What are the common equipment and supporting facilities in an assembly workshop?

An assembly workshop typically needs equipment grouped by six process steps: receiving, pre-treatment, sub-assembly, final assembly, inspection and packaging. Core machines include dock levelers, ultrasonic cleaners, differential-chain conveyors, servo presses, AGVs, six-axis robots, CMMs and automatic cartoners. Utilities cover screw compressors, chillers, PSA nitrogen, HVAC with FFUs, and fire-sprinkler systems. Must-have items satisfy 80 % of capacity; optional units such as vision-guided robots or robotic palletizers can be added later. Selecting local suppliers, open-protocol controls and simultaneous design of environmental facilities shorten payback and ensure EIA approval.

1. Classification logic

a. Follow the technological flow: logistics receiving → parts pre-treatment → sub-assembly → final assembly & debug → inspection → packaging & shipping.
b. For each stage, distinguish three sub-categories: core production machines, auxiliary tooling, and utility/environmental facilities—18 sub-groups in total that cover ≥90 % of normal needs.
c. Indicate “must-have vs. optional”, “local or imported acceptable”, and “example brand/spec” so that re-selection time is minimized.

2. Detailed description

1) Logistics receiving area

• Functions: unloading, unboxing, rough de-dusting, buffer storage.
• Core machines: hydraulic dock leveler (1.5 t, 1.1 × 2.0 m), handheld barcode scanner, mobile dock ramp.
• Auxiliary: canopy, crash barrier, outdoor LED display (shows call number), negative-pressure dust extraction nozzle (prevents dust while unboxing).

2) Parts pre-treatment area

• Functions: degreasing, deburring, anti-rust, drying.
• Core machines: ultrasonic cleaner (28 kHz, 300 L tank), pass-through spray washer (0.8 m mesh belt), hot-air circulation oven (120 °C, 4 trolleys).
• Tooling/instrument: ESD parts trolley, on-site cleanliness meter (particle counter).
• Environmental: wash wastewater collected → oil separator + DAF → discharge; VOC from solvent recovered by condensation unit.

3) Sub-assembly (synchronous pallet line)

• Function: pre-assemble parts into modules, takt 30–60 s.
• Core machines:
  – Differential chain conveyor (2 × speed, aluminium frame, 24 m, reversible)
  – Pneumatic torque driver (0.5–12 N·m, with angle monitoring)
  – Servo press (5 kN, position ±0.01 mm, force-displacement curve stored)
• Tooling: quick-change fixture pallet (±0.05 mm location), MES terminal (program pops up after scan).
• Auxiliary: cantilever balancer (50 kg, 2.5 m arm), local laminar hood (class 100, 0.3 m/s face velocity).

4) Final assembly & debug (off-line stations + in-line test)

• Function: integrate modules into finished unit and verify functions.
• Core machines:
  – AGV feeding cart (magnetic/QR hybrid, 800 kg)
  – 6-axis screw-driving robot (repeatability ±0.02 mm, with vision)
  – Motorised lift & rotate table (Ø 1.2 m, 500 kg, free-angle stop)
• Instruments:
  – Hi-pot tester (AC 5 kV / DC 6 kV)
  – Laser shaft alignment tool (for drive-line)
• Auxiliary: silence room (≤65 dB) + extraction arm (for welding/adhesive fumes).

5) Inspection & calibration area

• Function: final check on dimension, performance, appearance.
• Core machines:
  – CMM (0.8 µm + 3L/1000 accuracy)
  – High-speed industrial camera (120 fps, 20 MP) + AI defect-recognition software
• Auxiliary: granite surface plate (1 000 × 1 500 mm, grade 00), constant-climate room (20 °C ±1 °C, 50 %RH ±5 %).

6) Packaging & shipping area

• Function: bagging, cartoning, palletising.
• Core machines:
  – Case-erecting–packing–sealing monobloc (12 cartons/min)
  – On-line weigher & labeller (±10 g)
  – Robot palletiser (1 200 cycles/h, 2 m reach)
• Auxiliary: stretch wrapper, automatic strapping machine, LED board (shows order completion rate in real time).

