Case Studies

How we helped others improve their internal processes

INDUSTRIAL CONTROL SYSTEMS

Consumer Goods/Plastics

For a testimonial from our client CLICK HERE.

THE CHALLENGE

The customer’s cap machines had both obsolete and proprietary controls, thus when the cap machines broke down, there were no vendors to repair or replace them.

THE ANALYSIS

An analysis of their 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 their cap machines. We replaced the obsolete and proprietary controls with better, modern devices that can be bought off the shelf. These changes enabled the company to keep these machines in production, with a significant reduction in scrap.

ROBOTIC ASSEMBLY POKA-YOKE CELLS

Automotive Tier 1

THE CHALLENGE

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.

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’s 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.
Automotive OEM

THE CHALLENGE

ICSI was commissioned to design and build a test train4ing assembly line for the company battery plant. This facility manufactures the lithium-ion batteries used in the company’s 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, and multiple sensors and safety systems set up for new technicians to train on.

THE RESULT

Now the company 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.

SCADA – Automated Quality Control

Automotive Tier 1

THE CHALLENGE

Due to the growing demand for variation unit-to-unit at one of the company’s automotive plants, ICSI was tasked with developing a quick and easy way to make modifications to the assembly process.

THE ANALYSIS

An analysis of the automotive tier 1’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 easily to reduce downtime. It also allows Quality Control to determine the 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.

Case Studies

THE CHALLENGE

THE ANALYSIS

THE SOLUTION AND RESULT

ROBOTIC ASSEMBLY POKA-YOKE CELLS

THE CHALLENGE

THE ANALYSIS

THE SOLUTION

THE CHALLENGE

THE ANALYSIS

THE SOLUTION

THE RESULT

SCADA – Automated Quality Control

THE CHALLENGE

THE ANALYSIS

THE SOLUTION

THE RESULT

Our Mission

Our Core Values