Industry
Automotive supplier, bumper assembly.
Customer story · Automotive
WCA-Alro: market-specific bumper variants without drilling errors.
At its bumper assembly facility in Genk, Belgium, WCA-Alro uses Arkite to guide drilling, picking and assembly for every variant and to confirm each completed task digitally instead of on a paper checklist.
Last updated
At a glance
Project summary
Process
Drilling, picking, assembly and tooling for many variants.
Setup
Two 3D sensors and two projectors.
Integration
PC and internal network for planning and checklist confirmation.
The challenge
Variants multiplied by market, sensors and grilles
WCA-Alro assembles bumpers in Genk. The position of the license plate holes depends on the target market (US, EU or JPN). Combined with different sensors, grilles and other components, this resulted in a large number of product variants.
The process involves picking and placing many components, each a potential source of error. On top of that, the customer required a physical checklist for process confirmation, which took time and effort without providing useful insight.
Problems to solve
- Drilling locations that change per target market
- Many variants from combinations of market, sensors and grilles
- Correct picking and placement of numerous components
- Paper checklists that added work but no insight
The solution
Full process guidance with digital confirmation
WCA-Alro deployed Arkite across all assembly workstations at the facility, covering the entire process: component picking, drilling and assembly steps, and tooling requirements. Operators receive real-time visual instructions and alerts for the variant they are building.
Arkite connects with the facility's PC and internal network for planning and checklist confirmation. When an assembly task is completed, the confirmation is recorded automatically, which replaces the physical checklist while still demonstrating process compliance.
Implementation
How the stations are set up
- 01
Variant input
Planning information reaches the workstation through the internal network.
- 02
Guided drilling
Projections show the drilling locations for the target market of the bumper being built.
- 03
Picking and assembly
Two 3D sensors and two projectors guide component picking, assembly and tooling.
- 04
Automatic confirmation
Completed tasks are confirmed digitally, replacing the paper checklist.
Results
What WCA-Alro achieved
Drilling, picking and assembly errors eliminated
Real-time guidance and alerts eliminated these errors and improved assembly quality and consistency.
Less rework and scrap
Rework and scrap caused by human error, such as wrong picks and incorrect assembly, decreased.
Fewer faulty products delivered
Higher accuracy reduced the number of faulty products delivered to customers.
No more paper checklists
Automated checklist confirmation removed administrative work while maintaining process compliance.
Control variant complexity at the workstation
See how Arkite guides each variant and records completion without paper.