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Vertical Honing Machine – Structural Analysis & Runout Validation

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Vertical Honing Machine – Structural Analysis & Runout Validation

20%

Weight Reduced

25%

Improvement  Structural Rigidity

BACKGROUND

A Vertical Honing Machine was developed for high-precision machining applications where spindle accuracy 2-micron. 

CHALLENGE

  • Achieving ≤ 2 µm spindle runout under operating conditions
  • Maintaining high stiffness of the spindle and supporting structure
  • Minimizing deformation due to cutting forces
  • Preventing resonance and vibration affecting machining accuracy
  • Reducing machine weight while maintaining strength
  • Meeting customer-defined cycle time and functional requirements

APPROACH

  • Structural FEA under cutting load conditions
  • Weld strength verification
  • Modal analysis to identify and eliminate resonance risks
  • Deflection and stiffness assessment of critical components
  • Design optimization based on simulation results
  • Final validation prior to manufacturing release

2 Micron Spindle Runout Achieved

20% Machine Weight Reduction

5% Material Cost Reduction

25% Improvement in Structural Rigidity

Reduced Vibration & Resonance Risk

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Virtual Commissioning Case Study

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Virtual Commissioning Case Study

60%

Reduced commissioning time

30%

Reduced commissioning cost

BACKGROUND

A SPM manufacturer faced challenges in meeting tight delivery schedules due to long on-site commissioning and frequent design iterations.

CHALLENGE

  • Late discovery of control logic issues
  • Long on-site commissioning and test time
  • High cost due to rework and machine downtime
  • Difficulty in validating machine performance before physical build

APPROACH

  • Create accurate 3D model of machine in digital twin environment
  • Integrate PLC program, HMI, and field I/O virtually
  • Run machine sequences, test interlocks, alarms, and safety logic
  • Virtual Commissioning Complete
  • Validated system ready for on-site deployment

40% improvement in production efficiency

35% reduction in cycle time

30% reduction in product wastage

45% reduction in manual intervention

Improved filling accuracy and cap sealing consistency

Enhanced machine reliability and throughput

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Pick & Place Pillar Equipment Design Structural Analysis & Validation

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Pick & Place Pillar Equipment Design Structural Analysis & Validation

30%

Reduced Design Iteration

20%

Improved Structural Reliability

BACKGROUND

A Pick & Place Pillar Equipment was developed to assist shop-floor operators in lifting and handling heavy components safely and efficiently.

CHALLENGE

  • Withstanding rated lifting loads safely
  • Achieving required arm reach and rotational movement
  • Minimizing structural deformation under maximum loading
  • Ensuring adequate factor of safety for long-term operation
  • Optimizing weight while maintaining structural integrity
  • Validating design prior to manufacturing

APPROACH

  • Finite Element Analysis (FEA) using ANSYS Mechanical.
  • Meshing and load case definition.
  • Stress, deformation, and safety factor evaluation.
  • Design optimization based on simulation results.
  • Final validation and manufacturing release.

30% Design Iterations Reduced

20% Structural Reliability Improvement

15% Weight Optimization

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PET Bottle recycling machine

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PET Bottle recycling machine

25%

Faster design

15%

Higher productivity

100%

Design Validation

BACKGROUND

PET Bottle recycling machine manufacturer.

CHALLENGE

  • Design of a line that shall help multiply recycling capacity
  • Prove design virtually
  • Demonstrate multiplication

APPROACH

  • Use of Discrete Element Modeling (DEM) for particle simulation
  • Structural simulation of the machine parts and their optimization
  • Detailed modeling and documentation support

Proven flow simulation of plastic flakes 

Machine concept development and validation during design stage

Productivity gain

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Robot Utilization & Improved Throughput

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Robot Utilization & Improved Throughput

12%

Improved throughput

95%

Robot utilization

BACKGROUND

A leading automotive component manufacturer planned to increase throughput of its existing cylinder head cleaning line by introducing one more robot for additional cleaning operations. We performed digital simulation to validate reachability, check for clashes and verify optimal line performance (OLP) before physically implementing a newly introduced robot.

