CASE STUDIES

Nissan North America, Inc.

The Company

Established in 1933, Nissan is made up of a richly diverse group of people, as reflected in the company’s leadership team and the numerous corporate outreach programs in which we participate in the community.  Together, we have what it takes to build cars and trucks with the power to change both the way you view the world and the way you move in it.

 

The Challenge

Late in 2012, ICSI was commissioned to design and build a mock assembly line for the Nissan battery plant in Smyrna, TN. This is the facility which manufactures the lithium-ion batteries used in Nissan’s new Leaf electric cars.

The Analysis

The system we designed called for trainers to be able to disconnect or interrupt selected circuits inside lockable junction boxes, and then have the ability to trace down and pinpoint the problems. It uses 9-volt batteries to represent assembled car batteries.

 

The Solution

The completed system included: three robots; two computerized camera inspection systems; several sensors & safety systems, etc., all set up for new technicians to train on.

 

The Result

Now Nissan has a Battery Testing Station with which to train its employees and this job, one of the most complicated ICSI has attempted, was well received and has positioned us for more work in their facility.

Calsonic Kansei

The Company

Established in 1938, Calsonic Kansei is a global comprehensive automotive parts manufacturer, bringing a fresh breeze of new value to the world. We satisfy the optimum global procurement needs of automobile manufacturers with quality and speed.

 

The Challenge

Due to the growing demand for variation unit-to-unit at the Nissan automotive plant in Smyrna, TN. ICSI was tasked with developing a quick and easy way to make modifications to the assembly process.

The Analysis

An analysis of Calsonic’s automotive assembly process indicated an environment with the potential for operator error due to multiple variations of similar parts and the need for a flexible, user-friendly fail-proof traceability system.

The Solution

ICSI developed a user-customizable Parts Determining System (PDS) that utilizes bar code scanning, label printing, pick lights, torque readings, and screw counts to create a zero-error assembly and documentation system.

The Result

The ICSI PDS helps manufacturers determine and verify the correct part when there are variations of similar parts used.  It can assist Engineering and Maintenance to make updates quickly and to easily to reduce downtime. It also allows Quality Control  determine real root cause when issues occur.  For example: what part was picked, what was a given torque on a part, was the system in by-pass during an incident, etc.

Berry Plastics Corporation

The Company

Berry Plastics, founded in 1967, is a leading global manufacturer of injection-molded plastic packaging, thermoformed products, flexible films and packaging, as well as tapes and corrosion protection products. They conduct business in North and South America, Canada, UK, Europe, and Asia.

 

The Challenge

Berry Plastics’ cap machines had both obsolete & proprietary controls, thus when the cap machines broke down, there were no vendors to repair or replace them.

 

The Analysis

An analysis of Berry Plastics’ process indicated the old controls for their cap machines needed to be upgraded so that they could buy off-the-shelf parts and get support from local suppliers.

 

The Solution and result

ICSI re-engineered the controls for Berry Plastics’ cap machines. We replaced the obsolete & proprietary controls with better, modern devices that can be bought off the shelf. These changes enabled Berry Plastics to keep these machines in production, with a significant reduction in scrap.