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When Innovation & Performance Count
ISO 9001:2000 ISO 14001:2008 Certified
Page 1
Volume 5, Number 1
ORI
INC.
Fori Automation Global Locations Who We Are:
Global Design & Builder of Assembly, Welding &
Testing Equipment
N E WS
Our Capabilities:
Sales, Engineering (Mechanical / Controls /
Software), Manufacturing, Assembly, Full System
Integrator & Installation & Service on 5 Continents
Global Company
Locations in The USA, Mexico, Brazil, Germany,
India, China & Korea
Fori Automation Newsletter
Chassis Marriage with Integrated Module Assembly
Fori USA is completing the installation of an
engine decking system with integrated front
and rear suspension build assembly lines,
linked by Fori's twin strand conveyor. A wheel
corner build sub assembly line was also installed at the Michigan Assembly Plant in Wayne
Michigan. The pallets travel to build stations along the conveyor loop. The pallets are held
at each build station by cushioned anti-backup stops until build for that station is complete,
and then they are released back on the continuously moving conveyor to travel to the next
station. The front module assembly line also incorporates accumulating stops, pallet
diverters, and lift and rotate stations to allow both sides of the pallet to be worked on. These
conveyor systems streamline the assembly process while feeding the engine decking
system. The completed front suspension with the engine pallet is loaded onto the chassis
marriage carts by an elevator that transfers the completed pallet to the cart using extending
conveyors. Once on the chassis marriage decking cart (further assembly) is completed prior
to decking. The 21 carts travel around the marriage loop at variable speeds and through
several build stations. When the cart reaches the decking area Fori's patented electric lifts
lift the completed chassis to the vehicle body were it is then fastened. The empty engine
pallets are offloaded by an elevator where they re-enter the front suspension build
conveyor.
Aerospace News Update!
Fori Automation just secured orders to build AGVs for the Lockheed
Martin F35 joint strike fighter assembly line and Bombardier for the CSeries assembly line. All (25) AGVs will be used to move parts of the planes
through the assembly process. Look for additional information on our new
fleet of high capacity AGVs
in future newsletters.
ISO 9001:2000 ISO 14001:2008 Certified ITAR Certified Cage Code M20746
Top: Front suspension assembly conveyor.
Left: Elevator placing build pallet onto
chassis decking cart
In This Issue
Chassis Marriage / Module Assembly
Module Aligners
Fuel Tank Strap Weld System
Aerospace AGV
VW Chassis Marriage System
Sun Roof Motor Assembly
Lane Departure System
7 Assembly Systems for VW
Front & Rear Suspension Systems
Ammunition System Upgrades
Sun Roof Motor Test Bench
Instrument Panel Work Stations
Chassis Marriage Upgrade in China
End of Line Systems for Geely
End of Line Systems for Beijing Hyundai
Assembly Plant Rework
End of Line Testing
3-D Wheel Aligner with Fender Height
Rear Axle Sub Assembly
End of Line System for Nissan India
Front Corner Assembly System
Tire & Wheel Installation
Fluid Fill System for Fiat
Company Information
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50955 Wing Drive, Shelby Township, Michigan 48315 Phone: 586-247-2336 Option 4 Fax: 586-566-6773 www.foriauto.com
When Innovation & Performance Count
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Chrysler Venezuela
ISO 9001:2000 ISO 14001:2008 Certified
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INC.
Fori Automation is in the process of the design and
build of one (1) front suspension and one (1) rear
suspension module aligners for the Chrysler
Venezuela assembly plant to produce the new
2011 Jeep Grand Cherokee. The front suspension
aligner automatically sets camber and caster,
while manually setting toe on the new Jeep Grand
Cherokee that will be produced for the South
American market. The rear suspension aligner
automatically sets toe and camber. The module
aligners are similar to the systems provided to
Mobis for the 2011 Jeep Grand Cherokee that will
be produced at the Jefferson North assembly plant
in Detroit, MI. The challenge was to simplify Module Aligner
design of the aligners from the Mobis design due to the low production volume rate of 20,000 vehicles annually and reduced
model variants. The result is a cost effective aligner that matches the volume and product requirements.
