Custom Automation that Solves Programming and Production issues in Manufacturing

Solving Production Delays & Programming Issues

Navus

No matter what’s being produced, the manufacturing process can get complicated quickly. Every one of our manufacturing clients come to us with unique challenges somewhere in their process—including programming issues. Recently, a client approached us with recurring challenges they were facing in their manufacturing process due to the architecture of their control systems and its inability to do what they needed to without manual input. They needed a reliable system that could improve overall production and make it easier to operate.

There’s a reason we claim to solve complex challenges — our team is known for solving the challenges that our clients face. We’ve proven it time and time again. No matter the scale of the challenge you’re facing, our team works until they find a unique solution that works better for than you could have ever imagined.

Programming Issues Can Cause a Host of Production Problems

It seems simple enough, but if a system in your manufacturing facility isn’t programmed correctly, it’s almost impossible for the entire production system to do what it’s supposed to do. This understandably causes more than one problem in your facility. Production rates plummet, processes are stalled, it feels like something’s always in need of fixing, and it leaves you and your entire team with a major headache and no clear fix.

That’s the moment our engineers come to your rescue.

The featured client was dealing with all of the above frustrations when they approached us for a solution. Our engineers know the ins and out of a control system’s architecture, which allowed us to recreate the system they already had, but in a way that actually worked for them.

How did we do it?

The Navus Solution: Getting Back to the Architecture of it All

By going back to the root of what our clients needed their system to accomplish, our team was able to build a better, more efficient system. All aspects of the production line needed to understand and communicate with each other. Our client didn’t just need automation for automation’s sake— they needed a smart solution that actually did everything their production process required without constant input from operators.

Our client was continuously faced with the challenge to produce a consistent fit up, within a tight tolerance, on a multi-part assembly at a critical place within their manufacturing process. One missing piece in their previous system keeping them from accomplishing this was the ability to automatically recognize and compensate for part features and variables. This is a feature we’ve delivered to other clients before, including the project detailed in our white paper: MAKING THE IMPOSSIBLE POSSIBLE WITH SENSOR-GUIDED ROBOTICS. Because of our experience and reputation for delivering our clients systems that can identify their different parts, and intuitively know what to do with the parts, we knew we could deliver this particular solution.

Navus’ system was able to automatically overcome the variable tolerance stack ups in materials and assembly without the need for operator intervention or input. Due to Navus’ depth of knowledge in control system’s architecture, we were able to recreate a production cell that our client was familiar with. We weren’t trying to make their new system fit in their existing floorspace. We simply took the concept of what was already there, made it infinitely better, and integrated it into their facility seamlessly.

The ultimate result? Dramatically improved production rates and reliable part consistency to the downstream process. It was an easier system for operators to manage because it didn’t produce inconsistencies, slow production down with stalled time, or require constant tweaks and manual operation. Now all the operators have to do is oversee that the system is doing what it’s supposed to.

Automation Integration is Considering the Big Picture

When Navus goes to solve a challenge for a client through automation integration, we look at the big picture. We ask ourselves how the process we’re creating for you is going to work with the rest of your facility. Our solutions are built to communicate with the rest of your manufacturing process, and fit into the space you already have.

We promise to deliver solutions that work, and we don’t end the relationship once the process has been delivered. We pride ourselves on our client relationships and love to find other ways we can solve the challenges our clients face. 

Navus’ ability to solve your challenges ultimately comes down to our team and history of excellence. Every one of our engineers is passionate about solving specific challenges for our clients who partner with us. We’re dedicated to thinking outside of the box to ensure our turn-key system solutions accomplish what you need and solve the challenges you face. From electrical and controls system engineering to automation integration, and everything in between, we promise to partner with you in all aspects possible. When you choose to partner with us for your integration needs, you become a part of the Navus family.

Navus Automation, Inc., is a leading full-service automation integrator. Our world-class team has a reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions. From concept to completion, Navus provides robotic welding and automation systems built upon our unwavering commitment to excellence, precision, and reliability.

For more information on how our team can help you solve complex challenges in your manufacturing facility, reach out to us today!

