September 2026 Continued from previous page


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Emerald Technologies and C2 Smart Carts... same rate.


through the factory. The carts provide real-time


obstacle avoidance, configurable route mapping, a simple operator interface, connectivity with pro- duction equipment and external signals, and performance moni- toring through Quasi software. These capabilities allow the sys- tem to support high-mix manu- facturing without major changes to the plant’s infrastructure. Operators dispatch a cart by


pressing a button, while routes and destinations are configured around specific workflows.


Increasing Wave Solder Throughput


Emerald first deployed one


cart to return pallets from the end of its wave solder line to the beginning. The automated route performs a function similar to a pallet return conveyor but at a lower cost and without installing a fixed system. By eliminating the need for


operators to carry pallets back to the front of the line, the cart al- lows employees to remain fo- cused on production. The reduc- tion in walking and interruption has increased throughput and reduced wave solder run time. “These carts have signifi-


cantly increased our throughput by allowing the operators to re- main seated as opposed to con- stantly getting up to walk pallets back to the front of the line,” Brown says.


Streamlining SMT Material Delivery


The second application con-


nects the carts with Emerald’s automated reel storage towers. The towers stage components be- fore they are required and eject reels for upcoming production. A material handler places each reel on a smart cart, which delivers it to the appropriate SMT line for splicing before the pick-and- place equipment runs out of ma- terial.


Before the carts were intro-


duced, Emerald required one material handler for every two SMT lines. Automated delivery now allows one material handler to support five lines. The change has enabled the company to reas- sign employees to other work without interrupting production. The carts complement other


automation projects at the facili- ty. Emerald uses inline AOI sys- tems programmed to minimize false calls and has automated repetitive processes, including an application that previously re- quired an operator to install ap- proximately 3,000 screws per day. Together, these investments


reduce manual touchpoints, im- prove production flow, and allow the facility to expand output without adding headcount at the


Deployment was completed


quickly with assistance from Horizon Sales. The production floor was mapped, routes were verified, and the carts were inte- grated with Quasi’s monitoring software. The software supplies real-


time operating information and automated return-on-investment calculations. This was important because Emerald’s engineering team is required to collect post- installation data and validate new equipment performance. Shop-floor acceptance has


also been positive. Operators benefit from less walking and manual transportation, while the simple controls limit the


training and interaction required during normal use. The deployment builds on a


relationship between Emerald Technologies and Horizon Sales that has continued for approxi- mately 20 years. That history, combined with the supplier’s re- sponsiveness during installation and support, contributed to the decision to adopt the platform.


Supporting Future Growth The C2 smart carts demon-


strate how manufacturers can au- tomate internal logistics without fixed conveyor infrastructure. At Emerald, the systems have in- creased wave solder throughput, expanded the number of SMT lines one material handler can


Page 23


support, reduced non-value-added movement, and created greater capacity for growth. The project represents one


part of a broader effort to apply automation selectively where it can produce measurable gains. “This is only one step in an


ongoing journey toward manu- facturing excellence,” Brown con- cludes, “one where innovation, partnership, and disciplined exe- cution continue to drive measur- able results.” Contact: Emerald Technolo-


gies, 710 North Maple Road, Saline, MI 48176 % 734-944-2120 E-mail: sales@emeraldtechnologies.com Web: www.emeraldtechnolo- gies.com r


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