Martinrea
Fuel Tank Strap Weld Crates
Fuel Tank Straps Being Welded
Fori Automation USA has designed, built and installed a spot weld system for Martinrea International of Hopkinsville,
Kentucky. The system welds nearly every type of fuel tank straps for all of the Ford pickups and SUV's. The two system
process is capable of producing endless variants for a total of nearly thirteen million spot welds per year. Some of the unique
features are; crate style fixtures which contain four (4) straps at a time, simple effective tool changer, distinguishing part
presence laser with vision system and a post end of arm tooling plastic apply station. The laser vision system will improve the
overall equipment effectiveness by 5% based on eliminating fixed part present switches on the welding fixtures. This allows
the fixture to be simplified with no automated movement. New straps can be added by building new fixtures and programming
the laser system to detect part presence as well as manual clamps closed. This allows quick change over for new product
production. The state of the art plastic apply station applies all plastic protectors on the painted straps with a unique cam
motion. The system also allows for new straps with no additional programming.
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Spirit Aerosystems
INC.
Fori Automation has partnered with Brown Aerospace of Port Huron, MI to provide a state of the art automated drill machine
for the new Spirit Aerosystem's plant located in Kingston North Carolina. Fori Automation is supplying (2) heavy capacity
AGVs which will provide automatic navigation, docking, and leveling for the Brown Aerospace drill machine. These AGVs
will be shipped to Brown Aerospace where they will install and integrate their drill machine before shipping to Spirit
Aerosystems. Due to the tight drilling tolerances of the aerospace market, each 23,000 lb AGV had to be designed around a
strict .03” frame deflection requirement to ensure the drill machine frame did not flex or twist while moving from station to
station on the uneven concrete. Additional specifications required that the AGV be capable of leveling to .004 degrees, have
no more than .005” deflection after leveling, and that the x/y positioning tolerance of the AGV when docked to the floor
bushing at each station be .005”. Utilizing the Fori Automation AGV to
transport the drill machine vs. the previous manual method significantly
improved efficiency, reduced manpower requirements, and improved
cycle time. Fori Automation anticipates just over a 2 minute cycle time
from completion of drilling one panel to start of drilling a new panel 8' 6”
down the assembly line. Previous manual methods took nearly one day.
The Brown Aerospace drill machine is a first of its kind design for the
aerospace industry. This 23' tall 18,000 lbs precision drill machine
utilizes a curved rail system which mirrors the shape of the fuselage skin.
This curved rail system along with a precision linear cross rail system
provides precision placement of the drill head. Once in position the
machine drills the holes, spot faces, provides sealant, then installs and
secures the fasteners into the skin of the fuselage panel.
Patented Drive Steer
Magnetic Pick-Up
Floor Bushing - .005” x-y
Accuracy
Heavy Duty Suspended Casters
with Sweep Brushes
Automatically Guided,
Auto Decking / Leveling AGV
ORI
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INC.
ORI AUTOMATION do BRASIL LTDA
Servo Leveling Jack
with Expanding Arbor
High Voltage 312 V control system
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Volkswagen Bratislava
ISO 9001:2000 ISO 14001:2008 Certified
ORI GERMANY
GmbH
Robotic Marriage Fastening
Compression Fastening
Fori Germany has completed a system upgrade and addition to the chassis marriage line at the Volkswagen Bratislava plant
for the Touareg VW726 & Hybrid versions of the Touareg models. The following features were added to the current system;
robotic suspension fastening, new hoists, new lift bars, new engine pallets and 48 new nutrunners.
Volkswagen
The lane departure warning system uses a forward looking camera mounted behind the windshield which is linked to the car
controller. Utilizing image recognition software the lane departure system continuously tracks the visible lane markings. The
future vehicle position can be estimated using the lines painted on the roadway and some calculations. If the vehicle begins to
leave the lane, the system alerts the driver by an audible, visual or tactile signal. This system has been installed in the
Volkswagen AG plant in Emden Germany. The rear view camera is mounted on the car boot cover. The driver can see on the
screen a live view of the rear part of the vehicle. The system indicates in the display the approximation to an obstacle and
warns acoustically by small distances between the car and the
obstacle. The Fori Unit provides a reference sample (installed
behind the vehicle on the hall floor). The rear view camera takes a
picture of the sample, and the calibration is independently
Fori Germany
calculated in the car controller.
has designed
Volkswagen Chattanooga
and built
manipulators
f o r
t h e
Vo l k s w a g e n
Chattanooga
Tennessee plant
for the VW 411
model.
The
manipulators
aid in installing
the sun roof.
Sun Roof Manipulator
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Page 4
INC.
ORI AUTOMATION do BRASIL LTDA
Flip Down Calibration Unit
ORI INDIA
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When Innovation & Performance Count
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Volkswagen Chattanooga Systems
ISO 9001:2000 ISO 14001:2008 Certified
ORI GERMANY
GmbH
Chassis Marriage System
demarket. The model is
l SliUS
Vertitocathe
The Volkswagen Group of America is in the process of introducing a new
sedan
ependent
Indmid-size
based on the VW411 platform and will be built in a brand new, state of the art assembly facility in Chattanooga, Tennessee.
