25% Increased Output: How Thogus Transformed Helmet Production with Robotic Drilling

Founded in 1950 and headquartered in Avon Lake, Ohio, Thogus manufactures complex molded components for customers in industries ranging from healthcare to sporting goods. When a secondary drilling operation began limiting throughput on a football helmet production line, the company partnered with Robotic Technical Support Services (RTSS) to develop an automated solution capable of increasing output, improving flexibility and supporting future growth. 

The previous process relied on a semi-automated cell that struggled to keep pace with molding cycle times. As demand increased, the drilling operation became a production bottleneck, limiting the overall efficiency of the manufacturing process and restricting the number of helmet shells that could be produced each hour. 

To address the challenge, RTSS designed a custom robotic drilling system that integrates directly with Thogus’ injection molding operation. The system incorporates two FANUC LR Mate robots working within an automated cell connected to a 720-ton injection molding machine. After helmet shells are molded, the FANUC robots perform precision drilling operations before the finished parts move to inspection and pack-out. 

The solution was engineered not only to improve throughput, but also to provide the flexibility needed to support changing customer requirements. The automated cell accommodates up to six different helmet sizes and 12 machining configurations through program and fixture changes, allowing Thogus to quickly adapt to product modifications without extensive equipment changes. The FANUC LR Mate robots delivered the reach, payload capacity and reliability required to maintain consistent quality while supporting high-volume production. 

The results were immediate. Following implementation, Thogus increased production output by approximately 25%, eliminating a key manufacturing bottleneck and allowing the operation to better match the pace of the molding process. The system also improved uptime, reliability and overall production efficiency. 

Beyond the measurable productivity gains, the project established a scalable automation platform capable of supporting future growth. In fact, Thogus is already expanding with an additional RTSS automation system designed to further increase flexibility and throughput.

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If we continue to advance the automation, we're out front and we're driving value through automation and engineered services that make us productive and efficient and make our customers' jobs easier and more competitive.

Matt Hlavin CEO – Thogus