Stanley Assembly Technologies

Application
Loading 150-lb. Cadillac CTS cockpit modules (comprised of the instrument panel, steering wheel, actuator, airbags, pedals, and more) from a conveyor into vehicles at a rate of 300 cycles per day.

Business
General Motors - Assembly

The Challenge
To meet GM's strict ground rules prohibiting ergonomically stressful conditions to be placed on any operator, the push-pull forces on a 2,000 lb. IP cockpit loader (a pneumatic articulated arm tool) needed to be reduced from 77 to less than 24 lbs. (the GM Ergo Standard). Prior to the IAD solution, GM was able to use only the strongest, healthiest individuals, and had to rotate four operators to prevent overexertion and repetitive stress injuries as they manipulated the nearly 2,000 lb. moving mass. Proper posture and high strength were necessary to control the module and overcome the inertia of the cockpit loader.

The Solution
The iTrolley, installed as a retrofit on the existing arm, reduced the push-pull forces to less than 10% of their previous level by delivering computer-controlled, servo-driven power assist. In addition, productivity has been increased with the iTrolley's automatic "Return to Home" feature, which automatically sends the tool along the X-Y axis. This cuts walk time and frees operators to concentrate on proper cockpit installation while the tool returns to its starting point. The system also delivers far greater accuracy in load positioning, which further reduces operator exertion and increases efficiency. Quality is also improved as the operator has better control of the arm during insertion, preventing damage to the door seals that occasionally occurred with the manual tool.

Benefits