Know how NextFirst’s assembly line for the production of headlamp levellers helped our customer achieve 1 million assemblies per year with only 12 operators.

1. Internal Head Lamp Leveller Assembly Line
Client’s Challenge
The client, a leading automotive components
manufacturer wanted NextFirst to build an
assembly line to assemble an automobile internal
headlamp leveler. The biggest challenge was in
handling of threaded and geared plastic parts
during assembly. Critical assembly of the internal
mechanisms, a drive motor and PCB had to be done
with aggressive cycle time target to chase. Complex
testing such as functionality checking procedures
were performed at intermediate stages of assembly
as per client’s requirement.
Nextfirst Solution
The assembly line was built using our “Consult-
Design-Build” delivery model. The assembly line
consisted of 9 stations along with end of the line
testing and inspection gauges that included
material handling solution.
 A motorized spindle on a spring balance
was used during initial stages of assembly
and a critical inline position monitoring
system was also included.
 Intermediate assemblies were checked for
operational freeness of the mechanisms
assembled.
 Automatic grease dispensing mechanisms
installed in the assembly line controlled the
grease application operations.
 End of line test procedure was incorporated
for checking the IHLL performance.
Automatic sticker printing and dispensing
mechanism to paste sticker on the assemblies
that had successfully passed inspection tests.
Head lamp leveller assembly

2. Impact On Client’s Business
Customer was able to achieve production targets
of 1 million assemblies per year with only 12
operators handling the entire line.
NextFirst Engineering Technologies Pvt Ltd.
NextFirst, #60/3, 1st Cross, GNC Industrial
Area, Thathaguni, Kanakapura Road,
Bangalore – 560082
Contact us at:
General Info - info@nextfirst.com
Enquiries - bd@nextfirst.com
Sales - sales@nextfirst.com