As part of this endeavor, Fori Automation GmbH had successfully earned a contract of substantial size from the
Volkswagen Group in Wolfsburg, Germany to build a variety of equipment, tooling and automated systems for this VW
assembly plant, which is divided into 7 assembly line segments. Fori Automation is tasked to design, build and integrate
state of the art turn-key systems to the very specific VW standards utilizing Siemens Controls System, considering DIN,
EN and ISO norms, while meeting OSHA requirements and local electric codes. Although Fori Automation is very
familiar with the VW standards, the entire installation system has to be turned over to VW within a very stringent time
frame while managing dozens of sub-suppliers located on several continents. This task demands a top level world wide
organization like Fori Automation who can leverage experience, innovation, global team work and low cost
manufacturing abilities led by the Fori-International Project Management Team.
The assembly systems supplied are; Doors off – Doors on, Automatic installation of Roof Dampening Reinforcements or
DVD, Tilt/slide Sunroof installation or SAD. VIN stamping and Laser Marking, Gluing, Assembly and Installation,
Window Gluing Application, Battery Installation, Front End Assembly and Installation, Wheel Installation, Front- and
Rear Seat Installation, TransmissionAGV system and a ChassisAssembly System.
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ORI AUTOMATION do BRASIL LTDA
ORI INDIA
ORI CHINA
ORI GERMANY
ORI SOUTH AFRICA
ORI KOREA
LTD
ORI AUTOMATION de MÉXICO
When Innovation & Performance Count
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Mobis
ISO 9001:2000 ISO 14001:2008 Certified
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INC.
Fori has completed the design, build and
installation of a turn key system for Mobis,
which supplies the Chrysler Jeep Grand
Cherokee. The system comprises of; front
suspension assembly, rear suspension
assembly, front and rear brake assembly,
front coil over shock assembly, rear shock
assembly and rear spring systems. All of the
sub assembly stations (coil over shock etc.)
feed the main lines to streamline the
assembly process. The entire system is
capable of running 62 jph.
The front and rear suspension assembly
systems utilized Fori's press style modular
aligners. As stated in other Fori news letters,
these alignment systems were designed to
accommodate many different module sizes
and loading means. All the slides were
Robotically Loaded (with Manual backup) Module Aligners
designed to accommodate all vehicle
widths, jounce and rebound parameters.
The press style system allows change of the
upper and lower platen to accommodate
future module types. This system can be
orientated to be loaded by operator, robot,
pick & place, and conveyor. The aligners
are loaded robotically and both the front and
rear suspension system utilizes a friction
roller low profile conveyor system to
convey the production build pallets through
the assembly process. This gives the
operator freedom to move around the pallet.
On the rear line all press operations are
integrated into this conveyor system. This
makes for less part handling. Fori has also
integrated a Wheel Speed Sensor Test
station into both the front and rear brake
assembly conveyors which perform a pole Front Module Assembly System
pitch error test.
Systems
Alberici / ATK Lake City
Fori USA is in the process of building and integrating the mechanical refurbishment of the SCAMP Loading Lines one through four in
building 1 on the Lake City Army Ammunition Plant. Line four (4) will be first to be modernized, followed by line three (3), then two (2), then
one (1). As a subcontractor, Fori Automation is leading the part supplier coordination, the quality assurance aspect, as well as overseeing
the controls and software integration and trouble shooting of the line. These original
machines were built decades ago and require refurbishment utilizing very precise
machined components along with a state of the art controls system to accommodate
for current and future production of NATO round bullets. Refurbishment of 5.56mm
NATO bullet assembly machines, assembling 1,200-1,600 bullets per minute each
Dual Roll & Brake System
line.
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ORI AUTOMATION do BRASIL LTDA
ORI INDIA
ORI CHINA
ORI GERMANY
ORI SOUTH AFRICA
ORI KOREA
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ORI AUTOMATION de MÉXICO
When Innovation & Performance Count
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ORI AUTOMATION de MÉXICO
Webasto
Fori Mexico designed and installed a sun roof motor
assembly test bench for Webasto Mexico for the
Volkswagen model 361. The system snaps together the
two halves of the motor and inserts a plug into the
electrical connector. Each sun roof motor contains a
small processor that performs many functions. The
processor detects when the sun roof is fully open,
partially open and closing force/object detection to
avoid injuries. The system will also detect if the sun roof
if it is left open when the doors are locked and the engine
is not running. This software designed by Fori tests for
the correct release level of the sunroof. If the motor
passes a bar code label at is automatically printed out
and fixed on the motor. If the release level is incorrect
the Fori system automatically erases the current motor
program and installs the correct program and the test is
repeated.
