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High-Volume Robotic End-Effector Production
Global Industrial Automation OEM, Germany
A German industrial automation manufacturer partnered with PiPrecision to produce 50,000 aluminum end-effector components monthly. Through cellular manufacturing, SPC monitoring, and automated CMM inspection, we delivered 99.7% first-pass yield with zero-defect reliability.
99.7%
First-Pass Yield
0.08%
Defect Rate
50K/month
Production
15%
Cost Reduction
The Challenge
The client needed 50,000 units/month production with ±0.01mm tolerances, perfect perpendicularity for pneumatic fittings, and zero defects for just-in-time automotive delivery. Previous supplier had 3% defect rate causing line stoppages.
Our Solution
Implemented cellular manufacturing with dedicated tooling, SPC on 12 critical dimensions, automated CMM inspection, poka-yoke error-proofing, and 3-shift dedicated production with real-time dashboard.
The Results
99.7% first-pass yield, 0.08% defect rate, Cpk 2.1 on critical dimensions, 100% on-time delivery for 6 months, 15% cost reduction, eliminated €45K/month emergency air freight costs.
Project Gallery
Project Info
- Industry
- Automation & Robotics
- Service
- CNC Milling Service
- Client
- Global Industrial Automation OEM
- Location
- Germany
- Completed
- November 2024
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