Console Setting & Calibration Jigs
Advanced Industrial Engineering Ltd were awarded a contract to redesign, manufacture, and commission console setting & calibration jigs for a luxury car manufacturer.
Overview
Advanced Industrial Engineering were approached and asked to quote for the redesign and supply of ‘console’ setting and calibration jigs for a luxury car manufacture assembling vehicles in the UK.
The customer had an existing set of jigs but approached AdvancedIndustrial Engineering to re-engineer replacement jigs to reduce the weight forthe operator when in use.
The sales team at Advanced Industrial Engineering reviewedthe technical information provided by the customer and submitted a detailedtechnical proposal, including 3D design concept and full cost breakdown.
Background
The customer approached Advanced Industrial Engineering tohelp find a solution to reduce the weight of the existing console setting jigs.The weight reduction would aid the customers assembly operatives when positioningthe setting aid onto the vehicle underbody during the process.
After review of all vendor technical proposals, AdvancedIndustrial Engineering were successfully awarded a contract to supply new jigs.
Challenges, Constraints and Success
The challenge lay in re-engineering the existing jig design to ensure the current assembly process could be maintained. The customer had stated that the weight of the jig needed to be reduced where possible to aid the customers assembly operatives when loading / unloading the setting aid onto the vehicle underbody on each vehicle.
The redesigned jigs needed to use existing location points on the vehicle body where possible, achieving this would ensure the existing assembly process could be maintained where possible.
Success would be seen if the following activities were achieved and maintained. The safe and effective introduction of new equipment with minimal disruption to existing production. The successful adoption of the new jigs by the maintenance department. The customer continuing to achieve a high level of quality and accuracy of vehicle build.
Technical approach / Methodology
The Advanced Industrial Engineering technical proposal was made up of the following items:
(1) Provision of 4-off console bracket setting jigs based on existing Jig 20102 delivered by Advanced Industrial Engineering
(2) Provision of 1 off calibration jig & drawing for the setting jig shown above
The solution included:
• Full 3D and 2D design, signed off for manufacture by all parties.
• Factory Acceptance Testing (FAT) at AdvancedIndustrial Engineering’s facility with the customer present.
• Delivery, installation, and commissioning at the customer’s site.
• On-site operator training following successful Site Acceptance Test (SAT) sign off by the customer.
• Full certification and supply of project technical file including operator and maintenance instructions, TPM schedule, spare parts list, BOM, DRAs, DFMEA, load test certification, 3D STEP files, GA drawings, and safety guidance.
All equipment would be supplied and certified to the required regulatory standards with the correct technical documentation provided.
Implementation
After being successfully awarded a customer purchase order, Advanced Industrial Engineering begin the engineering design process. The team reviewed the existing equipment, assembly process and new technical proposal. The design department used the new sales concept as a basis for the new design.
All parties were engaged in the review process of the proposed solution maintaining close customer engagement at every stage up to sign off.
The new concept design reduced the overall weight of theconsole jig from 9.3kg to ~5.8-6.5kg.
Location points for securing the jig in position were maintained where possible or created where required due to the redesign.
Advanced Industrial Engineering designed and manufactured a calibration jig to ensure that the setting jig could be checked, giving the vehicle manufacture peace of mind that the console position when fitted was in a repeatable position.
Following the design sign off from the customer, Advanced Industrial Engineering began to purchase materials and start the manufacturing and assembly.
Factory Acceptance Testing (FAT) was carried out in the workshop at Advanced Industrial Engineering with the customer present, any changes or upgrades were recorded and implemented prior to shipping to the customer’s site.
Once at the customers site, Advanced Industrial Engineering’s installation team managed the full commissioning process, including a final Site Acceptance Test (SAT) confirming that all fixtures performed as designed.
Conclusion
In following Advanced Industrial Engineering’s proven processesand procedures, the company was able to re-engineer existing customer equipmentto improve assembly processes.
The solutions provided, met the requirements outlined by the end user, the delivery and support was performed to the highest level of quality by the onsite team with timing and budgets maintained.
From Concept to Commissioning.
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