IMI turnkey solution optimises process safety and efficiency for leading automotive OEM

Seeking new ways to optimise operations, the Michigan-based company approached IMI's team in Detroit to develop a bespoke solution for precisely unloading and positioning the irregular, complex-shaped, and heavy roll-formed parts used in truck beds.

Previously, the task was being undertaken manually, which came with associated safety challenges given the weight of each truck bed formed roll can be up to 10lbs/part with dimensions of 6" wide, 4" tall, and 51.5" long.

The overall goal of the project was to increase production capabilities, enhance throughput and optimise the ergonomics and safety of the overall handling process. Working with the customer, IMI developed a solution which incorporated IMI Norgren and IMI Bahr products, which are central to the turnkey unloading system.

Given the heavy loads, repetitive motion, and complex handling involved, the system needed to integrate a robust motion control solution capable of precise, high-speed operation. At the heart of the final system was IMI's custom-designed cartesian motion control technology, which ensures accurate, three-axis movement, crucial for positioning and unloading the rolls onto the truck bed.

The system combines IMI Norgren pneumatic actuation for efficient movement of lighter components with IMI Bahr electric actuation for precise, controlled positioning of heavier loads, a hybrid approach that balances speed and accuracy across the full handling cycle. Overall, the system allows for simultaneous, controlled movements, maximising throughput by reducing cycle times and optimising the flow of materials on the assembly line.

Crucially, the system has eliminated repetitive manual lifting and positioning of heavy loads, significantly reducing ergonomic risk and creating a safer working environment for production operators. This hybrid approach ensured a perfect balance between speed and accuracy, significantly increasing throughput on the OEM's assembly line by slashing cycle times while optimising material flow. This has delivered a significant increase in production capacity. This achievement was the result of cross-functional teamwork and clearly demonstrates the seamless integration of IMI's global product offering to meet local needs.

IMI's approach began with a detailed evaluation of the OEM's production flow, payload characteristics, available footprint, and safety requirements, before defining the optimal automation approach and engineering the integrated system around the specific handling challenge.

Ron Slone, Vice President of Sales, Americas, Industrial Automation, at IMI explained: "Our focus was on creating a system that not only improved productivity but also enhanced the ergonomic aspects of the process. By minimising manual handling and improving system efficiency, we were able to make a substantial difference to the customer's operations."

These sentiments were echoed by Jad Khattab, Director, Factory Automation, at IMI Detroit, who expressed the importance of collaboration and innovation in this project: "By combining the strengths of our local expertise in turnkey systems with the high-performance capabilities of IMI Norgren pneumatics and IMI Bahr electric actuators, we were able to deliver a solution that exceeded our client's expectations.

"The system's ability to amplify production while optimising handling and safety is a direct result of the strong partnerships between IMI and the OEM."

This project demonstrates the strength of IMI's integrated automation portfolio, combining IMI Norgren pneumatics, IMI Bahr electric motion, and local application engineering into a single-source turnkey system designed, built, and supported by one partner. Through collaboration and innovation, IMI has successfully delivered a system that met the OEM's needs for increased productivity, improved ergonomics, and optimised handling processes.