FiXar designed and built a dedicated assembly table for the efficient and error-proof assembly of Truck fillerpieces. The workstation supports four product variants (LH/RH with plug or extension), combining integrated quality verification, and Poka-Yoke principles to ensure consistent assembly quality.
For this project, FiXar developed a custom assembly workstation for the manual assembly of Truck fillerpieces. Designed as a compact, plug-and-play solution, the station enables operators to assemble four different product variants—left-hand and right-hand fillerpieces, each available with either plugs or an extension part—in a single ergonomic workstation.
The assembly table is built on a robust aluminium profile frame and features dedicated left- and right-hand product fixtures with integrated Poka-Yoke functionality to eliminate incorrect part positioning. Manual clamping with sensor feedback confirms correct fixture loading before assembly can continue, while a barcode-driven workflow guides the operator through the appropriate assembly sequence for each product variant.
To guarantee first-time-right production, FiXar designed dedicated checking fixtures equipped with multiple sensors that verify the presence of plugs, screws, sealing profiles, and connection pieces before the product is released. The verification results are transmitted directly to the customer’s PLC, allowing immediate detection of any assembly deviations and preventing non-conforming products from progressing further in the production process.
The workstation is completed with integrated LED lighting, storage for the checking fixtures, power outlets, an electrical cabinet with Siemens S7-1500 PLC, and a dedicated screw-driving solution, providing operators with an organised, ergonomic, and highly reliable assembly environment. The result is a clean, efficient, and quality-focused workstation that combines manual flexibility with automated verification to deliver consistent assembly performance
