How an electronics manufacturer scaled production with collaborative robots, achieving 45% throughput increase and 52% labor cost reduction with zero safety incidents.
TechAssembly Solutions manufactures electronic control modules for industrial equipment. The company operated 6 manual assembly lines with 120+ workers performing repetitive, high-precision tasks — resulting in high turnover (35% annually), quality inconsistencies (2.4% defect rate), and difficulty scaling to meet growing demand.
GridMatrix designed and deployed a hybrid human-robot collaborative assembly system with 12 UR+ collaborative arms, vision-based quality control, and intelligent task allocation — enabling 45% production increase with near-zero defects and improved worker safety.
The system integrates 12 UR10e collaborative arms programmed via graphical task builder — no specialized robotics knowledge required. Each robot is equipped with a Schunk intelligent gripper for part handling and adaptive force control. Vision-based quality control uses industrial cameras with Basler APIs and deep learning inference running on edge GPUs. The control system connects all robots via industrial Ethernet to a central orchestration engine built on ROS (Robot Operating System). Data from all robots and vision systems is collected in real-time for KPI tracking (cycle time, defects, OEE). Safety systems include force-torque sensors, emergency stop protocols, and collaborative force limitations per ISO/TS 15066 standards.
TechAssembly Solutions successfully transformed its assembly operations from manual to collaborative robotic production. With 45% throughput increase and 52% labor cost reduction per unit, the company increased profitability while reducing worker injury rates. Defect detection improved from 2.4% to 0.45%, enhancing customer satisfaction and reducing warranty costs. Workforce turnover decreased to 8% (from 35%) as workers transitioned to higher-skill robot supervision roles. The company has now doubled production capacity with the same factory footprint, positioning it to capture new enterprise contracts and expand into adjacent markets.
