Automation of the circuit breaker chamber assembly line for Schneider Electric Polska
- Mar 20
- 2 min read
Customer Challenges
For our client, Schneider Electric Industries Polska , we have completed a project of a fully automatic BC3 production line, consisting of three integrated modules: M10, M20 and M30 , which together constituted one whole
Before implementation, the assembly process was semi-automatic, which generated a number of problems:
Low productivity unable to keep up with growing demand.
Risk of human error during precise assembly of multiple components.
Lack of repeatable quality control – reliance on subjective visual assessment by the operator rather than precise gap measurements.
Our Solution: Innovation in the Service of Precision
We designed and built a line weighing over 8 tons (total) that integrated feeding, assembly and rigorous quality control processes.
Key technological elements:
Advanced Robotization: The use of as many as 13 Yamaha SCARA robots , which are responsible for the precise assembly of elements such as screens, contacts, carbons, extinguishers and discs.
Hepco Transport System: Use of the Hepco pallet transporter, serving up to 16 stations with extremely high positioning accuracy.
Keyence 3D Vision Systems: Implementation of two 3D laser profilometers for error-free gap measurement and detection of micro-damage (damage, cavities).
Flex Feeding: Integration of 6 innovative FlexiBowl vision feeders, providing flexibility when changing product references.
Digital Integration: Full communication with the e-kanban system and real-time logging of performance and error data.
Modularity and Process
Although the line works as one organism, we have divided it into three sections for logistical reasons:
M10: Feeding the chambers, assembling Joue Magnetic and Joue Isolante.
M20: Assembly of 11 different components (contacts, shields, nuts, etc.).
M30: Final riveting, precise gap control, marking printing and automatic buffering of the finished product.
The M30 station is equipped with an intelligent buffer that collects finished parts and issues them to the operator in packs of 16 pieces.
Achieved Results (KPI)
The implementation fully achieved the ambitious design assumptions:
Cycle time: Reduced to just 6 seconds .
Line Efficiency (OEE): Achieving 90% level.
Employment optimization: One operator instead of four (freeing up human resources for other tasks in the plant).
Quality: Reduction of complaints to a level close to zero thanks to 100% control with force, presence and vision sensors.
Continuity: The line is adapted to work in a 3-shift system.
Summary
By automating its assembly processes, Schneider Electric has acquired a line that not only significantly increased plant efficiency but also became a key supplier of components for other production processes. This implementation confirms that investing in precision robotics and 3D vision systems is the fastest path to eliminating shortages and increasing competitiveness.
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