FFE Engineering Section
Machinery Engineering Teams
Since our establishment in 2008, the FFE Engineering Team has successfully delivered over 150 projects, continuously advancing through cutting-edge technologies and innovative product development. Our dedicated team combines mechanical and electrical engineering expertise to drive factory automation and efficiency improvements.
150+
Projects Completed
Comprehensive machinery engineering solutions delivered since 2008
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6
Core Team Members
Split between mechanical and electrical engineering expertise
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17
Years of Excellence
Continuous advancement through innovation and technology
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Team Composition & Stability
Our engineering teams maintain consistent staffing levels with 3 mechanical engineers and 3 electrical engineers from FY24 through FY27, ensuring knowledge retention and project continuity. This stable foundation enables us to tackle increasingly complex automation challenges.
History of Technology Adaptation
History of Technology Adaptation
Our journey showcases progressive adoption of advanced automation technologies, from basic robotics to sophisticated vision systems and collaborative robots. Each innovation represents a strategic leap forward in manufacturing capability and precision.
Early Robotics Era
KUKA 6-axis for scoping: Implemented in NP Casting Auto Scope applications, establishing our foundation in robotic automation.
EPSON 6-axis with vision: Advanced pick & place operations in NC systems, integrating vision-guided robotics.
Advanced Vision & Robotics
Delta robot innovations: In-house designed delta robots paired with flexible part feeders and SEC vision feeders.
ABB 6-axis integration: Combined with vision systems for NC Pick & Place applications with enhanced reliability.
Quality Assurance Evolution
Barcode pokayoke: Traceability systems preventing assembly errors through automated verification.
Digital measurement: XY linear tables with contact sensors for DG Auto Checker dimensional inspection.
Soft gripper technology: Testing across all product lines for gentle, adaptive part handling.
Precision Motion Control
Servo motor interpolation: Developed for PC5 New Concept Mini Auto Lathe, enabling complex synchronized movements.
XY actuator systems: Deployed in Annealing Auto Loading with integrated vision for precise part placement.
Collaborative & Inspection Technologies
Cobot free picking: Utilizing collaborative robots for flexible material handling operations.
Advanced lighting systems: Lumitrax & Multispectrum lighting for superior surface appearance inspection.
EPSON MIPLE Vision: Comprehensive inline inspection systems for FA-II and WHA New Concept machines.
EPSON Robotics & Vision System Deployment
Our comprehensive EPSON technology ecosystem represents a strategic investment in standardized automation platforms. By consolidating on EPSON 6-axis robots, SCARA systems, and MIPLE vision processing equipment, we’ve achieved operational consistency, simplified maintenance protocols, and accelerated troubleshooting capabilities across all production facilities.
8
SCARA Robots
Eliminating 4 person equivalents through high-speed assembly automation
20
6-Axis Robots
Delivering 14 person manpower reduction across complex operations
8
MIPLE Systems
Vision inspection reducing 4 person quality control requirements
Technology Deployment Timeline
Our phased implementation strategy has systematically expanded automation capabilities while maintaining operational stability. Each deployment phase builds upon proven successes, minimizing risk while maximizing return on investment
2013-2015: Foundation Phase
- Initial EPSON 6-axis integration (3 units deployed)
- MIPLE training team establishment
- SEC One System robot pilot (1 unit)
- Vision processing skill development
2016-2018: Expansion Era
- Scaled to 12 SCARA units across multiple lines
- MIPLE system proliferation (7 units active)
- K&A brand integration projects
- Cross-platform standardization initiatives
2019-Present: Optimization
- Completed 17 additional 6-axis installations
- Total 11 MIPLE systems operational
- Advanced vision applications deployed
- Continuous improvement methodology
Cumulative Impact: The comprehensive EPSON ecosystem deployment has eliminated approximately 22 full-time equivalent positions while simultaneously improving quality metrics, reducing cycle times, and enabling 24/7 production capabilities previously impossible with manual operations.
INV MPPD4 Vision Appearance Inspection
Stamping Part Automated Vision Inspection System
This advanced automation project revolutionizes quality inspection for stamped components by implementing high-resolution vision technology. The system addresses critical challenges in manual inspection processes while significantly enhancing sorting capacity and consistency.
Current Manual Process Limitations
- Labor-intensive manual sorting requiring dedicated personnel
- Human judgment variability leading to inconsistent quality decisions
- Operator fatigue affecting detection accuracy during extended shifts
- Limited throughput capacity constraining production volume
- No digital traceability of inspection results
50% Manpower Reduction
From 2 persons (operator + QC) to 1 person through intelligent automation
Consistent Quality
Eliminates subjective human judgment variations with automated vision analysis
Enhanced Throughput
Increased sorting capacity enabling 24/7 unmanned operations
Defect Detection
Reliably identifies multiple defect types including color changes, gear burrs, and foreign material
Performance Comparison: OD < 6mm Components
The automated system achieves 23% faster cycle time while maintaining superior consistency across all defect categories.
