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.

Industrial Control Systems

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.

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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.

Process Industrial Controls Application

The Challenge

The customer, an industrial supplier of raw materials, commissioned ICSi to design and implement a control system for several chemicals. The control system would be used in a wide range of chemical products used in industrial, chemical, water treatment, mining, catalyst, and other applications.

The Analysis

The System we designed called for as little operator involvement as practical, aside from the general monitoring of the system. The system also needed to be customizable to be able to change setpoints for Pressure, Temperature, Level, Flow Rates, and Gas levels.

The Solution

The final system included over 200 valves, sensors, and motors all monitored and controlled by a PLC and SCADA System to keep it running safely and smoothly with as little operator interaction as possible. The System allows the customer to view a completed history of all aspects of the process as well as customize many aspects of the process operation through the Scada software.

Robotic Assembly Poka-Yoke Cells

Kasai

The Company

Customer, a tier 1 automotive supplier, required a dynamic visual inspection system to verify the presence of various components of a vehicle door, the system would communicate in tandem with another robot that would place the part in the station, and the system should be able to verify components based on the running part number.

The Analysis

An analysis of customer requirements indicated that due to the diversity of models to be executed, inspections to be carried out, and inspection tolerances, the application of a robotic system and a vision system would be adequate tools to ensure the confirmation of the assembly specifications.


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The Solution

ICSi integrated an inspection cell composed of a compact high-speed 6-axis Yaskawa robot (GP7) and a Keyence vision system, as well as a simplified safety controller to ensure the operator safety, the robot is capable of selecting the model to inspect based on the bar code that the same vision system captures and is capable of reaching 9 different positions and a maximum of 32 vision inspections in less than 30 seconds, the HMI and PLC programming design allows adding, editing or deleting inspections without the need to make programming changes in the PLC and minimal changes in the robot program.

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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.

Simpsons Strong Tie

The Challenge

Customer uses proprietary machines to collate their line of screws. These machines feed screws through a process that arranges, forms, and finally cuts into strips suitable for loading into the automatic screw system. Customer needed a vendor to build a new “state of the art” machine.

The Analysis

The machine needed to meet their existing customer specifications and incorporate functionality from other existing machines as well as improvements they had made throughout their life cycles. Several obsolete components would need to be replaced with newer components that are more readily available.

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The Solution

ICSI worked closely with customer engineers to make sure the machine was built to their specifications. Modifications were suggested and, with customer’s approval, implemented throughout the build process to improve machine function and spare parts availability. Documentation of the build was also improved with updated CAD, schematics, and BOMs. Customer now has a brand-new updated and improved machine to support increased production as well as detailed documentation to make their next build easier and faster.

SCADA – Automated Quality Control

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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.