Proof of Concept rendering

Proof of Concept: The Evidence of Simulation & Demonstration

Navus

Recently we were reminded of how wonderful it is to work with returning customers. A client we regularly work with in medium industry manufacturing had a multi-step system in their facility that cost them hundreds of thousands of dollars to accurately produce manufactured parts. Our engineers thought outside the box, allowing us to brainstorm and come to them with a brand new system that solved their problem with just one additional robot, rather than needing to purchase and integrate large, dedicated equipment

 

When we partner with you, we don’t just deliver a one-and-done solution. Our delivered solutions open up endless opportunities for your business. We achieve this by proposing solutions others haven’t considered. 

 

But proving our ability to deliver a comprehensive solution goes beyond a proposal. At Navus. we have the capability to deliver a proof of concept for many of the proposals we offer a client. With a proof of concept, we don’t have to try to convince you that our ideas will work. We show you our solutions in action.

What is Proof of Concept?

At Navus, we provide renderings and visuals when we engineer a solution so you can envision what we have in mind. But in order to actually test the solution, we encourage all clients to consider a proof of concept. This is an important step in any proposed integration solution as it allows the actual solution to be built at a smaller scale so we can show the system in action.

 

Navus uses state-of-the-art offline programming and simulation software to determine the feasibility of an idea. This happens before the first part is ever cut, fabricated, machined, or coated. This serves to further mitigate risk before building even small-scale test setups, whether to verify cycle time or ensure proper robot reach and accessibility.

 

If our proposed solution solves the challenges it’s supposed to during the proof of concept phase, then we move forward with building the solution to scale. However, if any part of it fails during the proof of concept phase, we go back to the drawing board. We refuse to deliver a system that is going to make your life harder or potentially fail once integrated in your facility.

Proof of Concept and the Confidence of a Complete Solution

Investing in a new integrated system for your facility shouldn’t go to waste. Innovative ideas can be discussed and proposed, but if they fail during the proof of concept phase, they’re not actual solutions for your needs. At Navus, we’re dedicated to perfecting any solution we propose during the proof of concept phase in order to save you headaches and cost when completing the final system. 

 

When our client was open to the idea of developing our proposal into a proof of concept, the initial investment was a fraction of the total system cost, and ultimately went a long way in saving them money. We were able to pull most of the parts for the proof of concept from inventory we already had onsite. This allowed us to bring our vision to life without ordering expensive parts prior to integrating the proven solution. This live demonstration was a small investment on our client’s part, but the return gave them so much more. It gave them a solution they could trust.

What Did Proof of Concept Provide For Our Client?

When you’re looking for a solution to a challenge, the last thing you want to do is waste time, money, or resources. Proof of concept testing may seem like an extra step, but it’s one worth taking. Testing a proposed solution every way possible can save you from wasting more time and money down the road if a solution isn’t properly examined.

 

The proposal we gave our client took a multi-system process they already had and required in their facility, and compacted it into one system using robotics. This solution uses flexible robotics fitted with reusable tooling and inexpensive fixtures that can be used for multiple different parts manufactured in our client’s facility. 

 

By using our in-house 6-axis industrial robots, PLCs, end of arm tooling, laser scanning/searching technology, force compliant grinding technology, welding capabilities, and custom programming, we built a smaller scale version of our proposed solution. Our client watched the proposal come to life through both simulation and demonstration, giving them the reassurance they needed to move forward with implementation.

Engineering the Smartest Automation Solutions Since 1998

Navus’ ability to solve your challenges ultimately comes down to our team and history of excellence. Every one of our engineers is passionate about solving specific challenges for our clients who partner with us. At Navus, we don’t resort to generic solutions. We’re dedicated to thinking outside of the box to ensure our turn-key system solutions accomplish what you need and solve the challenges you face. Proof of concept is just one way that we provide assurance to every client who hires us that their challenges are solved. 

 

Partnering with Navus isn’t just about figuring out a solution for your current challenges. Like this particular project shows, we promise to go beyond an initial proposal and offer new ideas and solutions that create a better future for your manufacturing space and company throughout our partnership. When you choose to partner with us for your integration needs, you become a part of the Navus family.

 

Navus Automation, Inc., is a leading full-service automation integrator. Our world-class team has a reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions. From concept to completion, Navus provides robotic welding and automation systems built upon our unwavering commitment to excellence, precision, and reliability.