Top 5 Detectable Defects
The Keyence 64MP vision system successfully identifies critical quality issues that are challenging for human inspectors to detect consistently, particularly under repetitive examination conditions.
This implementation demonstrates how advanced vision inspection technology can simultaneously improve quality consistency, reduce operational costs, and enhance production capacity. The system operates reliably during night shifts, providing 100% inspection coverage with comprehensive digital documentation.”
MPPD3 Makishin Auto Dimension Inspection
The automated dimension inspection sorting machine eliminates human error from critical measurement operations while enabling 100% inspection of suspect lots. This Keyence TMX-based vision system performs complex multi-point dimensional analysis at speeds impossible with manual techniques, ensuring dimensional compliance before parts reach assembly operations.
Manual Process Challenges
- Tedious comparator and projector measurements requiring sustained operator focus
- High probability of measurement recording errors during manual data entry
- Time-consuming inspection creating bottlenecks during lot confirmation
- Inconsistent measurement techniques between different operators
- Limited sampling coverage leaving potential defects undetected
Automated Solution Design
The system employs sophisticated part manipulation to capture all critical dimensions in a single automated cycle. A feeder bowl presents parts to a precision rotary unit, which positions them through four sequential measurement stations equipped with 2D vision cameras.
- Simultaneous multi-angle measurement capturing 10+ critical dimensions
- ±0.2μm measurement accuracy exceeding manual capabilities
- Automated pass/fail sorting with complete traceability
- 6-second total cycle time including image processing
System Performance Specifications
Cycle Time Performance
6 seconds total including part handling, measurement, and sorting decision
Accuracy Achievement
±0.2μm repeatability surpassing manual measurement capabilities
Image Processing Speed
4 seconds for complete multi-point dimensional analysis and validation
Investment Cost
194,000 RM total fabrication cost with projected 18-month ROI
Measurement Points
4 critical dimensions including 2x diagonal and 2x square measurements
Key Advantage: The system enables proactive quality control by enabling 100% inspection of lots flagged during outgoing inspection. This catch-and-correct capability prevents downstream quality issues while maintaining production flow, a capability impossible with manual inspection due to time constraints.
MPPD3 Media Separation Semi-Automation
This innovative tumbling media separation system addresses a persistent challenge in finishing operations: efficiently separating small precision parts from polishing media. The automated multi-layer shaking system standardizes separation parameters while dramatically reducing operator fatigue and cycle time variability.
Manual Operation Limitations
Traditional manual shaking methods subjected operators to repetitive strain while producing inconsistent results. Manual separation required sustained physical effort, with cycle times ranging from 3-5 minutes per container depending on operator technique and fatigue level.
- Physical strain causing operator discomfort and fatigue
- Variable separation quality based on individual technique
- Time-consuming process creating production bottlenecks
- Difficulty maintaining consistent parameters across shifts
Semi-Automated Solution Benefits
The engineered shaking system processes multiple layers simultaneously using programmable vibration patterns optimized for different part geometries. This standardization ensures consistent separation quality regardless of operator or shift.
- Ergonomic design eliminating repetitive strain injuries
- Standardized shaking parameters ensuring quality consistency
- Multi-layer capacity increasing throughput efficiency
- Programmable modes adapting to different part codes
Performance Comparison Analysis
Part Code 00222222F
Neji component requiring delicate media separation
Part Code A9000121720F
High-volume Neji production utilizing IC-021 media
IC-021 Media
Precision tumbling media for surface finishing operations
Manpower Reduction
Liberating operators for higher-value quality control activities
Cycle Time Improvement
Consistent 1-2 minute processing versus 3-5 minute manual operations
Project Investment: 47,000 RM total budget with March 2024 implementation. The system’s programmable nature enables rapid changeover between different part codes, maximizing equipment utilization across multiple product families.
Semi-Auto Wheel Round-Out Measuring
Advanced vision measurement system replacing manual projector inspection with automated dimensional verification. This RM 133K investment (October FY23, 3-year ROI) eliminates human measurement error while optimizing quality control manpower.
Manual Inspection Drawbacks
- 100% checking using projector equipment
- Operator fatigue from continuous visual inspection
- Measurement inconsistencies between QC personnel
- No automated data recording or trending
- 100-second cycle time per piece inspection
- 1.17 person manpower requirement
Quality Impact: Inconsistent manual judgment between different QC operators created measurement variability affecting process control decisions.
