be handled.

The collaborative robot was installed on a dedicated support pedestal, providing the appropriate working height and positioning for reliable access to both the conveyor and the machine. The complete setup enables the robot to perform the loading operation automatically and consistently, maintaining a continuous production flow with minimal operator intervention.

Results
 

The implemented solution successfully achieved the required production cycle time, while the collaborative robot operates at only around 50% of its available performance capacity. This means the system is currently running well below its maximum speed, providing additional flexibility for future process optimization if higher throughput is required.

By automating the repetitive loading operation, the client achieved a more consistent and predictable production flow, while reducing the physical workload placed on operators.

The solution now performs the pick-and-place process reliably and continuously, meeting the client’s production requirements while still maintaining significant performance reserve for future increases in production demand.

End Customer: Su****