Bumper Assembly Station

Repeated placement by an operator of multiple different features in the bumper area can lead to inconsistent and incorrect assembly. FiXar developed a Poka-Yoke assembly station with integrated vision systems that perform a quality inspection after each assembly step.

Poka-Yoke Assembly Station with integrated Vision Systems

For this automotive application, FiXar developed a flexible assembly and quality control station for a Tier 1 supplier, designed to handle multiple bumper variants within a single workstation.

Different bumper models required different colors, feature combinations and assembly sequences. FiXar engineered one modular station capable of processing 95% of product types while ensuring correct assembly and full traceability throughout the process. Through an intuitive HMI interface, the operator is guided step-by-step through the required assembly process for each specific product variant.

After assembly, integrated vision cameras and smart sensors perform a complete quality verification of the bumper and all assembled features. The system automatically generates an OK or NOK result and identifies any incorrect or missing assembly operations before the product can be released to the OEM.

Results

One flexible station for multiple bumper variants
Full product traceability through barcode handling
Reduced assembly errors and operator dependency

FRequently asked questions

Why was the assembly process automated?

The assembly was originally performed without operator guidance and a visual inspection leading to variations in both quality and process stability. Guiding and controlling the process ensures consistent assembly and improves overall process stability.

How did the light effect the vision camera's?

The vision cameras are sensitive to direct sunlight, while standard LED lighting does not affect system performance. Because the station was installed directly beneath a factory skylight, FiXar designed and enclosed the station to shield the vision system from ambient sunlight and ensure stable, reliable inspection results.

In which industry was this solution applied?

This automation solution was developed for an automotive application, where process stability, short cycle times and repeatability are critical.

Can this type of automation be applied to other processes?

Yes. Assembly Stations can be used for various production processes. FiXar develops each solution based on the specific process and production environment.

How can we help you?

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