When Legrand Australia needed to drive efficiency, it partnered with Applied Robotics for an intelligent automation solution that doubled output.
Part of the global Legrand network, Legrand Australia is a designer and manufacturer of more than 15,000 electrical components under several brands, providing electrical infrastructure for residential and commercial applications nationwide.
At their Sydney facility, Legrand Australia was producing a high-volume commodity product – light switches. With every home and building requiring multiple switches, maintaining efficient and cost-effective production was crucial.
Faced with global supply chain disruptions during the COVID pandemic, Legrand sought an Australian automation partner to streamline local production.
The limitations of manual assembly
The existing production process required continuous operator presence, with staff manually selecting and orienting base components from bulk storage; placing fastening components in the correct position; testing and inserting switch components; operating a foot-press to stamp the components together; and completing QC checks throughout the process.
“With the automation technologies available today, for this high-volume commodity, Legrand identified the opportunity for automation. The process required constant operator attention across two shifts, performing repetitive work,” said Solutions general manager, Applied Robotics, Andrew Hambly.
This labour-intensive approach limited production throughput, potentially risking competitive disadvantage against international manufacturers.
Local intelligence combats the risk of offshoring
Due to similar cost pressures, many small components are moving offshore, so production lines need to remain competitive to avoid loss of jobs and manufacturing capabilities.
“For Australian manufacturers, the challenge is either innovate to stay competitive, or risk losing production to overseas” said Hambly. “Our objective was to help Legrand maintain and strengthen their local manufacturing capabilities through intelligent automation.”
Solution: Automated assembly with intelligent component handling
To address these challenges, Applied designed an automation solution, transforming the assembly process from manual handling to autonomous operation.
At the heart of the solution is a system of three bowl feeders that automatically sort, orient and singulate the key components. Here’s how it works:
• Base components are fed from bulk storage into a vibratory bowl that guides them up a spiral track, orienting them correctly for placement.
• Switch components enter through a similar process, with an integrated vision system identifying their orientation for proper handling.
• Fastening components are automatically fed into the system in the correct position.
“The bowl feeders eliminate the need for manual sorting and orientation. Staff can simply tip bulk components into the system and let it run, rather than handling each piece by hand,” explained Hambly.
Vision-guided robotics for precise assembly
A key innovation in the system is the vision-guided robotic assembly process:
1. The system captures images of each switch component as it enters the assembly area.
2. Software instantly analyses the orientation of the component.
3. A robot picks up the switch and rotates it to the precise position based on the vision data.
4. The robot places the component in the base, applying consistent force to ensure proper seating while simultaneously verifying the correct assembly.
“The vision system examines each switch mechanism and tells the robot how to rotate it for perfect placement every time – something that previously relied on a manual operator,” said Hambly.
Continuous assembly motion eliminates bottlenecks
The automated assembly process takes place on a rotary table that moves components through multiple stations. First, grid plates are loaded onto the table at the first position, then the table rotates to a station where screw clusters are applied. Next, the vision-guided robot places the switch mechanism. After assembly, the components continue to a cover plate application station. Finally, completed assemblies are bagged automatically.
This approach enables continuous production without stopping for component changes, with multiple assemblies being processed simultaneously at different stages.
Easily switch between switch types and styles
The flexible system allows Legrand to adapt to different products to meet demand. Programmable ‘recipes’ enable operators to switch between product configurations and the system handles configurations from single switches up to six-gang units. Also, traditional or contemporary designs can be processed with minimal changeover time.
Results: Doubled output with reduced labour and enhanced quality
The automation solution has transformed Legrand Australia’s light switch production capabilities.
It has doubled production output compared to the previous manual process and reduced labour requirements from continuous operator presence to periodic monitoring. It has also enhanced product quality through consistent component placement and assembly and increased production flexibility with rapid changeover between different product types. This has preserved local manufacturing by making Australian production cost-competitive.
From constant operation to monitoring multiple processes
The most immediate impact has been the change in staff interaction with the production process.
“This kind of automation maximises human input by transforming the entire operation. Instead of an operator being tied to the machine for an entire shift, staff can now oversee multiple processes, returning periodically to replenish components,” explained Hambly.
This switch from dedicated operators to monitoring roles has allowed staff to tend to multiple machines and various tasks throughout the facility, optimising Legrand’s workforce.
Strengthening Australian manufacturing
Perhaps the most significant outcome is how the project has helped Legrand maintain and potentially expand their Australian manufacturing operations.
“When products can’t be produced cost-effectively locally, they inevitably move offshore. What we’ve done here is help Legrand stay competitive while keeping manufacturing jobs in Australia,” said Hambly.
Building a competitive future
The partnership between Applied Robotics and Legrand Australia demonstrates how intelligent automation can make local manufacturing viable, even for high-volume commodity products facing intense international competition.
Combining innovative feeding systems, vision technology and flexible robotics, Applied Robotics has helped transform a manual assembly process into an efficient, adaptable production system.