Adaptec Solutions Automates High-Volume, Manual Deburring Process for Aerospace customer Enje Aero

Enjet Aero is a precision aerospace manufacturer producing critical components for jet engine assemblies, with a strong commitment to quality and on-time delivery. Enjet Aero has nine manufacturing facilities across the United States, including Erie, PA. 

A highly manual deburring process created labor dependency, limiting throughput for a high-volume production program. In addition, variability in manual results made it difficult to maintain consistency, especially in a facility like Enjet Erie where 100% quality output is required.

• Customer: Enjet Aero
• Location: Erie, PA
• Industry: Aerospace Manufacturing
• Application: Robotic Material Removal / Deburring

Key Stages:

Evaluate & Align
Mapped the existing manual deburring process and defined:
• performance targets
• quality requirements
• system constraints
Design & Develop
Engineered a robotic automation cell to replicate and enhance the manual process. The design included simulation and tooling selection.
Integrate & Validate
Completed process development, Factory Acceptance Testing (FAT), and final validation to ensure cycle time and uptime targets were met.
Sustain
Enjet Aero’s Erie facility is supported by Adaptec’s field service team. As a Certified Service Provider (CSP) through FANUC, Adaptec offers 24/7/365 support with 75+ technicians strategically located across the nation.

Final Design

System Overview
Operators present trays of raw parts through an Adaptec mini-drawer system. From there, a robotic cell performs multiple deburring operations across different surfaces before returning finished parts to the same trays. Throughout the process, tool wear and abrasive health are continuously monitored to maintain consistency.

Key Technology
• FANUC LR-Mate 200iD robot for flexible part handling
• FANUC FS-15iA force sensor for precise force-controlled deburring
• Keyence vision system to monitor abrasive wear and tool health
• Allen-Bradley PLC and HMI for intuitive operator interaction
• Multi-stage deburring stations with automated abrasive change capability
• Drawer-based part presentation system for efficient batch handling

Flexibility by Design
The system supports both part-in-hand and abrasive-in-hand deburring, allowing it to adapt to different process requirements. In addition, the drawer system is designed for quick changeout of trays, fixtures, and tooling. Critical parameters like force, spindle speed, robot motion, and abrasive selection can all be fine-tuned to maintain a tightly controlled process across varying production needs.

Built for Production
To support high-volume output, the system incorporates multiple stations that allow abrasive media to be automatically changed during operation. Rather than relying on fixed intervals, the system uses vision-based monitoring to track abrasive wear and trigger tool changes based on actual usage, helping maintain consistency without interrupting flow.

Key Outcomes

Stabilized Throughput
Achieved a targeted cycle time of ~2 minutes per part, enabling predictable, scalable production.

Reduced Manual Dependency
Shifted a labor-intensive, skill-based process into a repeatable automated system.

Improved Process Consistency
Delivered controlled, repeatable deburring with reduced variability and rework.

Learning & Support

Challenges Tackled
One of the most critical challenges was selecting the right abrasive media for each deburring operation and developing a method for automatically changing tooling during production without compromising consistency.

Integration Approach
The system was designed as a standalone, cart-based cell to simplify installation and minimize disruption to existing operations.

Project Completion
Following process development and FAT, the system was validated against cycle time, quality, and uptime metrics before shipment and final site acceptance.

Ongoing Support
Adaptec provides remote support, preventative maintenance programs, and spare parts strategies to maintain uptime and system performance long-term.

Next Steps
The system design allows for scalability, including potential expansion with additional cells and further process optimization as production demand grows.