Success Stories:
Problem Statement:
Cycle Time Reduction.
Designing of Fixture for easy changing and clamping of part.
Solutions:
Changed the machining strategy from single setup to two setups.
Setup 2 fixture and machine only top face with 2 tabs on both the sides.
Sequence of operation modified along with tool change.
Setup 1 on the vice and machined all the sides except the bottom machining.
Business Benefits:
Cycle time improvement from 25 minutes to 8 minutes.
Saved 3780 hours of machine capacity in a year.
Machines available capacity will be increased for more work planning.
Problem Statement:
Create the NC program as per the 3D Model.
Follow tolerance as per the customer drawing.
Solutions:
Used smaller L/D ratio tools to get good surface finish.
Corner feed rate applied at start and end point of corner radius edge.
Defined optimized cutting parameter by using Vericut Force.
For steep surface machining areas went with max limit angle condition of machine.
Maximum material removal rate condition has been applied for all cutting tools.
In Setup 1, maximum material has been removed at reachable condition.
In Setup-2, kept part rigidity for machining.
Business Benefits:
Reduced setup time and Fixture cost.
Reduced the machining time by 50% and improved production quantity.
Reduced cutting tools cost.
Problem Statement:
NC program for 3D model.
Fixture designing for Holding casting part.
Solutions:
Holding the casting material in fixture and creating machined butting surface for next setup.
Use the tools and holders based on the complex surface.
Defined optimized cutting parameter as per cutting material.
Created instruction sheet for clamping part at different machining condition’s.
Selected high feed cutter to machine out extra material at faster rate.
Business Benefits:
Customized Fixture for both setup’s where LR and RH will be clamped.
Reduced cutting tools cost.
Problem Statement:
3D model creation as per 2D drawing.
NC program to 3D model.
Creating setups sheets and list of Tools used for each setup’s.
Solutions:
Suggested two different approach for machining
Complete Part machined in single setup.
Standard Jaws for holding material in main spindle.
Modified fixture for holding part in Sub spindle.
Shorter cutting tools used.
Defined optimized cutting parameters and Machining strategy.
Business Benefits:
Suggested Tsugami Turn Mill machine for single setup.
Providing complete manufacturing solutions.
Increase in production quantity by reducing the machining time.
Reducing the raw material cost by using Turn Mill.
Reducing the cutting tool cost.
Problem Statement:
Part allocation & tracking is done manually by entering data in an excel. Challenge is tracking the parts and the corresponding hours delivered by programmers, as there will be different versions of excel, which leads to mismatches & confusions.
Tracking of part is managed through a third-party tool called JIRA. JIRA tool has limitation, and it isn’t suitable for Engineering projects.
Management system is needed which helps in part allocation, managing the part programming life cycle with Dashboard capabilities for management to review the capacity and plan workload.
Solutions:
Import parts & FPY data feeds from ERP system (EPICOR).
Administration Module: For configuring the organization, Department, Division, Users.
Manage Parts module: For part allocation, time tracking and status tracking on parts.
Time Module: For tracking time based on period, programmer and project worked.
Defects Module: To track the defects of parts worked based on project.
Generation of graph on actual capacity and delivered capacity based on delivered hours.
Business Benefits:
A single source of truth for the delivered parts across departments, which helps to overcome mismatches and confusions in part tracking
Improves productivity & efficiency in workforce.
Problem Statement:
COS Implementation and 3D Verification for use in Downstream Manufacturing Applications.
Solutions:
All Dimensions duplication as per supplied master 2D Drawings.
All Part Profile Overlay of views from built 3D or updated model with supplied master 2D Drawings(digital 2D, CATIA V4 ).
Build 3D Model where required.
Business Benefits:
There are many Airbus, Boeing & other Programs having legacy data provided to their Manufacturing Suppliers.
All downstream applications of Manufacturing use now 3D Model Itself as Master Data.
The Input documentation errors needing revision at End Customer are identified before actual Production.
Problem Statement:
To accelerate Request for Quotations activities, BOT has been introduced to provide technical data related to raw material and special process well in an advance to RFQ-Team to speed up Quotation activities
Solutions:
RPA Team automated search and extract information from BOM and Material BOM with the creation of Material Database for the requested detail parts
Business Benefits:
Increase productivity across the board
Improve efficiency to generate savings
Greater accuracy goals with reliable consistency
Improve business data security
Create a better customer service experience
Problem Statement:
Masking & Marking process work instructions (ST BDWGs) in Excel & PDF format.
