Dozens of Robots Support the Production of Millions of Sensor-rich Units

A leading manufacturer of sensor-rich solutions, Sensata Technologies, moved away from traditional industrial robots for their autoloading processes in favor of the Universal Robots UR3e back in 2020, paving the way for their Malaysian plant’s transformation through collaborative automation.

Today, the plant in Selangor has dozens of Universal Robots, including UR3e and UR5e, that free up operators, improve safety and have increase production output by an impressive 20%.

The Challenge

When you manufacture sensor components, many processes are labour-intensive and require high levels of precision. However, manual assembly and handling components across production lines can lead to variability and inefficiencies, especially in repetitive tasks.

Key Value Drivers of UR Robots:

• Easy to learn programming
• System deployment can be done in-house without external experts
• Cobots can be quickly integrated into existing production lines and easily scaled up or down
  depending on production needs.
• Cobots can be re-programmed and reconfigured to handle different tasks.

Tasks Solved by Collaborative Robots:

• Machine Tending for welding, snubbers, cap assembly, and laser coding
• Pick and place parts into a unit
• Transfer pallets from machines into welding machines/ovens

Automation Challenges Solved:

• Precision in complex tasks
• Efficiency in repetitive operations
• Scalability and quality assurance
• Enhanced workforce support
• Improved workplace ergonomics

Boosting Productivity and Safety

The UR cobots have been quickly integrated into existing production lines, assisting with different processes in the plant’s production needs. Their easy-to-use systems gave Sensata instant improvements to production. UR cobots across the plant were programmed and reconfigured to handle different tasks, proving to be highly adaptable to new products or changes in the production process, whether welding, machine tending or palletising. The cobots’ small footprint also maximizes space within each cell, unlike the previous industrial robots which took up more space and were potentially more hazardous given their huge stature and close proximity to workers.

Precision Automation: Raising Accuracy and Output

Shahrul added: “Cobots can perform tasks with extreme precision, which is especially valuable in sensitive manufacturing processes such as ours in sensor production. They’ve been particularly effective in repetitive operations such as assembly and quality control, where consistency and accuracy are critical. Automation allows Sensata to maintain high quality and performance, while scaling production to meet demand.”

The deployment of UR cobots has significantly boosted production efficiency by 20%, contributing to a notable increase in daily output.

Integrating Systems In-house

Satisfied with the implementation of the UR3e within the production plant, Sensata sent four technical staff over to Universal Robots’ APAC headquarters in Singapore back in 2022 for training. Harnessing training from the cobot manufacturers, the technical staff brought back new knowledge to STM, further enhancing their In-House Automation Team to tackle challenges faced in the plant internally.

Divided into mechanical and machining, software and programming, and electrical and technical support, Sensata Malaysia’s In-House Automation Team develops tailored automation solutions to work seamlessly with UR cobots for their needs. Whether there is a need for connectors, grippers, pallet transfers or additions to autoload, the In-House Automation Team engineer solutions that integrate directly with UR cobots across manufacturing cells.

From Automation Users to In-house Innovators

Sensata’s journey with automation is truly remarkable, evolving from simply being users to building a full-fledged in-house automation team capable of deploying, maintaining, and integrating robotics solutions independently. This self-sufficiency is a rare achievement, reflecting the company’s commitment and satisfaction with the performance of UR cobots in their operations. Unlike many companies that may rely on external support for automation, Sensata’s drive to handle every aspect themselves underscores their dedication to operational excellence and innovation, setting a strong example in the industry.

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