 

For more information on how our team can help you solve complex challenges in your manufacturing facility, reach out to us today!

Rebuilding Results in Peak Efficiency

Back to the Future With Navus

Navus

Navus has been envisioning a future for our clients since 1998. The majority of our clients are repeat customers, no matter the scale of their industry or our project. When we partner with a client, we don’t just deliver a system and then say goodbye. We deliver new ideas that lead to greater opportunities for our clients’ businesses. In a way, our clients have become an important part of the Navus family, and we love any opportunity to continue working with them.

We recently had the rare opportunity to work with a customer on a machine we originally built for them 15 years ago! The machine was used on a consistent basis over the past 15 years to manufacture small parts in the medical industry, but it was clear they needed to either design a new machine or update the current one to meet their latest needs. Our team at Navus worked with our client to find the best solution for their needs. The result was our ability to revisit a piece of our company’s history, while solving a challenge for a valued client.

Should You Rebuild Your Current Machine? Or Invest in a New Machine?

Working in industrial manufacturing comes with a host of challenges and complexities on a regular basis, but our priority is always to find the perfect solution for your company. 

When our client came back to us after 15 years of happily using the machine we originally built them, they came with a dilemma. 

The machine they had used for the past 15 years to produce small parts for the medical industry worked the way they wanted it to. It produced legacy parts that are still relevant today, but there have also been important shifts and changes in the manufacturing world over the past 15 years. Our client wanted to know whether they should rebuild their current machine, or start over and invest in a new machine.

At Navus, we don’t just solve problems for our client — we partner with them to find the best solution for their needs. To solve our client’s dilemma, we started with a thorough evaluation of their current system. In order to make strong recommendations on their next step forward, we needed to understand the capacity at which they were currently operating, and what their goals for any future system would be. 

Once our evaluation was complete, we delivered a detailed report weighing the costs and benefits of rebuilding their original machine versus building a completely new system. We’ve historically taken meticulous notes of how our solutions and systems are engineered. Referencing these detailed notes while we were evaluating our client’s system ultimately helped our client understand which option would work best for their goals.

Rebuilding Results in Peak Efficiency

The machines and systems that are on the production floor are an investment, and you want to invest in the systems that are going to bring you the best results. Our team’s initial step to evaluate our client’s current system ensured that we were considering the best outcome from multiple perspectives. 

Our clients ultimately chose to rebuild the machine we previously built for them. They knew the system worked the way they needed it to, and it would only take a few updates to bring the machine in line with the 21st century.

From start to finish, the entire project was completed in 3 months. The end result was a machine rebuilt to exceed the original specifications, returned to our client in just a few weeks from starting the rebuild process. The new version of their machine runs at peak efficiency and continues to produce legacy products. Our client won’t have to worry about rebuilding or replacing this machine for years to come. It now does exactly what they need it to do, but even faster than before.

Engineering the Smartest Automation Solutions Since 1998

Navus’ ability to solve our clients’ challenges ultimately comes down to our team and history of excellence. Every one of our engineers is passionate about solving specific challenges for our clients who partner with us. At Navus, we don’t resort to the same solution other integrators offer. We’re dedicated to thinking outside of the box to ensure our turn-key system solutions accomplish what our competitors haven’t considered. 

Partnering with Navus isn’t just about figuring out a solution for your current challenges. We promise to offer new ideas and solutions that create a better future for your manufacturing space and company. 

Navus Automation, Inc., is a leading full-service automation integrator. Our world-class team has a reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions. From concept to completion, Navus provides robotic welding and automation systems built upon our unwavering commitment to excellence, precision, and reliability.

For more information on how our team can help you solve complex challenges in your manufacturing facility, reach out to us today!

Not All Integrators Are The Same: How Navus’ Programming Makes Us Stand Out Above Others

Navus

We don’t have to tell you about the challenges and complexity of making the different systems in your facility communicate and work together. If you find managing line production day-to-day feels more like a nightmare than the smooth process it should be, you may be partnered with the wrong automation integrator. Choosing the right automation integration partner makes all the difference in how well your systems run, their impact on your day, and the future growth of your company.

