Case Study: Inspection is the Hidden Bottleneck
As manufacturing demand increases, inspection often becomes the hidden constraint limiting overall production scalability. While upstream processes like machining and assembly are frequently automated, inspection commonly remains manual, variable, and labor-intensive.
BelleFlex Technologies, a Pittsburgh-based manufacturer of precision Belleville disc springs, faced this challenge head-on. Through a collaboration with Integrated Industrial Technologies (I2T), BelleFlex implemented a fully automated dual-robot inspection system using FANUC SR-6iA SCARA robots, KEYENCE TM-X5000 Telecentric Measurement systems, and Inductive Automation SCADA software.
The Result
More than 10X improvement in inspection throughput, dramatically improved consistency and accuracy, full traceability, and a scalable platform that has already supported additional system deployments.
The Challenge
BelleFlex Technologies built its reputation on delivering high-precision disc springs for mission-critical applications. However, 100% manual inspection and mechanical testing by skilled technicians created a significant bottleneck.
Key challenges included:
- Extremely slow and repetitive manual inspection processes
- Variability and risk of human error in visual and mechanical checks
- Limited throughput unable to match growing production demand
- Skilled labor tied up in low-value repetitive tasks
- Lack of scalability and integration with automated production flow
- Tight floor space constraints for any new equipment
The Solution
BelleFlex partnered with I2T and to engineer a compact, fully automated inspection cell tailored to their precise requirements.
System highlights
- Operator load trays and the system run autonomously
- Dual FANUC SR-6iA SCARA robots for high-speed, precise, and repeatable part handling
- Dual KEYENCE TM-X5000 cameras for orientation detection, count verification, and defect identification from all directions
- Automated mechanical load/tension testing
- Full sorting into good/reject trays with complete data logging and traceability
- Intuitive operator interface for setup, monitoring, and maintenance createed using Inductive Automation’s Perspective Module
- Integration with SQL database for data retention
A key design requirement was to preserve operational flexibility during the transition to automation. Rather than replacing BelleFlex’s existing inspection process outright, the system was engineered to integrate with their existing inspection unit in a way that allowed it to be removed and operated manually if needed. This approach minimized implementation risk while providing confidence that production could continue uninterrupted throughout the adoption process.
Results
The automated inspection system delivered immediate and measurable impact:
- More than 10X increase in inspection throughput
- Significantly improved consistency, accuracy, and repeatability
- Reduced reliance on manual labor, freeing skilled technicians for higher-value work
- Complete traceability and data logging for enhanced quality assurance
- Elimination of inspection as a production bottleneck
While the system was designed to accommodate manual operation as a contingency, the reliability and consistency of the automated process quickly demonstrated that it was no longer necessary. The automation delivered the performance required for production, allowing BelleFlex to fully embrace the new process with confidence.
“We’ve actually ordered two more full sets of automation… Having this automation gives us an additional level of confidence, knowing that the products we’re producing truly meet the high level of precision and tolerance our customers require.”
— John Bach General Manager – Engineering and Business Development, BelleFlex Technologies
Key Takeaway
Automation creates the greatest value when it targets real constraints — not just individual tasks. By addressing inspection as the limiting factor, BelleFlex unlocked throughput gains that benefited their entire manufacturing system.
Ready to Remove Your Hidden Bottleneck? Integrated Industrial Technologies (I2T) partners with manufacturers to identify capacity constraints and design custom automated inspection and robotics solutions that deliver measurable speed, consistency, and scalability.
Integrated Industrial Technologies (I2T) is a full-service industrial automation engineering firm specializing in robotic integration, machine vision systems, and advanced manufacturing solutions. We deliver application-specific systems that directly target production bottlenecks and integrate seamlessly into existing operations.