Automated Vision Solution
Keyence TM-X5000
High-resolution vision system captures dimensional data automatically
70% Faster
30-second cycle time versus 100 seconds manual inspection
Digital Records
Automated data logging enables trending and process analysis
The system eliminates operator-dependent judgment variations through consistent automated measurement criteria. Digital data recording enables sophisticated statistical process control and real-time quality monitoring.
30
Seconds Per Part
Automated inspection cycle time with vision capture and judgment
1.4
Persons Saved
Net reduction through automation (from 1.17 to optimized staffing)
100%
Inspection Coverage
Maintains full inspection while improving speed and consistency
Cycle Time Reduction
From 100 seconds to 30 seconds enables 3.3x throughput increase
Judgment Consistency
Eliminates inter-operator measurement variability
Cost Investment
133,000 RM total with 3-year ROI projection
The automated roundness measurement system has revolutionized our wheel quality verification. We’ve eliminated the ‘gray area’ judgments that plagued manual inspection, and our customers have noticed the improvement in dimensional consistency.” — Quality Assurance Lead
MPPD5 STR Part Auto Arrangement
Automated part orientation system transforming manual piece-by-piece arrangement into continuous 24-hour operation. This RM 89K FY23 project enables substantial manpower reduction for Wahli92 part centering materials while improving arrangement consistency.
Manual Arrangement Constraints
- Labor-intensive piece-by-piece manual positioning
- Single operator fully dedicated to arrangement task
- Limited to single-shift operation (8 hours)
- Arrangement quality varies with operator fatigue
- Production bottleneck during high-volume periods
Automation Advantages
1.25 Hours Per Tray
50% cycle time reduction from 3.5 hours manual processing
24-Hour Operation
Continuous running capability versus 8-hour manual shifts
0.5 Person Reduction
Operator freed for value-added tasks during automated cycles
Cycle Time Reduction
Faster processing per tray enables higher throughput
Shift Multiplication
24-hour operation versus 8-hour manual shifts
Manpower Optimization
From full-time to part-time operator requirement
The automated system eliminates human error in part orientation while enabling continuous operation. Operators can manage multiple machines or perform other value-added activities during automated arrangement cycles, maximizing labor efficiency across the production floor.
Annealing Box Auto Mode Selection
The annealing box automatic mode selection system represents a critical quality safeguard, eliminating a persistent source of production losses: incorrect heat treatment parameter settings. By automating parameter selection through barcode scanning, this system prevents costly lot disposals while ensuring consistent thermal processing across all production shifts.
Manual Parameter Selection Risks
Traditional manual pattern selection required operators to correctly identify and set annealing temperature programs for each part code. This human-dependent process created multiple failure modes leading to scrapped lots and sorting rejects.
- Operator selection errors causing wrong temperature profiles
- Pattern confusion between similar part codes
- Shift changeover communication breakdowns
- No verification step before cycle start
- Lot disposal costs from heat treatment errors
- Rework sorting adding non-value time
Automated Barcode Selection
The integrated barcode scanning system automatically reads job card identification and selects the correct annealing temperature program from a validated database. This fool-proof approach eliminates the possibility of parameter selection errors while creating complete traceability.
- Automatic parameter selection eliminating human error
- Validated database ensuring correct thermal profiles
- Visual confirmation display for operator verification
- Complete digital record of program selection
- Prevention of costly lot disposal from wrong settings
- Reduced quality sorting workload
Scan Job Card Barcode
Operator scans the job traveler identifying part code and lot number
Automatic Program Selection
System queries database and loads correct annealing temperature profile
Visual Confirmation Display
Selected program parameters displayed for operator verification before start
Digital Traceability Recording
Complete cycle data logged with part identification for quality documentation
Quality Impact
Elimination of lot disposals caused by incorrect annealing parameters represents substantial cost avoidance. Each prevented disposal saves material, labor, energy, and most critically, delivery schedule disruption.
Process Consistency
Automated parameter selection ensures identical thermal treatment for every lot of the same part code, regardless of operator, shift, or production timing. This consistency directly improves downstream assembly yields.
Traceability Enhancement
Digital recording of annealing program selection creates comprehensive quality documentation, enabling rapid root cause analysis when process variations occur and supporting customer quality audits.
Before barcode scanning, we averaged one lot disposal per month from annealing parameter errors. Since implementation, we’ve had zero disposal incidents. The system has paid for itself many times over just in prevented scrap costs, not counting the improved customer confidence from consistent quality.” — Heat Treatment Supervisor
Implementation Success: The annealing box auto mode selection system demonstrates how targeted automation addresses specific quality vulnerabilities. Rather than automating for automation’s sake, this project strategically eliminates a known failure mode, delivering immediate quality and cost benefits while requiring minimal operator training or process change.