Jendamark continues to push the boundaries of possibility with its longest and most automated powertrain production line so far. This differential assembly line is also the largest single-order project ever to be completed by the Group.
Designed to assemble the GM-A2xx platform differentials for General Motors, the line has been installed for ZF at their Gainesville facility in Georgia in the United States.
Jendamark’s head of powertrain assembly, Johan Labuschagne, says the project turnaround time was 12 months, as the entire line had to be designed from scratch.
“No existing machine designs could work for this specific product, except our pinion nut tightening machine, which also had to be modified,” says Labuschagne, adding that it was the first full differential assembly line supplied by Jendamark in 15 years.
“Our R&D experts guided the design team and from there we relied on our vast experience with manufacturing, assembly and commissioning to bring this production line to life.”
It was also the first line to use the latest version of Jendamark’s production and line management software, Odin.
This was particularly important as the assembly process involves gauging to select the right parts for optimum performance of the differential unit, and testing – including a backlash measurement and leak testing – to verify that the assembly process was done correctly.
“Its value has been proven, and we have received an order for another production line using Odin from the same customer,” says Labuschagne.
“We faced some serious hurdles, but the team put in the necessary research and hours to get the project over the finish line. Everyone can feel proud that we delivered a good product and won the customer’s confidence for future projects.”
THE BIG NUMBERS:
Total floor area: 50m x 22m
Total conveyor length: 130m
Machine footprint: 46m
Design: Loop conveyor system
Working stations: 18
Operators: 8
Robots: 5 (plus 1 installed by customer)