Hardware Robotic Flexible Coating Line
Project Background
The client is India's leading lock and metal hardware manufacturer, producing 200+ SKUs. Their existing manual coating line had high labor costs and inconsistent quality. They engaged MUSI to bring robotic flexible automation to their facility in Pune.
The Challenge
Lock products span 200+ SKUs with 20-30 product changeovers per day. Traditional fixed-program automatic lines lacked the flexibility needed. Lock structures are complex (cores, handles, decorative parts), with many recessed coating areas.
MUSI's Solution
MUSI designed a robotic flexible coating solution: ABB IRB1410 robot for vision-guided loading, 6 ABB IRB52 spray robots working in coordination, paired with 2-axis workpiece manipulators for full-coverage coating. Full MES integration enables order-driven program selection.
Equipment Configuration
| Robots | 12 ABB units (6 spray + 4 load/unload + 2 inspection) |
|---|---|
| Vision system | Cognex In-Sight 8000 series |
| Product SKUs | 200+ lock products |
| Changeover | ≤3 minutes (auto program switch) |
| Daily capacity | 20,000-25,000 pcs |
| Film uniformity | ±3 μm |
| Manning | Originally 32 people, now 6 |
| MES integration | Order-driven flexible production |
Implementation
4-month timeline: 30 days design, 90 days manufacturing, 20 days installation, 40 days robot offline programming + commissioning. Robot commissioning was the critical phase — MUSI's senior engineers worked alongside ABB India's tech team.
Results
Labor reduced 81%, per-unit cost down 42%, film pass rate from 86% to 99.6%. The transformation moved the client from 'traditional hardware factory' to 'smart manufacturing operation' — recognized by India's Ministry of Heavy Industries as a smart manufacturing demonstration project.
Client Feedback
"The investment was significant, but the returns far exceeded expectations. Robots are more stable and precise than manual operators, and we no longer worry about labor shortages."
— Project Manager, Client Side
Get a Similar Solution
If your industry and requirements match this case, contact MUSI to schedule a free consultation. We'll design an optimal solution based on your specific workpieces, capacity, and facility.