Case studies

How we helped others improve their internal processes.

We focus on providing you and your company with a solution that is not just innovated, but enhances the all-around performance within your walls. Take a look at our case studies below to see how we were able to help out businesses improve their current process.

Nissan North America, Inc.

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The Challenge

ICSI was commissioned to design and build a test training assembly line for the Nissan battery plant in Smyrna, TN. This facility 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 technicians trace down and pinpoint the problems.

The Solution

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

The Result

Now Nissan can safely and thoroughly train its battery assembly technicians offline. One of the most complicated test systems ICSI has completed, it has exceeded expectations and has positioned ICSi for more work with Nissan.

Marelli

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The Company

Established in 1938, Marelli is a global comprehensive automotive parts manufacturer, bringing a fresh breeze of new value to the world. They 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 Marelli’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 assists Engineering and Maintenance to make updates quickly and to easily to reduce downtime. It also allows Quality Control to 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

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The Company

Berry Plastics, founded in 1967, is a leading global manufacturer of injection-molded plastics, 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.

For a testimonial from our client CLICK HERE.

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 providing savings, etc.

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.