Traveling Sewing Kit

Problem Description

In my Automated Manufacturing course, my team designed and manufactured a portable sewing kit using a fully automated production system consisting of robotic arms, CNC machines, and a conveyor-based workflow. The project focused on designing a product that balanced functionality, manufacturability, and production efficiency while applying Lean manufacturing principles to optimize the manufacturing process.

Our final product was a compact, travel-friendly sewing kit designed for organization, ease of use, and efficient automated assembly. Using robotic automation and coordinated machining operations, we developed a manufacturing process capable of producing multiple kits with high consistency and minimal idle time.

Design

The sewing kit was designed in SolidWorks with both user functionality and manufacturability in mind. The base included multiple storage compartments for sewing supplied such as threat, measuring tape, buttons, pins, and scissors. Features such as angled pin slots, rounded internal corners, chamfered holes, and finger divots were incorporated to improve usability, simplify assembly, and reduce manufacturing errors.

The lid was designed symmetrically so it could be assembled in either orientation, reducing alignment constraints during manufacturing. Throughout the design process, we evaluated how each feature would impact machining time, robotic handling, and overall assembly efficiency.

Automated Manufacturing Process

To manufacture the sewing kits, we programmed three robotic arms and two CNC machines connected through a conveyor-based system. The robotic arms transferred parts between operations while the CNC machines machined the base and lid components.

Using CIM tables and cycle-time analysis, we identified manufacturing bottlenecks and optimized the production flow to improve throughput. To reduce idle time, machining operations were distributed strategically between the CNC machines, and robotic operations were performed in parallel with machining whenever possible.

We also implemented Lean manufacturing concepts, including:

  • Just-In-Time (JIT) manufacturing to minimize work-in-progress inventory
  • Jidoka principles to improve quality and reduce defects
  • Process optimization to reduce cycle time and improve consistency

To further improve manufacturability and assembly reliability, chamfered features and alignment-focused design decisions were incorporated to minimize robotic positioning errors and assembly misalignments.

Conclusions

This project strengthened my understanding of automated manufacturing systems and how product design decisions impact production efficiency and assembly reliably. Through integrating robotic arms, CNC machines, and conveyor workflows, I gained hands-on experiences with manufacturing automation, Lean principles, and process optimization. The project also reinforced the importance of teamwork, troubleshooting, and designing products with manufacturability in mind.

Skills

Manufacturing and Automation

  • Industrial robotics integration
  • CNC machining workflows
  • Conveyor-based automation systems
  • Production flow optimization

Mechanical Design

  • CAD design (SolidWorks)
  • Design for Manufacturability (DFM)
  • Assembly-focused design
  • Rapid prototyping and iteration

Lean Manufacturing

  • Just-In-Time (JIT) manufacturing
  • Jidoka and quality-focused design
  • Cycle-time analysis
  • Manufacturing process optimization

Engineering Collaboration

  • Cross-functional teamwork
  • Technical troubleshooting
  • Systems-level problem solving
  • Engineering process planning

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