Overview:

How ENWPS helped a Foundry with a Vision Monitoring System for correct dispensing of a crucial additive.

About The Client:

The client is a leading manufacturer of Automotive Braking Systems and Ferrous Castings in India.

Case Study Brief:

Addition of Inoculants (FeSi based alloys) into the liquid iron during pouring to improve the metallurgical quality of the cast iron is a routine task in a foundry. Correct dispensing of inoculation material into the pouring system is the tricky part in this process. The customer facility has the equipment for dispensing inoculation; but what they do not have is the equipment, which will ensure that the correct amount of inoculation is being dispensed.

If they do not monitor this inoculation process, not only the metallurgical quality of the casting will get affected, but also there will be a lot of wastage of the inoculant.

Our Work:

ENWPS designed and implemented a Vision Monitoring System to ensure accurate inoculant dispensing. We selected a high-speed Vision Camera capable of operating in high-temperature foundry conditions, and strategically installed it on the limited-space pouring platform. Special care was taken in choosing appropriate filters and protecting the camera from heat and dust.

Our custom software delivered real-time monitoring with visual data, numeric outputs, graphs, and logging capabilities. This solution enabled the client to consistently verify inoculant flow, improve casting quality, and minimize additive wastage.

Key Challenges:

o Ensure correct flow of Inoculation

o Ensure correct alignment of Inoculation tube/pipe

o Vision camera location and positioning

o Vision camera protection from heat and dust, and

o Choice of correct filters for the Vision Camera.

The Solution:

The Vision Camera is the heart of any Vision Monitoring System. To monitor the inoculant flow, we chose a Vision Camera, which will capture and process images at a very high speed, operate efficiently in the very high temperature environment and is easy to program.

The critical part was the camera installation on the platform of the pouring system equipment. The Pouring System pours the molten metal into the moulds. There was limitation on space for the camera installation due to cables lying on the platform and the heat produced by the molten metal. We chose the right location and positioned the camera in such a way that it will give the best results in monitoring the inoculant flow.

We provided a monitoring system that can be applied on every existing inoculation process to check the correct feeding and distribution of the inoculant powder into the iron stream. Our monitoring software application is featured with real images, numeric data and graphs with the option of data logging.

The Result:

The customer can now ensure the correct amount of inoculant feed into the iron stream. This improved the quality of the casting products and the process can now easily track the item in which the inoculant is not added properly.

Our Achievements: 

ENWPS successfully enhanced casting quality by implementing a vision system that ensures precise inoculant dispensing, significantly reducing material wastage and improving traceability. Despite challenging conditions like limited space and high temperatures, the solution integrated seamlessly with existing equipment and provided a user-friendly interface with real-time visual data and logging capabilities.

Overview:

The case study deals with one of our most challenging implementation projects, incorporating an Integrated Production Management System for a body shop. Any discrepancies at any stage/ part of the system can hamper overall production management. Despite obstacles and various constraints, our team accomplished the project with the precise and successful execution of the Integrated Production Management System (IPMS).

About The Client:

Tata Motors Group (Tata Motors) is a leading global automobile manufacturing company. Tata Motors is one of India’s largest OEMs offering an extensive range of integrated, smart and e-mobility solutions. Its diverse portfolio includes an extensive range of cars, sports utility vehicles, trucks, buses, and defense vehicles.

The Integrated Production Management System project was conducted for the TATA Motors manufacturing facility in Pune. The Pune facility is a full-range supplier of both commercial and passenger vehicles. The unit is equipped with state-of-the-art manufacturing capabilities, testing facilities, and sets standards for India’s automotive research and development.

Case Study Brief:

Integrated Production Management is a highly efficient system that enables shop-floor managers to receive real-time information, track and trace materials, and optimize production to improve output. It is an intelligent manufacturing system that manages different shops with complex setups for achieving flexible production, ensuring quality checks, events, and history data logs. The system executes stepwise inspection of products through a unique barcode-scanning system to track each part at different stages of production. It ascertains that the correct part is available at the required step of the process and effectively manages the entire process. The system essentially improves efficiency, facilitates optimization, dramatically reduces turnaround times, enhances the accuracy and quality of products, and improves the plant’s overall efficiency.

Tata Motors, Pune wanted to incorporate Integrated Production Management System (IPMS for its body shop division. ENWPS undertook the assignment as an Implementation and Development Partner for the project.

Our Work:

Our client, Tata Motors, was willing to install a similar flexible production system that can produce a unique model every minute while having no restrictions on model variations. Usually, such manufacturing units deploy a batch manufacturing production system, wherein the whole production line needs to be rebuilt whenever introducing a different model. However, Integrated Production Management aims to provide the right part at the right place for unique models without interfering with the whole manufacturing setup.

