Tenneco improves manifold assembly ergonomics with cobot-assisted AR guidance

Introduction

Heavy component assembly places significant physical demands on operators while requiring consistently high product quality. During manifold assembly, operators repeatedly lift, rotate and position heavy components before performing critical tightening operations, increasing fatigue and the risk of assembly errors.

To improve both operator ergonomics and process quality, Tenneco implemented Ansomat's cobot-assisted assembly solution. By combining collaborative robotics, augmented reality guidance, machine vision and controlled tightening, the workstation reduces physical strain while ensuring every assembly step is completed correctly and fully verified.

The Challenge - Reducing operator strain during heavy manifold assembly

Manifold assembly requires operators to handle heavy components multiple times throughout the production process. Every repositioning movement increases physical strain while maintaining the precision required for critical assembly operations.

Operators were responsible for:

• Lifting and positioning heavy manifolds
• Rotating components throughout the assembly process
• Following complex assembly sequences
• Performing controlled tightening operations
• Meeting demanding automotive quality requirements

The repetitive handling of heavy parts increased operator fatigue and introduced variability into the assembly process. At the same time, every fastener had to be tightened using the correct sequence and specification to guarantee product quality.

Tenneco needed a solution that could:

• Improve operator ergonomics
• Eliminate repetitive heavy lifting
• Standardise assembly procedures
• Guide operators through complex assembly tasks
• Ensure controlled tightening
• Improve production traceability
• Maintain consistent product quality

The Solution - Cobot-assisted assembly with AR guidance and digital process control

Rather than replacing operators, the collaborative robot acts as an intelligent assistant that performs the physically demanding handling tasks.

The cobot lifts, rotates and positions the manifold throughout the assembly process, allowing operators to remain in an ergonomic working position while focusing on precision assembly.

At every stage, Ansomat's software validates the process by combining:

• Cobot-assisted part handling
• Augmented Reality operator guidance
• Machine vision verification
• Controlled tightening
• Tool position control
• Digital process control
• Complete production traceability

The result is a safer workstation where operators perform less physically demanding work while maintaining a highly controlled and repeatable assembly process.

How It Works

the workstation combines collaborative robotics with intelligent process control to create an ergonomic and error-proof assembly process.

Cobot Handles Manifold Lifting & Rotation
The cobot takes over all heavy handling tasks, positioning and rotating the manifold so operators can work comfortably and safely.

Standard Robot & Cobot Integration
Ansomat’s pre-engineered robot integration makes setup fast and reliable, reducing commissioning time.

Projected Work Instructions on the Manifold
Augmented instructions are projected directly onto the part, guiding operators through each tightening step in the correct order.

Vision-Based Action Validation
Machine vision verifies that each action is performed correctly, preventing missed or incorrect steps.

ESTIC Controlled Tightening Tools
Smart fastening tools ensure every bolt is tightened with the correct parameters, eliminating variability.

Traditional vs Cobot-Assisted Assembly

The Results

By combining cobot assistance with guided and verified workflows, Tenneco achieved a safer and more reliable assembly process.

• Improved ergonomic setup for all operators
• Correct assembly sequence under the right conditions
• Reduced errors during tightening
• Higher consistency across shifts and operators

Why ergonomic assembly matters

As products become heavier and more complex, manufacturers must improve operator safety without compromising productivity or quality.

Collaborative robots enable manufacturers to automate physically demanding tasks while allowing operators to focus on skilled assembly work. When combined with AR guidance, machine vision and digital process control, cobots become part of a fully integrated manufacturing solution that improves ergonomics, reduces assembly errors and delivers complete production traceability.

Customer Benefits

Manufacturers implementing cobot-assisted ergonomic assembly can achieve:

• Improved operator ergonomics
• Reduced physical strain
• Safer workstations
• Standardised assembly processes
• AR-guided operator assistance
• Controlled tightening
• Digital process control
• Complete production traceability
• Higher first-time-right quality