Inside Logistics

Installation Inventory: Lights out for Otto

Hirotec America has partnered with Waterloo, Ontario-based OTTO Motors to automate spare parts production with a goal of lights-out 24/7 manufacturing


September 19, 2017
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The OTTO 1500 is paired with a Yaskawa Motoman dual-arm manipulator to pick up and dip parts in black oxide to protect them against corrosion.

Hirotec America has partnered with Waterloo, Ontario-based OTTO Motors to automate Hirotec Group’s spare parts production as part of a goal to achieve lights-out manufacturing for 24/7 operation.

The OTTO 1500 self-driving vehicle is used for automated material movement, while a Yaskawa Motoman dual-arm manipulator has been integrated onto the OTTO to pick up and dip parts in black oxide for corrosion protection.

“Hirotec is always looking for the next technology that is going to take over the industry,” noted Gary Krus, VP of business development at Hirotec America.

“We started by looking for a platform that could make a dual-arm manipulator into a fully mobile manipulation solution. By using the OTTO 1500 with the integrated Yaskawa Motoman manipulator, we have the technology to replicate human labour. OTTO lets us test and prepare future systems to meet our corporate goals of zero operators for spare parts,” he added.

Hirotec America provides weld assembly equipment for original equipment manufacturers (OEMs) including GM, Fiat Chrysler Automobiles, Ford, Toyota and BMW. For close to 30 years, the division has been a pivotal part of the global Hirotec Group with more than $200 million of the $1.6 billion in worldwide sales.

“The next frontier in manufacturing is lights-out production. For so many, and for so long, this has been a vision in the distant future, but the convergence of today’s technology and manufacturing sectors is allowing this vision to become a reality. It’s innovators like Hirotec America that are leveraging new capabilities — we’re excited to be their strategic partner to make it happen,” said Matt Rendall, CEO of OTTO Motors.

The first process that was automated within Hirotec Group’s spare parts production was the black oxide process, which involves moving and dipping parts from bucket to bucket in a sequence, with specific time delays between each sequence as parts become oxidized to provide a corrosion resistant surface.

Previously, the process was completed manually by whomever happened to be available from the shop floor — there was not a set operator on the line. As such, parts were prone to quality issues and were often required to re-enter the process, significantly impacting productivity and throughput.

“We can rely on the OTTO solution to do the same thing, exactly the same way, every time. We’re seeing much more consistent parts than what we saw with our manual process. We don’t have to run the parts through multiple times anymore, which has improved our productivity in spare parts production,” said Peter Mourelatos, R&D project engineer at Hirotec America.

“Operators can now remain focused on the valuable tasks in the shop, and not be distracted with secondary jobs like black oxide dipping.”

“We’ve successfully implemented mobile manipulation at our site, and I can see the OTTO vehicle being used by Hirotec operations globally. It’s just the beginning for us as we work towards our goal of lights-out manufacturing with zero operators for spare parts production,” explained Mourelatos.