AER Stafford has taken delivery of a bespoke sonic welding machine designed specifically for the production of components for a major electric vehicle manufacturer – part of a broader investment programme approaching £1 million in support of upcoming vehicle launches.
The machine is now fully commissioned, with all health and safety checks completed and operator training under way.
Built-in precision and error-proofing
Each component variant has its own dedicated fixture, electronically linked via RFI tags. The machine automatically selects the correct welding programme and only accepts parts in the correct orientation.
This is a Poka Yoke approach to manufacturing – a Japanese-originated discipline, literally translated as “mistake-proofing”, that designs out the possibility of human error rather than relying on inspection to catch it after the fact.
By building the error-proofing into the machine itself, AER Stafford eliminates the risk of incorrect assembly regardless of operator or shift, ensuring consistent output.
The setup was validated through a customer-witnessed Run @ Rate, which AER Stafford passed successfully. The customer left satisfied with both the process and the error-proofing built into the system.
Planning for a seven-year lifecycle
The sonic welder is the first of several new pieces of equipment due before summer, as AER Stafford prepares for full production across the programme.
Managing Director Clive Godfrey explains the thinking behind the investment: “By getting the process right from the start, we’re setting up a successful seven-year product lifecycle and avoiding the hidden costs that typically appear later.”
