Industry
Consumer products, juvenile car seats.
Customer story · Consumer products
Dorel and Senzer: complex assembly made accessible to every operator.
Senzer, a social employment organization, assembles Maxi-Cosi Rubi car seats for Dorel Juvenile. Arkite guides each step, controls every screw through smart tool integration and allows operators to take on more complex work.
Last updated
At a glance
Project summary
Process
Maxi-Cosi Rubi assembly, picking and screwing.
Setup
One Arkite 3D sensor unit and one projector.
Integration
Atlas Copco smart tooling, fixture interlock.
The challenge
Efficiency and inclusion in the same process
Senzer is a social organization that employs people with varying degrees of physical, mental or language limitations, while operating with a clear focus on efficiency and cost. That combination shaped every task design decision.
Tasks had to be kept as simple as possible, with a maximum takt time of 60 seconds. Extensive quality controls were built into the workflow, and line managers had to intervene frequently because of screw-related errors that led to rework or scrap.
The solution
Guidance, tool control and a defined recovery path
Senzer deployed Arkite for the Maxi-Cosi Rubi assembly. Arkite projects picking and assembly guidance onto the workstation, so each operator sees what to pick and where to work at every step.
The platform is integrated with Atlas Copco smart tooling to control the sequence, presence and torque of every screw. The assembly only starts once the product is mechanically locked in the fixture. When a screw error does occur, Arkite runs a defined rework or scrap procedure based on the type of mistake.
Applied capabilities
- Projected picking and assembly guidance
- Smart tool integration for screw sequence, presence and torque
- Fixture interlock: assembly starts only when the product is locked
- Rework or scrap procedure per type of screw error
- Guidance that lets operators take on more complex tasks
Implementation
How a car seat moves through the station
- 01
Lock the product
The seat is mechanically locked in the fixture. Only then does the guided process start.
- 02
Pick and assemble
Projections guide the operator through picking and each assembly step.
- 03
Tighten with control
The smart tool is guided through the screw sequence, and presence and torque are checked for every screw.
- 04
Handle deviations
If a screw error occurs, the platform guides the operator through the matching rework or scrap procedure.
Results
What Senzer achieved
Rework and scrap eliminated
Real-time guidance and smart tool integration eliminated rework, scrap and faulty products, with cost savings and higher product quality as a result.
Broader operator skills
Operators can now perform different and more complex tasks than before, which reduced training time and increased their multi-employability.
Five workstations become three
The reduction in takt time improved line efficiency and allowed Senzer to consolidate five workstations into three.
Guidance at the workstation widens the range of work each operator can do, without lowering the quality standard.
Make complex work accessible to more operators
See how Arkite adapts guidance to each operator while keeping quality under control.