Assembly & Quality Control Station for the Automotive Industry

About the project

For a client in the automotive industry, Sinergy managed the transition from a manual assembly process to a stable, semi-automated production solution.

The system was designed to assemble an inflation tube and valve with consistent precision, while reducing the operator’s role to component loading only. Quality control is performed in real time by a three-camera vision system that inspects and approves every unit, helping maintain consistent quality, reduce rejects, and improve output.

Sinergy’s Role
  • Identified several potential suppliers, all with the relevant experience in the automotive industry.
  • Presented three qualified proposals for the client’s consideration.
  • Required the selected supplier to develop the quality-control software in-house, without relying on subcontractors.
  • Managed the technical approval process on the ground in China, allowing the client to complete the project remotely without sending its own representatives to the manufacturer.
The Solution
  • A flexible semi-automated assembly station was developed to handle multiple tube diameters and connector types with minimal operator involvement.
  • The system combines automated assembly with a three-camera vision system for real-time quality inspection and built-in Poka-Yoke mechanisms to prevent assembly errors.
  • The complete station was tested and approved at the manufacturer’s facility in China before shipment.
Key Challenges
  • Flexibility Across Multiple Product Configurations
    The machine had to support the assembly of three different tube diameters and four different connector types, while maintaining repeatable quality across all configurations.
  • Error-Proof Operation
    Given the client’s staffing challenges and high employee turnover, the system had to follow a Poka-Yoke approach – minimizing the possibility of operator error and making the process as simple and reliable as possible.
  • Ready to Run on Arrival
    The machine had to be fully tested at the manufacturer’s site and shipped as a finished solution, ready for immediate use at the client’s facility without additional development or integration work on site.
Results

45-Day Delivery

The system was ready for trial production just 45 days after the client approved the final plans.

Vision-Based Quality Control

The station uses a camera-based inspection system and comparison algorithm to verify that each finished assembly meets the required specification.

3x Higher Productivity

The new process enabled the client to complete three times more assemblies in the same amount of time.

Poka-Yoke by Design

The solution was designed to prevent assembly errors at the operator level, improving consistency and reducing dependence on operator experience.

Gallery

All the projects