Project Success Stories
Discover detailed accounts of how our custom automation, machine modifications, and precision solutions transformed client performance and quality.
Leak Test Machine Modernization
Challenge:
Existing machine delivered inconsistent leak test results due to outdated controls and mechanical systems.
Solution:
Upgraded PLC and leak rate control, modified fixture and pneumatic systems, and integrated comprehensive poka-yoke features to ensure process reliability.
Result:
- Improved cycle time by 40%.
- Achieved 2 cc/min leak detection sensitivity.
- Reduced operator dependency and enhanced test accuracy.
- Increased existing machine life after modifications with good operating conditions and update all latest modifications.
Automation in Bush/Bearing Press Machines
Challenge:
Manual press operations led to inconsistent depth, operator fatigue, excess manpower, missed operations, and high rejection rates.
Solution:
Implemented a multi-station automated assembly line with interlinked press machines, integrated sensors, and poka-yoke systems to ensure consistent and reliable operation.
Result:
- 50% improvement in cycle time.
- Eliminated missed operations.
- Reduced manpower to a single operator.
- Achieved zero rejection through full automation.
Error-Proofing with Volute Blockage Detection
Challenge:
Internal sand core blockages in cast volute housings caused field failures.
Solution:
Engineered blockage detection using air pressure drop measurement & custom fixturing.
Result:
- Zero defects after implementation.
- Clear pass/fail indication.
- Ensured total inspection reliability.