Sun Roof Motor Assembly Station
Faurecia
Fori Mexico completed a system
for Faurecia in Puebla Mexico
consisting of 13 independent
assembly workstations to build
the instrument panel for the
B299 Ford Focus.Aprinted work
order with a bar code is received
by each work station. This work
order details the model #, color
and quantity of parts. Vision
cameras are used to verify the
correct models, colors and styles
are being assembled with the
correct parts. After assembly a
bar code printer produces a
barcode that will be attached to
the completed unit. The system
supports two color options and
four upgrade options at 60 jph
and a yearly capacity of 134,500.
Assembly Station
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Assembly Station
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ORI AUTOMATION do BRASIL LTDA
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ORI CHINA
Volkswagen Shanghai
Fori China has
completed a chassis
marriage system
u p g r a d e f o r
Volkswagen Shanghai
CP1 Plant. System
improvements
included: increase cart
speed from 25 jph to
32 jph, new Intermec
radio frequency
identification system
(RFID) and a new
front and rear tooling
for the Polo and Fabia
models. The system
was completely
installed and running
with the 3 week
shutdown period,
saving Volkswagen
S h a n g h a i
considerable money.
ISO 9001:2000 ISO 14001:2008 Certified
Chassis Marriage System Upgrade
Geely Huapu
Fori China has
recently completed
the installation of
end of line test
system at Huapu
plant in Shanghai,
China. The systems
consist of a digital
w h e e l a l i g n e r,
headlamp aimer, a
single axle roll test
system, a double
axle brake test
system and a data
link information
system. All the
systems are capable
of running 30 jobs
per hour.
Wheel Aligner / Headlamp Aimer / Roll Test
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Page 8
INC.
ORI AUTOMATION do BRASIL LTDA
ORI INDIA
ORI CHINA
ORI GERMANY
ORI SOUTH AFRICA
ORI KOREA
LTD
ORI AUTOMATION de MÉXICO
When Innovation & Performance Count
www.foriauto.com
ISO 9001:2000 ISO 14001:2008 Certified
ORI KOREA
Beijing Hyundai Motors
LTD
Fori Korea has recently completed the installation
of end of line test system at Beijing Hyundai Motor
Company, China. The systems consist of a wheel
aligner, headlamp aimer & a roll and brake testing
system capable of running 300,000 units a year. The
systems which normally take four (4) months to
deliver were delivered in just two (2) months. Fori
Korea met this very aggressive delivery by
leveraging their existing design knowledge from
the two (2) previously installed systems at the same
plant.
Wheel Aligner / Headlamp Aimer / Roll & Brake Testing System
Shanghai Volkswagen
Fori Korea recently completed the rework of the assembly shop at Shanghai Volkswagen Nanjing plant 4, China. Fori Korea
was initially contracted by SVW to provide an engineering study which included the development of the standard “RFQ” for
this project. Included in the RFQ were detailed equipment descriptions and technical specification that met VW strict
requirements. This plant will produce a new model VW411CS, Santana B2, and existing model Santana Vista after rework
with the line capability of 60 JPH. Furthermore Fori China received the PO for the manufacturing of the entire assembly line.
This project will be done another successful story as a cross continent project between Fori Korea and Fori China
Mahindra Mahindra
Fori Korea is in the process of developing a
new green field assembly plant for Mahindra
Mahindra in Chakan India to build their newly
developed SUV models W201 & U202. Their
future plans include introducing one of these
new vehicles into the US market. Fori Korea is
proud of its ongoing partnership with
Mahindra Mahindra in developing complete
end of line testing systems that can handle all
data management and plant communication.
Roll & Brake test System
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ORI AUTOMATION do BRASIL LTDA
ORI INDIA
ORI CHINA
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ORI AUTOMATION de MÉXICO
When Innovation & Performance Count
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ISO 9001:2000 ISO 14001:2008 Certified
ORI INDIA
Ford Chennai
Fori Automation India Pvt. Has completed an
upgrade for a wheel alignment and headlamp aiming
system for Ford India. This updated / reworked
system was part of the expansion of the Chennai
plant to accommodate the following vehicle models
Endeavour, Ikon, Fiesta, Figo & the Fusion with an
overall capacity of 150,000 a year. Fori India moved
the systems from their original factory in Pune to
their new home in Chennai. Several upgrades were
installed by Fori India including; new wheelbase
adjustment, measuring head risers, fender height
measurement using Fori's new 3-D laser modules
and automatic X and Y semi-automatic screwdrivers
for the headlamp aiming system.
