Automated Sealing Magnet Assembly for an Automotive Industry Supplier

About the project

Our client, a leading electronics supplier to the automotive industry, needed an automated solution capable of assembling 30,000 magnets per shift.

One of the key advantages of the solution we identified was the minimal need for material preparation. Components are fed directly into the assembly station in the same packaging in which they arrive from the suppliers, eliminating time-consuming and costly pre-processing steps.

The system is equipped with advanced sensors that inspect the quality of every assembly in real time. Using a proprietary self-correction model and adaptive control developed by the supplier, the machine can automatically adjust its operation and maintain consistent quality throughout production.

The station was also designed with data-driven manufacturing in mind. It continuously collects operational data, reports production status to the team, and issues alerts when faults or deviations from quality requirements are detected — enabling faster response and maximizing line availability.

Sinergy’s Role
  • Sinergy managed the supplier selection and project coordination in China, from identifying and evaluating potential manufacturers to due diligence and technical alignment.
  • We arranged meetings with the selected supplier and visits to existing customer sites in China, while supporting communication between the client and supplier throughout the development and implementation process.

The Solution
  • A fully automated assembly system was developed in which components can be fed directly into the station in their original supplier packaging, significantly reducing preparation requirements.
  • Integrated sensors inspect every assembly in real time, while the supplier’s self-correction and adaptive-control system automatically adjusts the process to maintain consistent quality. The station also collects production data, reports operational status, and generates alerts when faults or quality deviations are detected.
Key Challenges
  • Achieving a production capacity of 30,000 magnets per shift.
  • Combining mechanical systems, hardware, software, and automated quality control in one solution.
  • Minimizing material preparation and operator involvement.
  • Ensuring reliable remote maintenance and long-term technical support.
    Maintaining consistent quality at high production volumes.
Results

Joint Development and Ongoing Support

A second generation of the machine is currently being developed jointly by the client and the supplier, with Sinergy continuing to support the process.

A Long-Term Supplier Relationship

The project created a strong working relationship and mutual trust between the client and the supplier, who have since continued collaborating directly on additional projects.

Exceeded Production Targets

The system exceeded the client’s original production and quality requirements.

55% Cost Saving

The final solution was 55% less expensive than comparable proposals the client had received from local suppliers.

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