7) Workshop-wide utility & environmental facilities

• Compressed air: screw compressor (22 kW, 1.3 Nm³/min, VSD) + refrigerated dryer + 3-stage filtration, dew-point ≤3 °C.
• Process vacuum: rotary vane pump (100 m³/h, ultimate 0.5 mbar) for suction/handling.
• Nitrogen: PSA generator (99.9 %, 20 Nm³/h) for explosion-proof cabinets/soldering.
• Water: process chiller (ΔT = 5 °C, 15 kW), closed loop; oil wastewater passes oil interceptor + DAF before discharge.
• HVAC & cleanroom: make-up air unit (MAU) + FFU ceiling, 15–20 ACH, 22 °C ±2 °C, 50 %RH ±10 %; cleanliness 10 000–1 000 class depending on product.
• Fire fighting: very-early-suction smoke detection + wet sprinkler (68 °C bulb); CO₂ flooding for explosion-proof zones.
• Power: dual-circuit supply for class-2 load; UPS (10 kVA, 5 min back-up) at critical stations.

3. Master equipment schedule (copy-paste ready)

#	Stage	Machine / Facility	Must-have?	Key spec / parameter	Typical Qty (5 000 m² workshop)	Remarks
1	Receiving	Hydraulic dock leveler	★	1.5 t, 1.1 × 2.0 m	2 units	Dock to truck tail-lift
2	Receiving	Mobile dock ramp	★	6 t, 10° incline	1 unit	Temporary bay
3	Pre-treat	Ultrasonic cleaner	★	28 kHz, 300 L	1 set	Multi-tank
4	Pre-treat	Pass-through spray washer	★	0.8 m belt width	1 set	Degrease-rinse-blow
5	Sub-ass’y	Differential chain conveyor	★	2 × speed, 24 m	2 lines	Reversible
6	Sub-ass’y	Pneumatic torque driver	★	0.5–12 N·m	12 pcs	Angle monitoring
7	Sub-ass’y	Servo press	★	5 kN, ±0.01 mm	4 units	Force-displacement curve
8	Final	AGV feeding cart	○	800 kg, mag/QR hybrid	3 units	SLAM upgradeable
9	Final	6-axis screw robot	○	±0.02 mm	2 sets	With vision
10	Final	Lift-rotate table	★	Ø1.2 m, 500 kg	4 units	Free-angle stop
11	Inspect	CMM	★	0.8 µm + 3L/1000	1 unit	Climate room included
12	Inspect	Industrial camera + AI	○	120 fps, 20 MP	2 sets	Cosmetic defects
13	Pack	Erect-pack-seal monobloc	★	12 cartons/min	1 set	On-line weighing opt.
14	Pack	Robot palletiser	○	1 200 cycles/h	1 set	2 m reach
15	Utility	Screw air compressor	★	22 kW, 1.3 Nm³/min	2 units	1 work + 1 standby
16	Utility	PSA N₂ generator	○	99.9 %, 20 Nm³/h	1 set	For soldering / Ex-proof
17	Utility	MAU air-handling unit	★	15 000 m³/h	2 sets	VFD fans
18	Utility	Fire-sprinkler system	★	68 °C bulb heads	whole shop	incl. pump house

★ = needed in most assembly plants; ○ = add later depending on complexity / budget.

4. Implementation tips

1. Install all ★ items in phase-1; they cover ~80 % capacity. Add ○ items when volume ramps.
2. When selecting machines, prefer tier-1 local brands (servo presses, AGVs, robots) — 30 % cheaper than imports and faster service.
3. Require open protocols (OPC-UA / Modbus TCP) for every line-level machine; otherwise data-collection retro-fit will double the cost.
4. Environmental & safety facilities must be designed and constructed together with production machines — recent EIA approvals demand 100 % wastewater collection and “zero temporary storage” of hazardous waste; undersized oil interceptor or waste-room area will lead to direct rejection.