Custom Pneumatic Manipulator for Toyota Hilux Dashboard Component Handling in Cambodia

1. Customer Challenge & Part Study

In February 2026, a customer in Cambodia asked SSlifter to develop a pneumatic manipulator for dashboard components used for Toyota Hilux vehicles. The part is large and irregular, with wiring and HVAC-related assemblies, making repetitive manual handling difficult and demanding careful positioning.

The project began with actual-part photos, dimensional checks and communication about the production-line layout. This allowed the engineering team to define the handling geometry before finalizing the manipulator structure.

Dimensional verification of the dashboard component and production fixture.

Manual handling reference used to understand the real ergonomic challenge.

Project Objectives

• Reduce direct manual effort when moving the large dashboard component.
• Provide controlled positioning across the required workstation height range.
• Match the actual part geometry and the customer's assembly-line environment.
• Allow site adjustment where final production dimensions may require fine tuning.

2. Engineering Design & Custom Fixture

SSlifter converted the customer's part information and layout requirements into a customized manipulator concept. The engineering work covered reach, fixture shape, operator access, working height and interference with nearby production equipment.

Detailed fixture drawing used to define the gripping and contact geometry.

3D manipulator layout used to review reach, structure and workstation compatibility.

Key Engineering Points

• Customer-specific end-effector geometry based on the actual dashboard component.
• Manipulator structure reviewed against the available factory space.
• Working positions and operator access checked before fabrication.
• Design changes incorporated during customer communication before production.

3. Adjustable Structure & Operating Range

During design communication, the customer requested that the highlighted central support area be fixed with nuts and bolts instead of permanent welding. This provides adjustment flexibility during installation and commissioning at the real production site.

The customer also confirmed an operator working-height range from 642 mm to 1642 mm from ground. The manipulator geometry was therefore designed around this vertical operating requirement.

Bolted connection requirement for on-site adjustment.

Operating-height drawing confirming the 642-1642 mm working range.

Why This Customization Matters

• Bolted adjustment helps compensate for real site conditions after installation.
• The defined height range supports movement between lower and upper working positions.
• The solution is designed around the customer's process rather than a fixed standard machine.

4. Manufacturing, Assembly & Export Delivery

After the dimensions and structural details were confirmed, SSlifter proceeded with fabrication, pneumatic-system installation, assembly and functional checks. The finished manipulator was produced in the customer-selected yellow finish and prepared according to the approved project design.

Completed customized SSlifter pneumatic manipulator after assembly.

Protected and secured in a wooden export case before shipment to Cambodia.

For shipment, the equipment was protected with wrapping material and secured inside a wooden case to reduce movement and transport damage. The project covered the complete process from requirement discussion and engineering design to production and export packing.

Project Deliverables

• Assisted handling of a large automotive dashboard component.
• Improved operator control during repetitive positioning tasks.
• Customer-defined 642-1642 mm operating height range.
• Part-specific fixture concept and factory-layout compatibility.
• Adjustable bolted connection for easier site commissioning.