No matter what challenge you’re facing in your facility, different automation integrators will always come up with different ways to resolve your challenges. When choosing a partner, it comes down to choosing the smartest solution possible for your company. Integration isn’t just about solving your current challenge, it’s also about looking to the future and seeing possibilities for the success of your business that your current integration partner may not have considered. 

Our team at Navus has proven we stand out above other integrators with our knack for seeing what others didn’t, and applying ingenuity to not only solve immediate complex challenges for our clients, but also to think towards the future and how our turn-key systems can provide intelligent solutions that consider future challenges your company may face. In this blog series we explore how the work that we’ve done sets Navus apart from other integrators.

Additive Manufacturing With Metal Alloy

Additive manufacturing has taken the world by storm in the last several years. While it’s been around since the 1980s, it’s become more of a practical choice for manufacturers as the concept has gotten more advanced, and demand for a manufacturer’s products has increased past the traditional modes of manufacturing. 

A client recently approached us with the need for a robotic gantry that could handle additive manufacturing of 3D metal alloy objects in medium and heavy industry settings. The objects themselves needed to be made with multiple different metal alloys. They essentially needed an industrial 3D printer that could switch between materials seamlessly.

Our client needed a new robotic gantry that could work with one they currently owned. In addition, they needed new, custom software that could anticipate all of their needs and keep both gantries calibrated and working correctly. 

Custom Software for a Robotic Gantry

A robotic gantry without the right software is similar to buying a computer without an operating system. It’s a machine that can accomplish marvelous things, but without the right programming, it’s nothing but an elaborate shell. It was crucial that our client have new custom software to keep both gantries, their current gantry and the one we were building, coordinated. 

Building custom software that integrates existing processes and equipment, which may have been built by a different integrator, and new processes and equipment is a daunting task. The new process merged both gantries together across 13 different axes and kept everything working together within a tolerance of 1mm of welding wire. The intricacy and complexity of what was required of this software was a daunting task. But it wasn’t too daunting for our engineers. 

The end result of this project was a brand new process that combined the old with the new and unique. Our newly built robotic gantry was put on the same track as the one already in place. Our custom software ensured the entire system was calibrated so all 13 axes worked together seamlessly within 1mm of welding wire, and that the robot knew where everything was within a 3D space at all times.

The additive manufacturing process we created could use multiple metal alloys within the same part, allowing our client to create objects with one kind of metal on the inside, and a different one on the outside, or a combination of different metals in different parts of the object. This is something made completely possible through additive manufacturing that could never be achieved through a traditional casting process. 

How Did We Do It?

Our client wanted an addition to their gantry so they could do consistent additive manufacturing with metal alloy in their facility, but they also needed a custom software that kept the robotic gantry our team created working properly.

The biggest challenges we faced were ensuring that axes were coordinated to work together, and blending the real world with the 3D printing world. Both required an enormous amount of calibration and testing.

The system we designed:

  • Gave our client the capability to print 3D parts with metal alloys
  • Kept all of the axes calibrated so they could use the system without fear of it failing 
  • Programmed the robot so it knows where everything is within the 3D space of the gantry
  • Allowed our client to create 3D objects made from multiple types of metal materials

The result? With this new process, our client is able to print objects using metal alloys. If you’re curious how we could help you and your company in a similar way, contact a member of our team today!

Why Are Navus’ Solutions Smarter Than Other Automation Integrators’ Solutions?

It all comes down to our team at Navus. Every one of our engineers is passionate about solving specific challenges for every single one of our clients who partners with us. Our experience, ability to think outside of the box, and passion make all of the difference in ensuring our turn-key system solutions accomplish what other automation integrators can’t. Partnering with Navus isn’t just about figuring out a solution for your current challenges. With every client we partner with, we promise to bring new ideas and solutions to the table that create future possibilities for your manufacturing space, and the future growth of your company. 

Navus Automation, Inc., is a leading full-service automation integrator. Our world-class team has a reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions. From concept to completion, Navus provides robotic welding and automation systems built upon our unwavering commitment to excellence, precision, and reliability.

For more information on how our team can help you solve complex challenges in your manufacturing facility, reach out to us today!