The IPMS was installed for the body shop of the consumer vehicles manufacturing division, where every next model can be different from another. Below are the steps and processes undertaken for successful integration.

o IPMS provides the production plan to SPC (Sequence PC).

o The programmable logic controller requests the next variant to SPC.

o SPC sends variant to PLC and prints barcode for the car (a unique Car ID).

o SPC periodically polls the status information from all the line PLCs.

o SPC displays the line status on each line on an Andon board.

o Flexible Production: Every next car can be different from another one.

o Provided RAID 5 disk protection.

A backup PC is also provided to back up all the line PLCs.

Key Challenges:

o Freedom of adding variants and models for new cars without restrictions

o Flexible production management by optimizing real-time data

The Solution:

Our team installed the Integrated Production System on-site along with rigorous testing and analysis of the whole production system. We installed in-built software that keeps track of the entire production process through barcode scanning. The software also provides real-time feedback and data about inventory levels, production plans, order tracking, and associated tasks.

The system developed efficiently manages the marriage stations and assembly lines with different components entering the process from various stations. Moreover, the system is intelligently designed to work efficiently even when any error occurs. It includes take-out stations, which remove all the aligned parts from the production line, without interrupting the production process. And whenever the issue is resolved all the parts are again placed in the previous order through take-in stations.

The Result:

The solution enabled the customer to achieve the following.

o A flexible production system that produces a different variant or model every 54 seconds.

o One million programmable variants were made available to introduce new features in the model or upgrade the existing ones.

o Unique barcode-scanning system for keeping a record of each part at different stages of assembly. It ensures that the correct part is available at the required step of the marriage line.

o It increased production output and efficiency.

o The system enables shop-floor managers to receive real-time information, track and trace materials, and optimize the production process to the availability of parts.

o Deployment of a flawless manufacturing process that can provide real-time feedback of the manufacturing process with necessary changes. This prevents the manufacturing of defective products.

o Reduced lead time and capability to introduce multiple customizations according to customers’ needs.

o Enhanced accuracy of the product by keeping a check on marriage stations.

o Effective planning and sequencing of the daily manufacturing process.

o Other utilities of the system involve data logging, fault detection, regular backup, and ample storage for keeping all the information secured.

o Also, hot-swappable drives were installed, which enabled the replacement of drives without turning off the production process. So, in case any dysfunctionality occurs, the data remains secure.

The system has been working efficiently since its installation in 2012, and our client has been able to optimize and enhance its manufacturing process to the fullest.

Our Achievements: 

Our team emerged with flying colors, overcoming all the criticalities and obstacles in integration.

Overview:

The Case study highlights the adeptness of our team at ENWPS to successfully implement a complex project at the General Motors, Talegaon car assembly plant as per their pre-defined set of standards.

About The Client:

Our client, General Motors (GM), is a global company specializing in the production of cars, trucks, and SUVs and providing parts and services to support manufacturing operations. The company is the second-largest automaker in the world. The project assigned to ENWPS was concerned with General Motors, Talegaon plant.

The Talegaon plant currently assembles the following vehicles for the Indian market:

o Chevrolet Spark (legacy Daewoo Matiz)

o Chevrolet Cruze

o Chevrolet Beat (global-market Chevrolet Spark)

o Chevrolet Sail Sedan and Chevrolet Sail Hatchback

Case Study Brief:

The case study deals with implementing the Lean Error Proofing (LEP) system for the assembly plant. LEP is an industrial concept used by General Motors for improving the assembly procedures and resolving the issues of downtime and missing fasteners. The purpose of LEP is to reduce variations in the production process by eliminating a potential failure due to human error or process failure. Error proofing means preventing minor mistakes in the production flow at their initial stage rather than down the line when a product has already been completed and distributed.

Another term for Lean Error Proofing (LEP) is “Poka-yoke’, which follows the mistake-proofing approach towards manufacturing. It is a Japanese term where ‘Poka’ means ‘inadvertent errors,’ and ‘yoke’ means ‘to avoid.’ Therefore, avoiding unexpected or coincidental errors from production that may lead to unfavorable results.

General Motors wanted to install a similar LEP system for their Talegaon assembly plant. ENWPS undertook the assignment as an Implementation and Development Partner.

Our Work:

As part of the project, ENWPS was assigned the task of developing and installing the LEP logic to integrate the error-proof workflow. Our team performed installation and programming of eight different lines in GM’s General Assembly shop, namely –

o Trim Line 1

o Trim Line 2

o High Chassis 1

o High Chassis 2

o Low Chassis

o Engine Dressing

o Final Line

o Cockpit

Key Challenges:

– Tight Deadlines and Hectic Work Schedule: For a consistent 100+ days, our team worked on-site in the second shift after the first shift had concluded the daily task. The work scope included developing logic, completing installation work, and reverting the existing logic of the running line before the operations begin on the line the next day.

