Toyota RAV4 Assembly Cell Optimization
Tape / Tabber Cell Design
Redesigned an automated tape-and-tabber cell for the RAV4 Centre Pillar Garnish, adding 200 panels per day while holding 1 mm placement tolerances.
Overview
Improved the efficiency and reliability of an automated tape and tabber application cell used in producing Toyota RAV4 center pillar garnish components. Focused on increasing part production while maintaining placement tolerances to Toyota standards.
Objective
Inconsistent tape alignment was traced to excessive assembly tolerances — resolved by iteratively comparing CAD models to physical builds and adjusting fixture dimensions. Recurring tape jamming at the applicating end required modifying the sliding-block geometry and tapehead design to limit adhesive contact and ensure smooth feed motion.
Approach
Iterative CAD-to-physical comparison: measure, adjust fixture dimensions, rebuild, re-test. Sliding-block and tapehead geometry redesigned around DFM principles to minimise moving parts and simplify maintenance.
Results
- —Increased production output by +200 panels / day
- —Maintained 1 mm positional tolerances for tape application onto the panel
- —Enabled easier maintenance and part changeovers through optimised designs
- —Simplified mechanical paths to eliminate unnecessary moving components, reducing failure rates and improving cycle time
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