Turn-Key Systems Solution At Its Finest

Not All Integrators Are The Same: How Navus Created Something New Out of Pre-Existing Systems

Navus

We don’t have to tell you about the challenges and complexity of making the different systems in your facility communicate and work together. If you find managing line production day-to-day feels more like a nightmare than the smooth process it should be, you may be partnered with the wrong automation integrator. Choosing the right automation integrators makes all the difference in how well your systems run, their impact on your day, and the future growth of your company.

No matter what challenge you’re facing in your manufacturing facility, different automation integrators will always come up with different ways to resolve your challenges. When choosing a partner, it comes down to choosing the smartest solution possible for your company. Integration isn’t just about solving your current challenge, it’s also about looking to the future and seeing possibilities for the success of your business that your current integration partner may not have considered. 

Our team at Navus has proven our ability to stand out above other integrators with our knack for seeing what others didn’t, and applying ingenuity to not only solve immediate complex challenges for our clients, but also to think towards the future and how our turn-key systems can provide intelligent solutions that consider future challenges your company may face. In this blog series we explore how the work that we’ve done sets Navus apart from other integrators.

Turn-Key Systems Solution At Its Finest

This particular client had worked with other automation integration companies before working with us at Navus. The systems these other integrators had created were okay, in the fact that they did the job they were supposed to do, but their solutions were broken up into different processes and systems that weren’t serving the client well. 

Our team was able to take what our client’s former integration partner had done and turn it into an innovative, singular process that takes up minimal space on their manufacturing floor, and opened up endless possibilities for the future of automated systems in their manufacturing facility.

How Did We Do It?

Navus came in and picked up the pieces that other integration companies had left behind. All of the separate systems worked fine, but they created more complexity and challenges for our client’s daily life than they needed to. The finer touches our team engineered turned these pre-existing systems into a more robust and consistent solution for our clients that accomplished multiple processes from beginning to end in just one, singular system. This project is the perfect example of just how much we can do at Navus through robotics and programming. 

Our client needed a system that could trim and expand specific parts they manufacture. The process itself was complex, requiring the system to locate and identify different tools, as well as identify how and when to use each tool in the trimming and expansion process. With their previously engineered solutions, our clients relied on robots having to be programmed for each separate part, and then prompted to do each separate piece. Ultimately this cost time and money that didn’t need to be wasted.

Navus engineers programmed the single robot in the system to search and identify different parts and tools. The robot was also calibrated to use each tool for specific tasks in the manufacturing process, without having to program the robot for all of the different parts, or separate the different steps into different line layouts. Our solution took what were traditionally separate systems in a manufacturing facility and transformed it into one cohesive, consistent, and reliable solution for the client. This solution didn’t just solve their immediate problem, but it created an opportunity for them to assess how their other integrated solutions might be optimized.

Why Are Navus’ Solutions Smarter Than Other Automation Integrators’ Solutions?

It all comes down to our team at Navus. Every one of our engineers is passionate about solving specific challenges for every single one of our clients who partners with us. Our experience, ability to think outside of the box, and passion make all of the difference in ensuring our turn-key system solutions accomplish what other automation integrators can’t. Partnering with Navus isn’t just about figuring out a solution for your current challenges. With every client we partner with, we promise to bring new ideas and solutions to the table that create future possibilities for your manufacturing space, and the future growth of your company. 

Navus Automation, Inc., is a leading full-service automation integrator. Our world-class team has a reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions. From concept to completion, Navus provides robotic welding and automation systems built upon our unwavering commitment to excellence, precision, and reliability.

For more information on how our team can help you solve complex challenges in your manufacturing facility, reach out to us today!

Sensor-Guided Robotics Handling Multi-Ton Parts?

Not All Integrators Are The Same: How Navus Saw What Others Couldn’t

Navus

We don’t have to tell you about the challenges and complexity of making the different systems in your facility communicate and work together. If you find managing line production day-to-day feels more like a nightmare than the smooth process it should be, you may be partnered with the wrong automation integrator. Choosing the right automation integrators makes all the difference in how well your systems run, their impact on your day, and the future growth of your company.

No matter what challenge you’re facing in your manufacturing facility, different automation integrators will always come up with different ways to resolve your challenges. When choosing a partner, it comes down to choosing the smartest solution possible for your company. Integration isn’t just about solving your current challenge, it’s also about looking to the future and seeing possibilities for the success of your business that your current integration partner may not have considered. 

