Over 10 Times Higher Throughput Achieved Through Automated Inspection
Automated dual-robot inspection system boosts BelleFlex throughput 10x, improving accuracy, consistency, and traceability while enabling scalable production.
Challenges
- Repetitive, dull and time-consuming task
- High risk of human error in visual and mechanical checks
- Limited capacity prevented production scaling
- Tight floor space constraints for any new equipment
Results
Scalable solution — BelleFlex ordered two additional identical systems
10 times increase in production capacity, improved quality consistency, and reduced error rates
Higher customer confidence through triple verified, fully documented results
Compact dual robot cell fit within existing floor space
Story
BelleFlex Technologies built its reputation on producing precision disc springs for industries where reliability is critical. Every component must meet strict tolerances, yet the company relied on manual inspection performed by its most experienced technician. The process was slow, repetitive, and limited BelleFlex’s ability to scale as demand increased.
To overcome this bottleneck, Belleflex partnered with Integrated Industrial Technologies (I2T), an automation integrator with deep expertise in robotics, inspection and material handling. After reviewing the workflow, I2T set out to design a fully automated solution capable of delivering higher throughput and consistent quality.
Working closely with BelleFlex’s engineering and production teams, I2T developed a compact dual robot inspection cell built around FANUC SR-6iA SCARA robots. The system automates every step of the process: loading parts from trays, presenting them to a vision system for orientation and count verification, transferring them into a mechanical tester to measure spring tension, and sorting each part into good or reject trays based on the results. Once the operator loads the trays and closes the cell, the system takes full control—inspecting, testing, and recording every part in a central database.
The shift from manual to automated inspection delivered immediate impact. A process that once handled only a few thousand parts now supports 10 times the volume with greater accuracy and complete traceability. The improved consistency and documented results strengthened BelleFlex’s ability to meet the stringent requirements of its customers.
The success of the initial installation has led BelleFlex to invest in two additional identical systems. With three matching cells, the company gained redundancy, increased throughput and the flexibility to explore new product types and technical requirements without disrupting production.
By partnering with I2T and deploying FANUC robotics, BelleFlex transformed a labor intensive bottleneck into a scalable, data driven advantage. The automated inspection system delivers higher accuracy, faster throughput and reliable documentation—all within a small footprint that fits seamlessly into the existing production environment. It also positions the company for continued growth in industries where precision and reliability are essential.
We’ve actually ordered two more full sets of automation… Having this automation gives us an additional level of confidence, knowing that the products we’re producing truly meet the high level of precision and tolerance our customers require.
John Bach General Manager - Engineering and Business Development – BelleFlex TechnologiesFANUC Products Used
SR-6iA
The FANUC SR-6iA SCARA Robot makes a great choice for assembly, pick and place, inspection and packaging applications requiring a payload capacity up to 6 kg.
- Max Payload:
- 6 kg
- Reach:
- 650 mm
Meet I2T - Integrated Industrial Technologies, Inc, FANUC Authorized System Integrator
Integrated Industrial Technologies, Inc. (I2T) provides industrial control and automation solutions to markets worldwide. We provide engineering services including design, programming, equipment assembly, and final system commissioning. I2T provides custom fabrication, welding and complete turn-key machined products. Formed in 1990 to provide custom industrial automation solutions to a wide variety of manufacturing and industrial companies, I2T’s team has worked with many top companies providing complete turnkey motion control, and automation solutions that include: project management, detailed control specification custom software development, robot programming, vision inspection and tracking, electrical and mechanical design, along with project commissioning and training.
About BelleFlex Technologies
At BelleFlex® Technologies, we are dedicated to delivering high-performance Belleville disc springs engineered for reliability and precision. As a trusted U.S.-based manufacturer, we serve customers across industries who demand application-specific solutions, quick lead times, and direct engineering support. With more than 100 years of combined engineering and manufacturing expertise, BelleFlex is not just a spring manufacturer—we are a solutions partner, offering a level of service and communication that sets us apart. BelleFlex quality and safety programs insure successful mission-critical and severe service applications, where failure is not an option.
