How-to-Guide / Automated Assembly / Motion Control

How To Rebalance Your Assembly Line Quickly with Minimal Cost--While Maintaining Quality

March 5, 2014

Today’s manufacturing companies need to be able to change a line in “Hours & Days,” not “Weeks & Months!”  Changing demand requires rapid response. Your assembly line’s output must reflect market demand and adapt in a fraction of the time – all while maintaining quality. The key to this is “flexibility.” eFlex Assembly by eFlex Systems is the solution that does all of this!

Case Study on a Global Automotive Company’s Powertrain Assembly Operations

When the market changed rapidly and demand shifted to a different model, this manufacturer standardized their global Powertrain operations with eFlex Assembly architecture.

Before Market Shift

Highly automated fixed tooling 6- and 4-cylinder engine assembly lines.

6-cyl line ran several shifts to meet demand.

4-cyl line ran one shift to meet demand.

After Market Shift

Overnight, demand shifted towards the 4-cyl engine.

Suddenly the 6-cyl line met its production requirements by 10 am, and sat idle the rest of the day.

The 4-cyl engine line could not increase its capacity beyond its original design capabilities.

Vehicle sales were lost due to the inherent nature of the design, which lacked the flexibility to respond to market changes. Had the lines been more flexible by design, they could have redeployed their capital to meet market change. As a result, they chose eFlex Assembly for their global standard.

Attributes of eFlex Assembly

eFlex Assembly is a complete assembly solution. It is flexible, data-driven, standardized, seamlessly integrated and lean.


Reconfigurable without re-programming.

Reconfigurable with a user-friendly interface, in which all users can easily make changes to the process, without requiring controls engineering.

When a change is made, it acts systemically across all systems. (For example, if a task is added, it is instantly reflected in the repair loops, HMI’s and reporting.)

Data Driven

100% sampling of rejects and task timing, down to the subtask.


Hardware: A plug ‘n play standardized hardware design and an easy-to-use configuration UI enables changes to the process in a fraction of the time. (The constraint becomes moving the equipment!)

Software: Pre-engineered software encapsulates most process scenarios. (Model management, prerequisite handling and canned logic for process tasks.)

Analytics: Clear information supports and improves decision-making.

Processes: Quickly change within defined standards. Well-defined processes greatly increase flexibility.

Seamlessly Integrated Systems

Single Framework: All systems work within a single framework with a common data repository, so other systems seamlessly have access to critical data.

 Process Centric: The process drives all systems. 

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