Know how NextFirst’s assembly line for the production of alternators helped the customer ramp up capacity to 1000 units a day with only 10 operators

1. Alternator Assembly Line
The client, a leading auto electrical components
manufacturer wanted NextFirst to built a assembly
line to assemble alternator with 9,000,000 units per
year production target to achieve. The biggest
challenge was complex testing requirements with
high accuracy measurement against aggressive
cycle time. The assembly of the drive pulley on the
shaft was very critical and required very accurate
alignment. The assembly line has to perform quality
check on rectifier and regulator.
Nextfirst Solution
The assembly line was built using our 'Consult-
Design-Build' delivery model. The entire
assembly line consisted total of 11 stations.
The material transfer from one station to
another was done by manual conveyor. The
line was capable of handling 3 variants of
alternators.
Tightening of 4 screws for the assembly of
the alternator was done using servo drive
with feedback system to ensure that
accurate tightening torque is achieved.
Hydro-pneumatic cylinders used for the
large assembling forces.
The high degree of alignment helped in
reducing the mechanical noise of the
alternators during its operation.
HIPOT tests were conducted on
intermediate assemblies.
Rectifier & regulator tests including
frequency measurements were performed
along with no load and load tests.
ISSUE: 01
Nov 2018
Alternator

2. Customer was able to achieve a per day capacity to
be obtained was 1000 with only 10 operators
handling the entire line. Automated screw tightening
operation of 04 screws in one shot helped customer
to achieve the required production targets.
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