– Challenges During Installation: Installing the cable trays and laying the power cable at Chassis line at a height of 40 feet using a Boom Lift.

The Solution:

Despite all the obstacles in the process, our team concluded the development and installation of the Lean Error Proof (LEP) system while complying with GM standards. The everyday work scope involved strategically planning the day-to-day activities to avoid interruption in the line operations. Our team collaboratively worked with the GM team to ensure seamless production and prevent any calamity during the tasks. With the help of skilled programmers, electrical supervisors, safety officers, and skilled laborers, the project was concluded within the stipulated time. Below, solutions were provided by the ENWPS team as part of the successful implementation of the LEP system.

o Providing identification, guidance, verification of correct part, and work completion

o Quality Management System on production floor

o Torque Tool (TT) -correct torque selection, application, and confirmation

o Part Pick (PP) -part selection, guidance, verification, and confirmation

o Process tool (PT) -process tool/equipment interfacing for selection, application & confirmation.

o Providing electrical drawings design and draft using Eplan P8 as per GM standards to the maintenance team to troubleshoot electrical errors if any

o Support and Documentation

The Result:

The LEP system implementation and development project was successfully concluded without interfering with the car production in the plant. ENWPS became one of the most trusted vendors of General Motors, as this concept was established globally for the first time in General Motors Talegaon.

Our Achievements:

Assembly lines are complex and involve various barriers in implementing any new concept, as any small error can disrupt the entire process. Therefore, the successful accomplishment was possible from the team’s sheer hard work and dedication.

As a result of it, ENWPS was entitled to Implementation Partner of General Motors Technical Center, Bangalore, for the Lean Error Proofing system. Later, General Motors India recommended ENWPS for carrying out a similar LEP concept implementation for General Motors Egypt.

Glimpses of the Project:

Overview:

The case study focuses on one of the successful project implementations by the ENWPS team. What makes this project unique is that despite challenging circumstances our team found its way to accomplish the tasks with smart planning and speedy execution which gave extraordinary results.

About The Client:

Our client, Varroc Lighting Systems India Pvt. Ltd is one of the biggest suppliers of exterior vehicle lighting systems for various leading automotive manufacturers.

Case Study Brief:

On 18th February 2020, a massive fire broke into the manufacturing premises of Varroc’s Pune-based unit in Hinjewadi. The whole plant burnt down leaving no possibility of getting back on track anytime soon. The manufacturing unit used to produce headlamps and taillamps for passenger and commercial vehicles. Their client base included various reputed companies – Mahindra and Mahindra Ltd., Tata Motors, Skoda Auto Volkswagen India Pvt Ltd., Volvo Eicher Commercial Vehicles Ltd., Renault Nissan Automotive India Pvt Ltd., including others.

Image Source: The Indian Express

The incident created havoc among the vehicles manufacturers as it disrupted the supply chain and hampered the manufacturing process. For overcoming the increasing distress, an action plan was formulated. For implementation, Varroc Lighting Systems approached ENWPS. As part of the plan, a new manufacturing plant integration had to be performed inside an existing plant in Chakan that was running to full capacity. ENWPS undertook the task and was in charge of providing four robot cells at the earliest time possible.

Key Challenges:

o Extreme pressure from Varroc Lighting Systems for faster integration due to growing unrest among its clientele.
o Availability of robots in such a short duration of time.
o Complete integration of robots in limited space.

Our Work:

Our team implemented the project from scratch with strategic planning. Following are the tasks accomplished during our project implementation within 26 days’ time frame-

o Sourcing Robots
o Designing of Compact Robot Cell
o Robot Cell Manufacturing
o PLC Panel Integration and Wiring
o Human-Machine Interface Installation
o Robot and PLC Configuration
o Robot Programming
o PLC Programming

The Solution:

With continuous efforts, ENWPS formed a standard among the four robot cells, such that any robot can perform the plasma and gluing application on any headlight out of the 12 vehicle models that were to be manufactured.

The Result:

o We delivered 1st robot cell on 11th March 2020 with complete integration.
o Within less than a month, the production of headlights began again.
o The production of headlights resumed from 13th March 2020 for major automobile giants in the Pune area.

Our Achievements:

Despite time constraints and several hurdles, we delivered what we promised. We overcame challenges by relentless dedication and well-thought planning. Moreover, the compact robot cell emerged as our innovative in-house designed product, which was mounted in a limited space.

Glimpses of the Project: