From Traditional Factory to Smart Factory
Watch how the implementation of the Smart Factory Assembly system has transformed the assembly of Mecal's machines, improving productivity, quality and traceability.
Success Stories
Digital Innovation: The Transformation of Assembly Lines at Mecal
Mecal, a company with over 50 years of experience in the production of wiring machinery, needed a more efficient system for its assembly lines.
"Our desire to guarantee our customers an increasingly high-quality product and to have total control over the process led us to digitize our assembly lines. This has made monitoring more effective and allowed us to optimize production management without compromising on quality." - Riccardo Morello, Mecal Product Engineering and Development Manager
The Turning Point: Implementing Smart Factory Assembly
After a careful evaluation of the available solutions, Mecal chose Bossard to introduce the Smart Factory Assembly platform. This technology, based on ELAM software, has made it possible to improve operational precision and quality management without disrupting the established production structure.
Assembly lines, previously organized in batches on work tables, were optimized for greater operational ergonomics and more effective resource management. The adoption of digitized workstations has reduced the need for unnecessary travel, improving the well-being of operators. A key element of the transformation has been the introduction of smart tools, which can interact with the digital system to ensure more accurate clamping. Each operation is performed in a controlled sequence, reducing the risk of errors and increasing the repeatability of the process.
Challenges: Space, Complexity and Compliance
Mecal, a precision engineering company specializing in the production of machinery for the manufacture of wiring harnesses, has embarked on a process of evolution towards an increasingly innovative and high-performance production system. The traditional system had some critical issues related to production space requirements and the complexity of managing the assembly phases. In addition, the testing and validation process for the finished product required constant attention to ensure the highest level of compliance.
Connection of IoT Devices
One of the assembly workstations has been equipped with a SmartTower. Each level of the tower rotates the components in the correct order towards the assembly worker. The pick is validated by a confirmation button or by weight (e.g. when picking 10 screws of 10g each, the system recognizes the weight to be removed as 100g).
To further optimize assembly time and reduce material picking errors at the same time, a pick-to-light system shows the operator where to pick the necessary components via the integrated light display. The pick-to-light process is validated via an integrated sensor.
Digital Instructions
Our system includes centralized digital assembly instructions created by Mecal in collaboration with Bossard. Operators were actively involved in the process of digitizing the instructions by participating in training sessions and directly experiencing the benefits of the new system.
The creation of interactive instructions significantly reduces the complexity of product variations and allows changes to be made efficiently and instantly. Step-by-step guidance during the assembly phases drastically reduces the time and resources required to train new operators.
Data Control and Quality
Each phase of the assembly process is now monitored in a systematic and structured manner. Each product is associated with a digital card that documents the relevant assembly parameters, such as the angle of rotation and the torque applied to the screws, ensuring consistency and reliability.
This information, managed through the ELAM Solutions platform, provides a clear and centralized view of the process, supporting continuous improvement and quality control. Thanks to the integration of connected devices, real-time data collection and operational traceability, Smart Factory Assembly is the engine of Mecal's new production organization.
A Radical Change
"The implementation of the Smart Factory Assembly system has represented a profound change in Mecal's production processes. The optimization of workflows and the reduction of downtime have made production smoother and more responsive. The re-organization of space has allowed new areas to be allocated to additional strategic activities. In parallel, the quality of the products has been further strengthened, thanks to more precise traceability and a drastic reduction in assembly errors." – Riccardo Morello
Improvements for Employees
The benefits of Smart Factory Assembly extended far beyond numbers alone. Operators appreciated the improved working conditions, greater autonomy and the opportunity to acquire new skills. Production managers were provided with more accurate and reliable data, facilitating production planning and control. Finally, customers benefited from higher quality products.
Living up to the Challenges of Industrial Modernization
The transformation undertaken by Mecal demonstrates how a manufacturing company can successfully evolve by adopting digital solutions to meet the challenges of industrial modernization. The integration of Smart Factory Assembly has strengthened the company's ability to respond to market needs, improving the quality perceived by the customer and helping to consolidate a leading position in the sector.
Adopting a New Mindset
The transformation brought with it some challenges, such as changing the mindset of operators accustomed to the traditional system. In addition, the assembly lines had to be reorganized, redefining operational flows and scheduling tools for each phase. Thanks to training and continuous support, these difficulties were successfully overcome. With Smart Factory Assembly, the process has been revolutionized: Each operator assembles a unit following a lean flow, with ergonomic workstations, tools at hand and digital instructions for faster and more precise assembly.
Looking ahead, there are plans to extend the system to other assembly lines, including mini-applicator models. This will further optimize the productivity of the departments and continue the path of improvement in quality and customer service.
Customer Benefits at a Glance
The adoption of Smart Factory Assembly has generated tangible improvements in several key areas of Mecal's production:
- Increased operational efficiency by optimizing flows and reducing unproductive time
- Functional reorganization of production spaces, with consequent enhancement of available areas
- More ergonomic workstations, benefiting the health and productivity of operators
- Clear and interactive digital operating instructions guiding each step of assembly
- Accurate control of each clamping and use of components, ensuring precision and consistency
- Timely monitoring of machining times, useful for analysis and continuous improvement
- Complete traceability of the process, supporting quality certification of the final product
Smart Factory Assembly
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