Fori Automation Technical News
3-D Wheel Alignment System with Fender Measurement
Volkswagen India
Fori India supplied an offline rear axle sub assembly
system to Volkswagen India with a capacity of 6 jobs
per hour for the Polo 250 & 251 vehicle models. This
system in Pune India consists of overhead KBK
system for loading & unloading, nut runner reaction
arms, trolleys with the ability to swivel, aluminum
rear axle sub assembly pallets, line side presentation
tables and transfer trolleys.
Rear Axle Sub Assembly
Nissan India
Fori India has completed the installation of end of line
systems for Nissan Motors of India. The 20 jobs per
hour system for the Micra model includes; wheel
alignment system, headlamp aiming system, free roll
test system, single axle static brake test, audit head
lamp aiming test and a smoke meter testing system.
All of these systems included special ventilation per
Nissan specifications.
End of Line System
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ORI AUTOMATION do BRASIL LTDA
ORI INDIA
ORI CHINA
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When Innovation & Performance Count
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ISO 9001:2000 ISO 14001:2008 Certified
ORI AUTOMATION do BRASIL
LTDA
GM Rosario
Fori Brazil installed a front corner
assembly system with a 40 jph rate in
the General Motors Rosario plant in
Argentina. Utilizing the race track style
Fori's twin strand conveyor
significantly reduced the required floor
space while at the same time reducing
man power to run and control the
production cells. A poke yoke system
ensures the components are placed
error free on the pallets which increases
performance and product reliability.
Fori Automation Featured Product
Front Corner Assembly System on a Fori Twin Strand Conveyor
GM São Caetano do Sul
Fori Brazil completed the installation of a tire &
wheel assembly & inflation system for General
Motors Brazil in the São Caetano do Sul plant. The
system is capable of running a 12 second cycle
time which equates to 275 units an hour (55
vehicles with a spare tire) Tires ranged in size from
13” to 17”. The tire & wheel identification is
completed automatically using a beam array and
vision recognition system. Several combinations
of rim diameter, wheel width, tire diameters (outer
and inner diameter), tire width and wheel aspect
can be set for flexible programming and setup
covering up to 30 different combinations.
Tire & Wheel / Inflation System
Fiat
Fori Brazil has completed the design, build and installation of a
gear box filling system for Fiat Automoveis at Betim (Brazilian
plant). This system includes equipment for 3 different assembly
lines that run mineral, synthetic and semi-synthetic oil with new
adapters with the ability of faster connection. This system is
capable of running 60 jobs per hour.
Fluid Flow Adapters
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ORI AUTOMATION do BRASIL LTDA
Fluid Fill Controls
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ISO 9001:2000 ISO 14001:2008 Certified
ITAR Certified
Mission Statement
Cage Code M20746
To provide our customers with sound, imaginative and competitive solutions to their production needs, applying innovative technology in
practical ways. To provide rewarding employment with personal growth and educational opportunities for our people, challenging their
resourcefulness to find better ways and encouraging them to take ownership; to be enthusiastic team players and to take pride in their
accomplishments. To have a performance reputation that allows us to become “The Customer's Choice”.
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Fori Automation inc,
Shelby Twp., MI, USA
Tel: 586-247-2336
Fax: 586-566-6773
email: sales@foriauto.com
Fori Korea Ltd.
Sihung-Si, Korea
Tel: 82-31-496-3400
Fax: 82-31-431-5280
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Fori Automation do Brasil
São Paulo, Brazil
Tel: 55-11-4124-7624
Fax: 55-11-4337-3172
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Fori Automation GbmH
Merzig, Germany
Tel: + 49 (0) 6861-70090
Fax: + 49 (0) 6861-7009-310
email: sales@foriauto.com
Fori Automation China
Beijing, BDA, 100176 China
Tel: 86-10-6780-2940
Fax: 86-10-6780-2945
email: sales@foriauto.com
Fori Automation India
Pune, India
Tel: +91-20-6613 5817 / 18
Fax: +91-20-6613 5819
email: sales@foriauto.com
Fori Automation de México
Saltillo, Coahuila, Mexico
Tel: 52-844-416-8918
email: sales@foriauto.com
Fori South Africa
Primrose, South Africa
Tel: +586-247-2336
Fax: + 586-247-6773
email: sales@foriauto.com
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50955 Wing Drive, Shelby Township, Michigan 48315 Phone: 586-247-2336 Option 4 Fax: 586-566-6773 www.foriauto.com