Our team at Navus has proven our ability to stand out above other integrators with our knack for seeing what others didn’t, and applying ingenuity to not only solve immediate complex challenges for our clients, but also to think towards the future and how our turn-key systems can provide intelligent solutions that consider future challenges your company may face. In this blog series we explore how the work that we’ve done sets Navus apart from other integrators.

Sensor-Guided Robotics Handling Multi-Ton Parts?

A couple of years ago we gained a client in a nontraditional way because of our ability to think of the smartest way to solve challenges. Their facility manufactured multi-ton parts, and they wanted to automate a part of the process that had historically been done manually by employees. They required a machine that could automatically locate and identify one of their heavy parts by recognizing its shape and features, create a tool path for the part, and mill all sharp edges to a close-tolerance radius, all while ensuring downstream processing success using robotic programming. 

Our client hired a different integration team before they approached us, but the system that their first integration partner engineered failed when it actually came to programming a robot to locate and identify each part before milling the sharp edges. Our client recognized that this was a central part of the solution they needed, and reached out to us for a second opinion. Our entire team was confident we could engineer a solution and we put our heads together to figure out how to accomplish what seemed impossible to accomplish.

How Did We Do It?

Whatever system and machine we developed needed to account for fluctuation in size and weight of our client’s manufactured parts. Part positioning tolerances and dimensional variations can decrease productivity, causing high rejection rates and downtime in industrial robotic applications, and we wanted to avoid those roadblocks at all cost. Our machine needed to consistently deliver a part at the end of the tool path that has been measured with all sharp edges milled into a precise radius in less than an hour from start to finish, with no need for manual manipulation.

Robotics were our best friend when it came to solving this particular challenge. Our team utilized experience and ingenuity to create a system that could: 

  1. Find and measure a particular part
  2. Write a program for itself based on the position of the edges of the part
  3. Automatically grind edges to a precise radius 

The result of our ingenuity was a multi-faceted machine that accomplished all of our client’s intended goals. The process we engineered utilized sensor guided robotics, automatic tool path generation from sensor inputs, automatic robot program generation, and custom designed material handling equipment to reliably move and precisely position very heavy materials. Our clients required the process to take under an hour in order to be more efficient, and our machine accomplished the entire process beginning to end in only 25 minutes. 

Our team’s ability to think outside of the norm for robotics and programming solved a problem that seemed nearly impossible for our client. We took what other automation integrators failed at and turned it into a solution that went above and beyond what our client expected. Read more of the specifics about how we solved their challenges by downloading our recent white paper.

Why Are Navus’ Solutions Smarter Than Other Automation Integrators’ Solutions?

It all comes down to our team at Navus. Every one of our engineers is passionate about solving specific challenges for every single one of our clients who partners with us. Our experience, ability to think outside of the box, and passion make all of the difference in ensuring our turn-key system solutions accomplish what other automation integrators can’t. Partnering with Navus isn’t just about figuring out a solution for your current challenges. With every client we partner with, we promise to bring new ideas and solutions to the table that create future possibilities for your manufacturing space, and the future growth of your company. 

Navus Automation, Inc., is a leading full-service automation integrator. Our world-class team has a reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions. From concept to completion, Navus provides robotic welding and automation systems built upon our unwavering commitment to excellence, precision, and reliability.

For more information on how our team can help you solve complex challenges in your manufacturing facility, reach out to us today!

Why Are Navus’ Solutions Smarter Than Other Automation Integrators’ Solutions?

Not All Automation Integrators Are The Same: How Navus Engineered What Didn’t Exist

Navus

We don’t have to tell you about the challenges and complexity of making the different systems in your facility communicate and work together. If you find managing line production day-to-day feels more like a nightmare than the smooth process it should be, you may be partnered with the wrong automation integrator. Choosing the right automation integrators makes all the difference in how well your systems run, their impact on your day, and the future growth of your company.

No matter what challenge you’re facing in your manufacturing facility, different automation integrators will always come up with different ways to resolve your challenges. When choosing a partner, it comes down to choosing the smartest solution possible for your company. Integration isn’t just about solving your current challenge, it’s also about looking to the future and seeing possibilities for the success of your business that your current integration partner may not have considered. 

