Consumer Goods High-Speed Assembly System

Customer Challenge

A leading consumer goods manufacturer required a high-speed automated assembly solution for a hair trimmer product family consisting of 11 variants and 22 components.

The project presented several key challenges:

• Tight assembly tolerances
• Support for metal and plastic case variants
• Requirement for removable pallet inserts
• High product mix complexity
• Aggressive throughput expectations

The customer needed a system capable of maintaining precision while also allowing flexibility for future product expansion and rapid changeover.

HG Automation Solution

HG Automation’s Adaptek Group addressed this challenge using our patented 32-station linear transfer platform, a proven machine architecture designed to accelerate project delivery while reducing engineering cost and risk.

Unlike fully custom one-off designs, this patented platform allows us to leverage an already validated engineering foundation, significantly improving:

• Speed to delivery
• Scalability
• Cost efficiency
• Future expandability

This approach enabled the customer to move from concept to production faster, while benefiting from a robust and field-proven design framework.

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System Highlights

The completed system includes:

• 32-station linear transfer system
• 4 SCARA assembly robots
• 14 bowl feeders
• Fastening and pressing with active feedback
• Allen-Bradley controls platform
• 6-second cycle time

The modular transfer design, paired with removable pallet inserts, provides flexibility to support multiple case styles and future SKU growth.

Integrated active feedback ensures each fastening and pressing operation is verified for proper force and completion, improving both quality and traceability.

Results & Customer Impact

By leveraging our patented platform, the customer achieved:

• 6-second production cycle time
• Faster machine deployment
• Lower engineering lead time
• Reduced overall project cost
• High-mix manufacturing flexibility
• Improved quality validation

This project demonstrates how HG Automation helps manufacturers bring products to market faster through proven automation platforms engineered for flexibility and scale.