The initial purpose for implementing an automated solution was to relieve production staff from the onerous physical tasks of assembling locks and screwing face plates. In contrast to traditional robotic solutions, Universal Robots’ small and lightweight robotic arms work safely alongside staff (subject to risk assessment).

Like all Universal Robots, the UR5’s state-of-the-art force limit safety feature automatically prevents the robot from operating when movement is interrupted. The UR5 doesn’t exert a force greater than the limit specified in the adjustable safety settings, which can be set from 100-250 newtons.

Prior to deploying the UR5, operational staff were rotated every two hours, due to the demands of repetitive wrist and shoulder movements. By automating the final step on the lock bodies production line, the UR5 has relieved operators of work hazards. Knowing that employees can work in very close proximity to the UR5 without safety guarding provides ASSA ABLOY NZ with peace of mind.

Staff reaction to the UR5 – Victoria – has been extremely positive and they have upskilled as a result of cobot integration. New roles are being created for the team which are more focused on quality and process monitoring of material supply, compared to the role of a traditional assembly worker.

“We’re so pleased to see the team’s sense of pride in the new skills they’ve developed as a result of operating Victoria. Permanent staff have taken on the responsibility of mentoring temporary staff on how to work with Victoria,” said Mataio Goding, Production Manager, ASSA ABLOY NZ.

The UR5 ensures there’s no variation during the final assembly stage, improving consistency of product. The UR5 enables ASSA ABLOY NZ to deliver on its operational strategy of ‘any colour any key any time’ – producing any key or lock, in any colour – with a two day turnaround. This provides a competitive advantage as automation has traditionally only been relevant for large scale production.

“We have seen improvement in quality as a result of a more consistent assembly process,” said Goding.

Automating repetitive tasks and improved consistency of output means less time and resources are required on the production line. Staff can be redeployed into more value added tasks, driving efficiency across the business. ASSA ABLOY expects to see a cost saving within the next 12 months that will pay for the UR5.

Based on the success of Victoria’s installation and commissioning, ASSA ABLOY NZ is developing another process that involves two UR5s producing door hinges, with 22 different variants of product.