Our team at Navus has proven our ability to stand out above other integrators with our knack for seeing what others didn’t, and applying ingenuity to not only solve immediate complex challenges for our clients, but also to think towards the future and how our turn-key systems can provide intelligent solutions that consider future challenges your company may face. In this blog series we explore how the work that we’ve done sets Navus apart from other integrators.

Seamless Integration & No Line Layout Changes

One of the most unique client challenges we’ve helped resolve to date was a modular machine for the assembly of small parts. The machine needed to handle a 26-step manufacturing process contained in the single, modular machine. Our client had pre-existing systems that built these particular parts in their manufacturing facility, but the legacy systems were not able to produce fast enough to meet the demanded volume of manufactured products. They needed additional systems to decrease production time for orders that followed the same general manufacturing steps, but that could be contained within a small footprint of the manufacturing floor. 

The system that Navus proposed did more than just solve our client’s initial challenge. It opened up a new world of possibilities for the future of their manufacturing facility and production times that translates directly to the growth of their business.

The end result of this project was a machine that assembled parts faster than our client could have imagined, without taking up extra space on the manufacturing floor. The design and programming of the machine itself created a platform for which all of their future line layout can be accomplished without the need to change manufacturing floor space requirements—and in fact, free up more manufacturing floor space to include new lines as their business grows.

How Did We Do It?

One of our client’s main goals was to utilize automation to achieve a faster production time. The goal for each part of the automation process was to be completed under 2.5 seconds. But the automation system had to be flexible in order to account for multiple variations in the product. On top of this, our client wanted to affordably automate the assembly process inline with existing equipment without changing their facility’s floor plan.

For this system’s automation application, we needed to create a machine cased within a custom safety enclosure that also featured an in-feed conveyor system with part escapements, a label application system, a height inspection sensor, nail feeding and insertion systems, a part nest tooling system, an operator control panel, and an out-feed conveyor system.  

We did it all with the use of a flexible robotic automation process contained within one modular machine. 

Instead of the traditional approach of using multiple robots programmed for different steps of the assembly process down a long assembly line, our engineers’ solution used a robot’s ability to do multiple functions in the assembly process to make our client’s desires a reality.

The turn-key systems solution we designed:

  • Automated the label application process
  • Inspects and verifies the height of certain parts
  • Feeds nails into the correct spot
  • Nests boxes together
  • Provides a robotic quality check (and disposes of faulty parts)
  • All contained in one modular machine that took up minimal floor space in our client’s facility

The result? With this new process, our client was able to produce 24 individual, finished parts within one minute, increasing their capacity for production without the need to change manufacturing floor space requirements. For more details about this particular project, check out our recent visual case study!

Why Are Navus’ Solutions Smarter Than Other Automation Integrators’ Solutions?

It all comes down to our team at Navus. Every one of our engineers is passionate about solving specific challenges for every single one of our clients who partners with us. Our experience, ability to think outside of the box, and passion make all of the difference in ensuring our turn-key system solutions accomplish what other automation integrators can’t. Partnering with Navus isn’t just about figuring out a solution for your current challenges. With every client we partner with, we promise to bring new ideas and solutions to the table that create future possibilities for your manufacturing space, and the future growth of your company. 

Navus Automation, Inc., is a leading full-service automation integrator. Our world-class team has a reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions. From concept to completion, Navus provides robotic welding and automation systems built upon our unwavering commitment to excellence, precision, and reliability.

For more information on how our team can help you solve complex challenges in your manufacturing facility, reach out to us today!

White Paper: Making the Impossible Possible with Sensor-Guided Robotics

Navus

Navus has always been known for our ground-breaking welding work, but did you know that we specialize in a range of industry-specific custom automation? Over the years we’ve helped countless clients realize the potential for their business to grow faster and stronger through automated processes. In heavy-industry manufacturing, custom automation can be especially beneficial. 

White Paper: Transforming Medium-Industry Manufacturing Through Vision-Guided Robotics and CAD to Path Generation

Navus

Automation using robotics isn’t a new concept in the world of manufacturing, but many industries are still discovering robotics’ endless possibilities. Medium-industry manufacturing is associated with automotive, aluminum die casting, and durable goods, but residential construction falls into the same category. Building a prefabricated residential structure may seem like it’s a heavy-industry project, but it’s really a lot of medium-industry pieces combined to create one finished product, much like a car.

