A 20-station indexed assembly line, worked drive and pneumatic sizing calculations, safety-zone design, and the commissioning sequence that takes a line from ring-out to unattended full-rate production.
The project brief: a 600-unit-per-shift appliance-motor subassembly line built around 20 stations on an indexed pallet conveyor, arranged in a serpentine layout because the required 30 m of pitch length simply cannot fit inside the allocated 11 m-deep production bay in a straight line. From there, everything else follows — the main line drive's torque and power requirement, the pneumatic system's air demand and compressor sizing, the choice between electronic and mechanical indexing, and the zoned safety architecture that lets one section of the line be serviced without shutting down the other nineteen stations.
This module walks the whole project the way a real production/manufacturing engineer would: a fully worked friction-plus-acceleration force, torque, and power calculation for the main line drive; the case for electronic indexing over a mechanical cam indexer given a planned future product-mix change; a worked free-air pneumatic demand and compressor sizing calculation, including why the receiver tank is sized above the average demand; a worked ISO 13855 light-curtain minimum safe distance calculation; and the six-stage commissioning sequence, ending in a process capability (Cpk) study that barely clears its release threshold. The full worked numbers, complete bill of materials, and finished design reasoning are part of the unlocked module below.