Metal Stamper Overcomes Labor Shortage with Automation Upgrade
Pentaflex upgraded brake spider production with JR Automation and FANUC robots, reducing labor dependence while increasing output and ensuring quality.
Challenges
- Manufacturing labor shortage
- Aging automation systems
- Shrinking profits
Results
Labor optimization
Increased output
Increased manufacturing floor flexibility
Story
The foundational part for the braking system of heavy truck trailer axles is a called a “brake spider”— a critical safety component in vehicle manufacturing. For 40 years, metal stamping and assembly company Pentaflex has been manufacturing this key product for their principal customer. With this goal in mind, the Ohio-based company aimed to invest in and upgrade their manufacturing technology to enhance their core product.
With an aging system on their hands, and an ongoing struggle to find available and reliable labor, the company saw an opportunity to enhance their manufacturing processes. To solve these issues, Pentaflex connected with global automation leader, JR Automation.
JR Automation provided Pentaflex with a custom automation solution that integrated FANUC’s material-handling M-20iD/25 and M-710iC/50 robots, along with the compact and flexible LR Mate 200iD robots. This system reduced the number of labor units needed per shift from seven to two, helping the company decrease its dependence on inconsistent labor and upskill its current employees.
Automation streamlined the management of production schedules for Pentaflex, while enhancing flexibility on the manufacturing floor allowed employees to be utilized more effectively throughout the workday.
It’s going to be a real gamechanger because we previously were making this particular product utilizing seven units of labor per shift and we’ve now been able to take that down to two… allowing us flexibility to use those people elsewhere in the facility.
Ross McGregor President and CEO – PentaflexFANUC Products Used
M-20iD/25
The FANUC M‑20iD/25 is a compact 6‑axis robot ideal for machine loading and unloading, parts handling and precise positioning in crowded factory environments.
- Max Payload:
- 25 kg
- Reach:
- 1831 mm
LR Mate 200iD/7L
Fast at handling small payloads, the FANUC LR Mate 200iD/7L compact multi-purpose industrial robot offers an enhanced reach at 911mm and payloads of up to 7 kg.
- Max Payload:
- 7 kg
- Reach:
- 911 mm
M-710iC/50
The FANUC M‑710iC/50 is a compact 6 axis robot popular for machine tending, grinding, polishing, deburring, water jet cutting and washing applications.
- Max Payload:
- 50 kg
- Reach:
- 2050 mm
About Pentaflex
Pentaflex, Inc. is a contract manufacturer of metal stampings and assemblies located in Springfield, Ohio. Specializing in heavy gauge and highly formed components, Pentaflex supplies the commercial truck, automotive, medical, and off-road industries, among others. Our vision at Pentaflex is to be the supplier of choice for customers who require complex, heavy gauge deep drawn components and sub-assemblies.
