The Future is Automated: Meet Milbank’s New Robotic Arm

Milbank has taken a bold step into the future of manufacturing by partnering with Interactive Design Inc., an automation integrator based in Lenexa, KS. With the help of IDI, Milbank is adding a new family member to the production floor. Consider this your formal introduction to Martha Ann, a robotic arm named after our founder, Charlie Milbank’s wife and Milbank matriarch.

The collaboration between IDI and Milbank is changing the way Milbank assembles its test switch subassemblies, particularly the hinge and blade assembly and jaw assembly. Previously a manual process, the new automated system is not only a nod to technological advancement but also a key element in Milbank’s plans to streamline production.

Out with the Old, In with the Robo-new

Milbank's previous method was time consuming and required two operators. Carpal tunnel was also a potential risk for both operators- it was time to make a change. Enter the new automated system that promises to double the production capacity and completely eliminates the risk of carpal tunnel.

Automation is an integral part of our production process moving forward, but our Milbank family members are always our top priority. While these operators are being replaced by Martha Ann in this capacity, they’ll be redeployed to different positions within the plant, thanks to their new robotic coworkers.

Meet the Robots: Stakers and Riveters Join the Workforce

The new assembly line features two robots in one unit. The first robot takes on the role of a staker, handling hinges and bolts with the finesse only a machine can produce. It picks, places and stakes with such precision that you’d think it was playing a high-stakes game of Operation.

Robot number two is the riveter, a true craftsman in its own right. It picks blades with surgical precision, slots them onto the hinges, and then prepares the assembly to be riveted. If synchronized robotics was a thing, we’d have front row seats.

A Technological Symphony of Feeders and Vision Inspection Cameras

The system doesn’t stop at robotic prowess. It includes three vibratory feeders that keep the parts flowing smoothly- from hinges to bolts to blades. Operators keep these feeders filled, ensuring the robots never run out of their 'building blocks'.

Additionally, the line is equipped with several vision inspection cameras to ensure that every assembly is perfect. Any assemblies that don’t make the cut are sent to the rejection bin.

Production Goals: Setting the Bar High

Martha Ann is designed to churn out six subassemblies per minute- this system isn't just keeping up; it's setting the pace for future growth. The new system began its journey on April 1^st, 2024, and has been nothing short of a production powerhouse.

Currently, Milbank and Interactive Design Inc. are fine-tuning Martha Ann to maximize throughput. We hold everyone at Milbank to the standard of good enough doesn’t work here, a sentiment that’s true of our human and robot family members.