Amazon Robotics - Sequoia

Problem:

• Warehouse floor layout required flexible placement of the control cabinet relative to the ASRS.

• Original cable routing limited flexibility, with fixed cable entry points causing deployment complexity.

Goals:

• Standardize cable configurations for flexible machine placement.

• Minimize on-site cable routing during installations.

• Reduce cable-related costs.

Solution:

• Redesigned internal cable routing, eliminating floor-mounted cable trays.

• Implemented a reversible cable junction system, allowing easy cabinet placement on either side of the machine.

Results:

• Significantly reduced deployment time and complexity.

• Decreased overall cable lengths and costs.

• Reduced part count, simplifying manufacturing and maintenance.

3. Cable Routing Enhancement

Problem:

• Installation teams faced challenges due to unclear cable routing paths.

• Absence of defined routing instructions caused cable damage risks.

Goals:

• Develop precise 3D cable routing paths and documentation.

• Prevent cables from exceeding minimum bend radii.

Solution:

• Created detailed 3D cable routing models in SolidWorks.

• Established a comprehensive database of cable connectors, bend radius limits, and defined zip tie locations.

Results:

• Enabled clear, easy-to-follow installation instructions.

• Improved cable routing reliability, eliminating risks of damage or improper installation.

• Enhanced overall installation efficiency and reduced build complexity.

5. Production Team Build Support

Activities:

• Collaborated directly with the production team to swiftly resolve assembly issues.

• Documented unresolved challenges through Engineering Change Orders (ECOs) for systematic future improvements.

Results:

• Enhanced immediate production efficiency.

• Identified key areas for long-term design improvements.

6. Material-Based Part Optimization

2. Bolted Joint Analysis

Problem:

• Excessive use of varied fasteners leading to high redundancy and increased assembly times.

Goals:

• Perform comprehensive bolted joint analysis to optimize fastener usage.

• Standardize fasteners to streamline assembly.

Solution:

• Conducted detailed bolt load analysis to validate safety factors and eliminate redundant fasteners.

• Unified fastener types across assemblies.

Results:

• Reduced the variety and number of fasteners, significantly cutting down assembly time.

• Enhanced efficiency in production processes.

4. Cable Fastener Optimization

Problem:

• Traditional zip-ties provided insufficient cable support, causing installation and reliability issues.

• Sheet metal profile cut-outs were costly and inefficient.

Goals:

• Identify more effective and cost-efficient cable fastening solutions.

Solution:

• Tested and implemented Oval Christmas-tree cable ties, significantly improving cable support and installation ease.

Results:

• Improved cable stability and reduced installation time.

• Enhanced overall durability and reduced component cost.

7. BOM Cost Optimization