The latest free white paper we’ve published features a medium-industry project that introduced automation to the featured clients’ facility. Our client had historically had their employees manually measure and cut all of the floorboards needed for a prefabricated residential building. The issue with a manual process lies in the room for human error. Each floorboard piece had different required measurements in order to match the layout of multiple building plans. Employees at their manufacturing facility measured, cut, and organized each floorboard with their own hands. Our clients knew there had to be a more efficient and precise way to complete this part of their process.

Our engineers are always excited to design a new process for a client, but this project was particularly exciting. Our clients had no other automated processes within their facilities. The process our engineers designed would be the first for the entire company. 

Our clients needed a process that could translate building plans from two dimensional CAD drawings to finished floorboards, cut, stacked, and organized in order of their use in the downstream process. The automated system required vision-guided robotics, custom software, and adaptability with minimal input from an operator.

Though the project seemed complicated, our engineering team knew they could design a system that met all of our clients’ needs, as well as delivering faster production times and decreased safety risks for employees within their facility. The result of our engineers’ expertise was an easy-to-use-system that integrated with their other processes to deliver finished products faster than they thought possible.

In this free white paper, you’ll discover how this custom, adaptable system:

  • Decreases safety risks to employees through remote operation
  • Creates more revenue through increased throughput
  • Saves time and money through decreased production time
  • Eliminates the possibility of human errors with precise measurements translated with robotics and custom software to result in cut, organized floorboards

To discover more about how Navus engineers used vision-guided robotics to design a custom automation process that worked for our client’s needs, you can read all about it in the free white paper, Transforming Medium-Industry Manufacturing Through Vision-Guided Robotics and CAD to Path Generation.

Navus Automation Inc. is a leading full-service automation integrator. Our world-class team has a reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions. From concept to completion, Navus provides robotic welding and automation systems built upon our unwavering commitment to excellence, precision, and reliability

DOWNLOAD NOW

Visual Case Study: Custom Automation for Dynamic Productivity in Light Industrial Manufacturing

Navus

At NAVUS we develop and design projects of all scales and levels. Sometimes the projects we do are focused on achieving a process design that seemed impossible for our clients due to complexity or scale. Our engineers excel at tasks and projects that take a complicated process and streamline it to suit your company’s needs. 

Recently we acquired a client that already had automated processes within their facility for the production of a particular product, however, their downstream process required these products to change orientation in order to be packaged correctly without associate intervention. Our engineers were given specific goals, materials, and space to work with in order to create the custom automated process and integrate it with existing processes within our client’s manufacturing facility. Not only did we have very specific parameters, but the product itself was complicated. Our client needed assembly of multiple components to be accomplished within the space they dedicated to our process. The finished process would have to be dynamic in multiple ways.

To complete this project, our engineers needed to:

  • Design an automated process that integrated with existing processes within our client’s manufacturing facility
  • Keep the footprint of the process small, meaning multiple stages of assembly had to happen in the same process enclosure
  • Ensure that the process could nest multiple parts precisely together to comply with downstream packaging systems

The finished process was proposed to produce 24 parts per minute with the supervision of only one operator. These specific guidelines and requests from our client were definitely different from the projects we typically highlight:

  • The scale of the product itself is smaller than the products and parts we typically engineer custom automation processes for
  • The variables we had to keep in mind while designing and engineering the process made it a much more complex project
  • The finished process needed to work with other processes in the facility, but we could still make it something completely unique for our client

All of the variables and complexity presented an intriguing and unique project for our engineers to navigate. Together with our valuable vendors, we designed an automated process that worked and looked more refined than our clients could have imagined. To discover more about how Navus engineers used robotics to design a custom automation process that worked for our client’s needs, you can experience it all through our free visual case study, Custom Automation for Dynamic Productivity in Light Industrial Manufacturing, by clicking here to download.

Navus Automation Inc. is a leading full-service automation integrator. Our world-class team has a reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions. From concept to completion, Navus provides robotic welding and automation systems built upon our unwavering commitment to excellence, precision, and reliability.

DOWNLOAD NOW

1 2 3