At Ford Thailand Manufacturing, man and machine are working together to significantly reduce the risk of injury and enhance productivity.
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At Ford Thailand Manufacturing, man and machine are working together on the door assembly line, significantly reducing the risk of worker injuries thanks to the introduction of cobots (collaborative robots). These cobots, specifically the UR10e models, are responsible for installing weatherproof shields into Ranger doors – a task that demands accuracy, strength, and skill.
Rather than replacing employees, these cobots enable operators to allocate their time more effectively to intricate tasks such as installing wiring looms, thereby avoiding the physical strains associated with repetitive duties. With a reach of 1 m, the cobots are strategically positioned along the assembly line. A sensor detects the arrival and exact positioning of each door, ensuring the cobots perform their tasks with precision – to the mm.
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Once the door is in position, the cobot uses a roller attached to its ‘wrist’ to apply consistent pressure to a pre-applied adhesive bead on the weatherproof liner, effectively sealing it against the door’s sheet metal.
Worawit Sertkratok, facility engineer, final assembly at Ford Thailand Manufacturing, said:
“The cobots know exactly how much force to apply (up to 5kg) and can do it more easily and precisely than we can. They can follow a complex path avoiding any no-go zones on the door, ensuring the shield is completely sealed against water ingress. And they can do it the same every single time which means we can achieve the quality expected.”
Previously, installing the weatherproof shield required workers to use a hand-held roller, applying significant force to ensure a proper seal – a strenuous and repetitive task that often led to strains in wrist, elbow, and shoulder joints. The introduction of cobots has eliminated this strain, simultaneously enhancing the health and wellbeing of workers and improving the quality and speed of the installation process.
“Before the cobot was installed, it was hard work installing the weatherproof liners. The cobot doesn’t get tired or ever need a break. It’s made a big difference to quality and health on the line,” added Worawit.
