Complete Assembly, Functional Test, Traceability and Packout System

A major Tier 1 supplier approached Southern Tooling to replace a labor-intensive assembly and test process for a high-volume consumer mobility product. Their existing workflow required multiple stations, heavy operator involvement, and lacked the consistent traceability demanded by their OEM customer. As volumes increased, quality variation, ergonomic risks, and throughput limitations became major constraints.

Southern Tooling engineered a fully integrated, turnkey $3.4M automation system that combined mechanical assembly, motor installation, functional verification, sound-booth decibel testing, laser etching, video and audio recording, and final packout within a single coordinated platform. Each station was designed for reliability, repeatability, and long-term serviceability, with recipe-driven controls allowing quick changeovers across product variants.

The solution delivered precise alignment and torque accuracy during assembly, automated functional testing with real-time data capture, and standardized acoustic validation using a fully enclosed sound booth. Laser marking and digital traceability ensured that every unit left the line with a complete quality history.

Within the first 90 days, the customer achieved a 27% increase in throughput, a dramatic reduction in rework, and full compliance with OEM traceability and audit requirements. The system is now the production standard for this product family across multiple facilities.