Design Solution for Brake Line Insert Assembly

The project proposes a design solution to address a quality issue in brake line assembly due to human error in a supplier's manual production process. The solution aims to eliminate human error, support high production volumes, and meet expectations of both Company X and its supplier. The objective of this project is to develop a production system that increases the accuracy of brake line sealing insert assembly, reduce the cycle time of the assembly process, improve the consistency and quality of the assembled products, minimize human error and enhance workplace safety. The design process starts by assessing existing manual assembly process to identify areas of human error and inefficiencies. This is followed by defining key requirements for the automated system through customer consultations. Three concepts are then created from which the final design is selected. The next step is the creation of a detailed design using CAD programs where technical drawings and bill of materials are generated. The key findings from the implementation of the automated brake line sealing insert assembly system revealed significant improvements in several areas. Cost savings will be realized through reduced labour dependency and minimized errors. Automation enhanced workplace safety by eliminating the risks. The automated brake line sealing insert assembly system has shown significant improvements in several areas, including cost savings, reduced labour dependency, and improved workplace safety by eliminating manual handling risks. The implementation of an automated brake line assembly process addresses human error issues, improving precision and ensuring consistent quality at scale, enabling Company X to meet growing production demands and maintain high-quality standards.