Case Study: How Honeywell, Spokane Valley Increased Yield 10% Through Advanced Automation

To address the constraints:

• 21 manual process steps
• 85% yield
• High variability and rework driving production costs up
• Safety and ergonomic concerns

Honeywell Spokane partnered with Acieta to design and implement a high-volume, integrated robotic cell. The system combined robotic handling, polishing, and bead blasting with vision guidance, custom EOAT, and a unified SCADA architecture integrating equipment from multiple global suppliers.

• Core Robotics Operations:
  A FANUC R-2000iC/210F on an RTU supported critical handling and transfer functions, complemented by vision systems for precise part location and verification. Two FANUC M20iD/25 robots performed polishing and bead blasting, delivering high-precision finishes with parts-per-billion accuracy.
• Component Integration:
  The system architecture brought together equipment from different suppliers, including German-built machine tools, Italian wash systems, and Japanese material scanners. Using a SCADA platform for system output monitoring, these devices were integrated into a unified, reliable process.
• Custom Tooling Development:
  Specialized EOAT tooling was engineered to delicately handle 130 lb fragile components, incorporating polyurethane touchpoints and precise actuators. This development reduced manual intervention steps from twenty-one to just two, enabling operators to concentrate on higher-value tasks.

By collaborating with Acieta’s engineering and integration team, Honeywell, Spokane Valley was able to achieve clear, measurable results:

• Yield increased from 85% to over 95%
• 90% reduction in manual steps (from 21 to 2)
• Lower per-unit costs by reducing scrap and rework
• Production scaled without adding labor
• Operators upskilled into in-house automation specialists

Beyond performance gains, the project strengthened internal capability. Operators were upskilled into in-house automation specialists, trained in robot programming, vision system calibration, and digital twin technology. Team members like Darren Fry, Lead Manufacturing Technician, now help lead automation efforts internally — fostering a culture of continuous learning, technical ownership, and long-term workforce retention.

Honeywell Spokane Valley’s project demonstrates how collaborative engineering, advanced robotics, and strategic planning translate into measurable gains in capacity, quality, and safety. It’s a strong example of modern manufacturing where ingenuity and operational rigor drive scalable performance.

More than an upgrade in equipment, the partnership builds a foundation for sustained performance as demand evolves.