Solutions:
Identify the region of masking and Part Marking from engineering Data
Using CATIA V5, In 3D model Create Masking areas and respectively giving color code to easily identify for the operators.
Using CATIA V5, Create CAT Drawing Showing views like ISO, Bottom, Back Side if required detailed views along with Masking dimensions.
Each masking process is represented graphically using a set of symbols.
Business Benefits:
Reduce errors and help to standardize processes across a manufacturing company.
Improved productivity, efficiency and quality.
Pictorial representation helps the operator to finish the Masking operations quickly there by reducing the actual time required to refer multiple documents.
Problem Statement:
Designing a fixture For 2 Steel part in a single billet accommodating LH and RH parts with Water jet.
Solutions:
Locating Two Parts in the Billet to make the Equal Waterjet for Each Part.
Designing Single Fixture which can be used for Both parts in each operation..
Fixture was designed which can also used for Stress relieving Operation.
Business Benefits:
Reduction in raw material cost using Waterjet billet.
Minimum fixture Components to reduce fixture weight and cost.
| Business Process | Solution | Key Benefits |
|---|---|---|
| RFQ | Rapid and accurate break down of assemblies and collection of raw material, manufacturing process and specifications from BOM documents for bid response | Increased Productivity (speed) by 83% – Approx.1 minute per part through BOT Vs 6 minutes per part through Manual |
| Intra Company PO | Automate Intra-Company PO creation from UACE to UACV in EpicorRO & create Sales Order in EpicorVN (Spirit) | Increased Productivity (speed) by 67% – Approx. 10 minutes per SO through BOT Vs 30 minutes per SO through Manual |
| Shipping (Logistics) | Automate end to end shipping process – Manifest (as input)-> Packing Slip -> BOL -> Invoice | Increased Productivity (speed) by 73% – Approx. 8 mins per shipment through BOT Vs 30 minutes per shipment Manually |
| First Article Inspection (FAI) | Automatic updating of critical FAI data into customer systems (Net-Inspect Form 1 & 2) | Increased Productivity (speed) by 92% – Approx. 50 seconds per part through BOT Vs 10 minutes per part through Manual |
| Data import for Advanced Supplier List (ASL) app | Automated process to extract data from various Issue forms (scanned PDFs from suppliers) and load to an excel template, which will be imported into ASL app. Implemented using AWS Textract (Machine Learning service) to automate and extracts handwritten & scan pdfs | Increased Productivity (speed) by 70% – Approximately 5 minutes per form through BOT Vs 15 minutes per form through Manual |
| Purchase Order (PO) | Automated processing of PO documents to generate SO in Epicor for Spirit, Airbus, PAG, Aircraft & RUAG customers | Increased Productivity (speed) by 72 % – Approx.7 minutes per PO through BOT Vs 25 minutes per PO through Manual process |
| EPICOR Part Data Entry | Rapid and accurate population of customer inputs into ERP | Increased Productivity (speed) by 75% – Approx. 10 minutes per part through BOT Vs 40 minutes per part through Manual |
| Substitute Material | Rapid and accurate collection of substitute material from customer BOM’s to take more informed decision regarding procurement of raw materials. This is used for RFQ parts to make informed bidding. | Increased Productivity (speed) by 80% – Approx. 1 minute per part through BOT Vs 5 minutes per part through Manual |
| Process Checklist | Creation of a Process checklist excel for a given part with all the customer requirement for that part as per BOM, so that WSD team can make sure that the part produced checks all the requirements | Increased Productivity (speed) by 67% – Approx. 15 minutes per part through BOT Vs Approx. 45 minutes per part through Manual |
| Watermark obsolete files | Watermark the obsolete files. Input data is pdf, tiff etc files and output is the watermarked files which are no longer required in work package. Also, move the unnecessary files to archive folder location | Increased Productivity (speed) by 80% - Approx 2 minutes for each file VS 10 minutes to search and move the file manually |
| Doc-Copy/Transfer | Automatic downloading ERP files from Pro.File app, transferring to WP based on certain condition, generating unmoved and consolidated files log report | Increased Productivity (speed) by 73% - 4 times faster compared to manual work. Bot takes 4 minutes whereas manual work takes 15 minutes |
