Case Study: Automotive Antenna Manufacturer

How an Automotive Antenna Manufacturer Reduced Cycle Time by 50% with a 2-in-1 Auto Soldering and Auto Screwing System 

Customer Profile 

• Industry: Automotive electronics 
  
• Location: Kuala Lumpur, Malaysia 
  
• Application: Antenna module assembly 
  
• Process: Manual soldering and screw fastening (2-step process) 

The customer manufactures automotive antenna assemblies requiring both automated soldering and automated screw (mechanical fastening) within the same station. 

The Engineering Challenge 

The original process required: 

• Two separate manual steps 
• Two operators per station 
• Sequential soldering and screw fastening 
• Repeated handling of the same unit 

This resulted in: 

• Longer cycle time 
• Increased manpower dependency 
• Process variability between operators 
• Handling inefficiency 

The requirement: 

Integrate soldering and screwing into a single controlled process while reducing cycle time and manpower. 

Solution Implemented 

Tokimeku deployed a 2-in-1 integrated automation system combining: 

• Auto soldering module 
• Torque-controlled screw fastening module 
• Controlled sequence programming 
• Single-station process flow 

The system allowed both processes to be completed within one integrated cycle, eliminating redundant handling and transition time.

The Results 

Post-implementation outcomes: 

• 50% reduction in cycle time 
• Reduced from 2 operators to 1 operator per station 
• Improved process standardisation 
• Reduced handling variability 
• Higher throughput per shift 

The integration eliminated process gaps between soldering and fastening operations. 

Strategic Impact 

1. Manpower Optimisation 
   Reduced operator requirement per station while maintaining output. 
2. Process Consolidation 
   Converted a two-step manual process into a single controlled automation sequence. 
3. Productivity Increase 
   50% faster cycle time improved line capacity without additional space or manpower. 
4. Operational Scalability 
   The integrated design supports future automation upgrades and expansion. 

Request a Process Evaluation 

Tokimeku can evaluate consolidation opportunities through integrated automation. 

Speak to our automation specialists to assess feasibility.