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Postazione SFA Mecal

Digital innovation: the transformation of Mecal's assembly lines

Italia Manufacturing Small (up to 100 employees) Smart Factory Assembly
Mecal, a company with over 50 years of experience in the production of cable harnessing machinery, needed a more efficient system for its assembly lines. Smart Factory Assembly introduced ergonomic workstations, digitisation of processes and real-time monitoring, improving quality and efficiency.

Riccardo Morello‘The desire to guarantee our customers an ever higher quality product and to have total control over the process has led us to digitise the assembly lines. This has made monitoring more effective and allowed us to optimise production management, without compromising on quality.’ 
Riccardo Morello 
Mecal Product Engineering and Development Management  

From traditional factory to smart factory: Mecal's transformation

Mecal, a precision engineering company with a 50-year history, specialising in the production of machinery for making wiring harnesses, has embarked on a process of evolution towards an increasingly innovative and high-performance production system. The traditional system had some critical issues related to the production footprint and the complexity of managing the assembly stages. In addition, the testing and validation process of the finished product required constant attention to ensure the highest level of conformity.

The turning point: the implementation of Smart Factory Assembly

After a careful evaluation of the available solutions, Mecal chose Bossard, an established partner in the supply of fasteners, to introduce the Smart Factory Assembly (SFA) platform. This technology, based on ELAM software, has made it possible to improve operational precision and quality management without disrupting the established production structure.

Assembly lines, previously organised in batches on work tables, have been optimised for greater operational ergonomics and more effective resource management. The adoption of digitised workstations has reduced the need for unnecessary travel, improving the well-being of operators. A key element of the transformation has been the introduction of smart tools, which can interact with the digital system to ensure more accurate clamping. Each operation is performed in a controlled sequence, reducing the risk of errors and increasing the repeatability of the process.

Smart TowerConnection of IoT devices

One of the assembly workstations has been equipped with a Smart Tower, each level of the tower rotates the components in the correct order towards the assembly worker and the pick is validated by a confirmation button or by weight (e.g. picking of 10 screws of 10 g each - the system recognises the weight to be removed as 100 g).

To further optimise assembly time and at the same time reduce material picking errors, a pick-to-light system shows the operator where to pick the necessary components via the integrated light display. The pick-to-light process is validated via an integrated sensor.

Digital instructions

The Smart Factory Assembly system includes centralised digital assembly instructions created by Mecal in collaboration with Bossard. The operators were actively involved in the process of digitising the instructions by participating in training sessions and directly experiencing the benefits of the new system.

The creation of the interactive instructions makes it possible to greatly reduce the complexity of product variations and to make changes efficiently and instantly. Step-by-step guidance through the assembly stages drastically reduces the time and resources spent on training new operators.

Data control and quality Every stage of the assembly process is now monitored in a systematic and structured manner. Each product is associated with a digital card that documents the relevant assembly parameters, such as the angle of rotation and torque applied to the screws, ensuring consistency and reliability.

This information, managed through the ELAM Solutions platform, allows a clear and centralised view of the process, supporting continuous improvement and quality control. With the integration of connected devices, real-time data collection and operational traceability, the Smart Factory Assembly solution is the intelligent engine of Mecal's new production organisation.

A radical change

 Riccardo Morello: The implementation of the Smart Factory Assembly system has represented a profound change in Mecal's production processes. The optimisation of workflows and the reduction of downtime have made production smoother and more responsive. The reorganisation of space has allowed new areas to be allocated to additional strategic activities. In parallel, the quality of the products has been further strengthened, thanks to more precise traceability and a drastic reduction in assembly errors.

Not only an impact on production but also on the daily lives of Mecal operators

The benefits of Smart Factory Assembly extended far beyond numbers alone. Operators appreciated the improved working conditions, greater autonomy and the opportunity to acquire new skills. Production managers were provided with more accurate and reliable data, facilitating production planning and control. Finally, customers benefited from higher quality products.
Operators, the direct beneficiaries of the system, appreciated the improvement in working conditions and the increase in overall efficiency. 

Conclusion

The transformation undertaken by Mecal demonstrates how a mechanical company can successfully evolve by adopting digital solutions to meet the challenges of industrial modernisation. The integration of the Smart Factory Assembly system has strengthened the company's ability to respond to market needs, improving the quality perceived by the customer and helping to consolidate a leading position in the sector.

The transformation brought with it some challenges, such as changing the mindset of operators accustomed to the traditional system. In addition, the assembly lines had to be reorganised, redefining operational flows and scheduling tools for each phase. Thanks to training and continuous support, these difficulties were successfully overcome. With Smart Factory Assembly, the process has been revolutionised: each operator assembles a unit following a lean flow, with ergonomic workstations, tools at hand and digital instructions for faster and more precise assembly.

Looking ahead, there are plans to extend the SFA system to other assembly lines, including mini-applicator models. This will further optimise the productivity of the departments and continue the path of continuous improvement in quality and customer service.

The adoption of the Smart Factory Assembly system has generated tangible improvement in several key areas of production:

  • Increased operational efficiency by optimising flows and reducing unproductive time.
  • Functional reorganisation of production spaces, with consequent enhancement of available areas.
  • More ergonomic workstations, benefiting the health and productivity of operators.
    Clear and interactive digital operating instructions guiding each step of assembly.
  • Accurate control of each clamping and use of components, ensuring precision and consistency.
  • Timely monitoring of machining times, useful for analysis and continuous improvement.
  • Complete traceability of the process, supporting quality certification of the final product.

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