| Process Applicability | Automatically extract the required information from BOM pdf files and save them in dedicated excel sheet | Increased Productivity (speed) by ~80% - 50 files will be extracted in 20 minutes but manually to extract data from 50 files it will take hours |
| Process Checklist | Search text on the engineering drawings and images. Input is image files, and the output is highlighted search results across the image | Increased Productivity (speed) by 90% - Approx. 1 minute per text search through BOT Vs 10 minutes per text search through Manual |
| Work Package clean-up | Moving the unused docs from the work packages with reference to the docs linked in Epicor. Input in excel sheet with path and output is cleaned work package folder | Increased Productivity (speed) by 95% - Approx 1 minute to move 50 files Vs 20 minutes if moved manually |
| Other Benefits |
|---|
| Reduced Human Error & Rework - Zero errors through BOT |
| Enhanced Customer Satisfaction through faster Turnaround Times (TAT) |
| Reduced Operating Expenses (reduce people processing the same work manually) |
| Reduced fatigue on employees and increased employee satisfaction |
Scope:
APQP is a proven process in Automobile industry. Aerospace and Defence industries have started adapting it in recent years.
Digital transformation of the global manufacturing supply chain by creating stability, control and repeatability in critical skills, processes and systems through the 5 phases
Solutions:
AAPQP product suites contains all the core modules - Process Flow Diagram (PFD), Failure Mode Effect Analysis (FMEA), Statistical Process Control (SPC), Corrective Action Report (CAR), 8 Discipline of Problem Solving (8D), Lesson Learned , Layered Process Audit (LPA) and Competency Management.
Providing secure, encrypted, IOT enabled software solutions to embed Process Stability, Control and Repeatability throughout the Product lifecycle. We align ourselves with Industry 4.0 to create Industry Differentiators & Competitive Advantage.
Real time collaboration and proactive intervention through systems integration (horizontal and vertical) and data analytics.
Digital solution developed using AWS cloud and cutting-edge technologies – React, Node.js, Java etc.
Business Benefits:
Each module gives an incremental benefit in positive impact to cost of poor quality (COPQ), quantifiable reduction in manual activities and duplications.
Increase in the confidence of the customers by increasing the productivity.
Helps reduce risk by identifying problems earlier in the design phase, since the cost of correction is much lesser in early stage.
Ensuring compliance with industry standards – AS9145, ISO9001 / 27001.
Problem Statement:
Small & Medium Manufacturing Companies are using manual process to load boxes into trucks or containers.
Challenge in loading boxes optimally being a manual process.
Expertise is required to load boxes/pallets into trucks/containers.
Effective loading is required to ease the loading at destination.
Solutions:
3D Render of truck/container provided to the operator for better assessment.
Key insights such as the center of gravity, weight balance, axle loads of the truck/container etc are provided.
Generate multiple reports which will help the loading operators & drivers.
Business Benefits:
Reduction in shipping costs & delivery time by optimized solution to load boxes/pallets on to trucks/containers.
Improve efficiency of operators with various options:-
Consider weight/size of boxes while loading.
Load Boxes sequentially.
Consider loading constraints.
Manually add additional boxes.
Provision to input different truck sizes.
Provide destination sequences.
Get axle weights and total truck weights.
Scope:
Automatic Inspection of assembly parts using computer vision (CV) and artificial intelligence (AI) techniques.
Introduce intelligence to quality inspection systems.
Solutions:
Cognex Software:-
Provides state-of-the-art CV & AI techniques under one roof.
Good User Interface to view and inspect parts.
Can be tightly integrated with industrial PLCs and camera.
A master reference part is programmed into the software to which every other part should be compared.
Linear Axis System:-
Enables parts to be inspected with little human intervention.
10m long Delrin bed - Driven by servomotor, chain drive and control units.
Moves linearly in one axis while triggering camera and taking images - Capable of housing up to 8 cameras and light accessories.
Can talk to Cognex cameras using PLCs and PoE.
Business Benefits:
Reduction of Human intervention, inspection time which increases the productivity.
Identification of missing sub-assembly parts & helps in finding out parts which aren’t in specifications.