01 · VALIDATION
Simulation Validation
Toolpath and geometry studies used to validate the revised fixture profile before physical build.
← HOMEAssembly Fixture — Safety &
CS-014 · CASE STUDY
Assembly Fixture — Safety &
Ergonomics Improvement.
A critical OEM assembly station, re-engineered end-to-end. CAD, FEA, simulation and poka-yoke — applied where it matters: on the line.
CAD · CAM · SIMULATIONREV. 03 — 2024
01 · PROBLEM
An OEM assembly station was bottlenecking a critical line — operator strain, long fixture changeovers, frequent downtime and the constant risk of wrong-part loading during suspended-engine handling.
02 · ENGINEERING SOLUTION
ATE redesigned the station around a new fixture architecture validated in CAD/CAM simulation, then added poka-yoke locating logic and an operator-friendly loading sequence before production release.
03 · RESULT
Changeover time down 42%. Line downtime down 31%. Operator safety up. Zero defect parts since deployment. The station now runs faster with less manual intervention and lower risk.
ENGINEERING EVIDENCE
02 · VALIDATION
Prototype Fixture Model
Prototype model used to verify locating points, surface contact and reach before release to fabrication.
OPERATOR PAIN POINT
Manual fixture swaps were slowing the line and increasing handling risk.
The earlier setup depended on the operator changing fixture logic depending on which engine variant was hanging overhead. That added delay, created avoidable cognitive load and increased the chance of mismatch during a live production cycle.
- 01Existing fixture strategy required manual interpretation by the operator.
- 02Variant-specific handling increased changeover time at the station.
- 03ATE reworked the locating logic to make the sequence clearer and safer.
- 04The updated fixture flow reduced downtime while improving repeatability.
BENEFITS DELIVERED
↓ 42%
Changeover Time
↓ 31%
Downtime
Poka-Yoke
Error-Proofed
↑ Ergo
Operator Safety
0 PPM
Defect Rate