Case study 2: Solution Design

Brief: Design and develop a new Metal Component Forming System.

A multinational manufacturer had a requirement to design a high performance metal forming system. Traditional press tools were not providing satisfactory performance and were deemed unsuitable for this particular application.

Designwise Automation was requested to evaluate the current equipment and propose a new enhanced alternative. An integral aspect of this evaluation was consulting with a wide range of the client's key staff members. This enabled a comprehensive overview of the requirements. Through consultation, the key requirements were identified:

  1. In line forming system to feed assembly process
  2. Cycle on demand at 150 parts per minute
  3. Trouble free operation
  4. Ease of set up and adjustment
  5. Process capability to 6 sigma.

Designwise Automation produced 3-D Models of the proposed solution. This was then presented to the Client and after further consultations agreement was reached on the detailed path forward.

These designs were then converted to reality within 8 weeks. On delivery of the first system the client immediately placed orders for fifteen more, for other company operations around the world.

Benefits: The benefits of this solution were:

  1. High process capability.
  2. Ease of use: operator training is minimal.
  3. Low noise levels and efficient operation.
  4. Minimal maintenance requirement.
  5. Low requirement for technical back-up.

An important aspect of this project was the initial consultation with the client's key staff members. Through careful management, this contribution from staff provided Designwise Automation with a deep appreciation of the requirements as well as creating a consensus of approval for the new system amongst the client's staff. The result is a more efficient solution, rapidly designed due to minimal iterations.