CHALLENGE

  • Ensuring Reachability
  • Clash-Free Operation
  • Optimal Line Performance

APPROACH

  • Created accurate 3D model of the existing line and new robot
  • Performed reachability analysis for all target points on the cylinder head
  • Conducted clash detection with robots, fixtures, conveyors and guarding
  • Evaluated line cycle time and robot utilization for OLP
  • Fine-tuned robot position and sequence to ensure smooth operation

100% Reachability of all cleaning points

Zero clash detected

12% improvement in line throughput

95% robot utilization achieved

vertical-honig-feat

Vertical Honing Machine

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Vertical Honing Machine

30%

Reduced Assembly Integration Time

20%

Reduction in Design Rework

BACKGROUND

The Vertical Honing Machine was developed to create a fully integrated manufacturing system consisting of multiple assemblies including the base, spindle & column, expansion, brushing, index table, fixture, rotary union, sensor, guard, and HMI systems.

CHALLENGE

  • Planning and integration of 10+ major machine assemblies
  • Maintaining alignment and accuracy between spindle, fixture, and index table systems
  • Coordinating mechanical, pneumatic, and control systems
  • Ensuring manufacturability and ease of assembly
  • Standardization of components across assemblies
  • Creating complete BOM and assembly documentation for execution phase

APPROACH

  • Developed complete machine architecture and assembly hierarchy
  • Planned base, column, spindle, expansion, fixture, brushing, guard, and HMI systems
  • Standardized purchased and fabricated components
  • Created detailed 3D CAD models and assembly structures
  • Generated manufacturing drawings and BOMs
  • Performed assembly fitment and interference verification
  • Released complete documentation package for manufacturing and execution

100% Assembly Planning Completed

98% First-Time Assembly Fitment Accuracy

30% Reduction in Assembly Integration Time

25% Faster Project Execution

20% Reduction in Design Rework

15% Reduction in Manufacturing Errors

100% BOM & Documentation Release

100% Manufacturing Readiness Achieved

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Developing Effective Training Manuals with IQ3

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Developing Effective Training Manuals with IQ3

60%

Reduced document update time

30%

Improvement in assessment scores

BACKGROUND

A global manufacturing company needed to standardize and modernize its training manuals for equipment operation and safety procedures. The existing manuals were in PDF and Word formats, stored in multiple locations, and difficult to maintain.

CHALLENGE

  • Inconsistent Content
  • Difficult to Maintain
  • Low Engagement
  • Limited Visibility

APPROACH

  • Structured Content Development
  • Rich & Interactive Content
  • Centralized Management
  • Easy Updates & Reuse
  • Track & Improve

60% Reduction in document update time

100% Consistent branding and structure

45% Increase in learner engagement

30% Improvement in assessment scores

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MES Implementation for SPM Manufacturer

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MES Implementation for SPM Manufacturer

80%

Reduced manual reporting

92%

Schedule adherence
Improvement

BACKGROUND

An SPM manufacturer required a solution to gain better control, visibility, and traceability of highly customized machine-building operations.

CHALLENGE

  • Limited visibility of shop-floor activities
  • Manual production reporting and paperwork
  • Difficulty tracking machine build progress
  • Delays in material availability and assembly operations
  • Lack of real-time KPI monitoring
  • Quality issues due to incomplete traceability
  • Inaccurate production planning and delivery commitments

APPROACH

  • Implemented MES solution integrating with ERP, Design and Production system to create digital manufacturing environment

Real-time production visibility across all assembly stations

Improved on-time delivery performance

Reduced manual reporting effort by 80%

Complete machine build genealogy and traceability

Faster issue identification and corrective action

Improved coordination between planning, stores, assembly, and quality departments 

Enhanced decision-making through live production dashboards

case-study-feat

Streamlining Engineering Data Management with Teamcenter

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Streamlining Engineering Data Management with Teamcenter

25%

Reduced design time

Minimized excess inventory

BACKGROUND

A manufacturing company required a centralized system to manage growing engineering and CAD data efficiently.

CHALLENGE

  • Difficulty in managing CAD data, revisions, duplicate files, and design reuse was impacting productivity.

APPROACH

  • Implemented Teamcenter Rapid Start integrated with CAD tools to centralize data and automate PDM processes.

Reduced design time by 25%, improved collaboration, streamlined workflows, and minimized excess inventory.

vertical-honing-feat

Design Of Vertical Honing Machine – 2 Micron Runout Achievement

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Design Of Vertical Honing Machine – 2 Micron Runout Achievement

20%

Weight Reduced

25%

Improvement in Structural

BACKGROUND

Design and development of a Vertical Honing Machine (SPM) capable of achieving extremely high machining accuracy with spindle/tool runout limited to 2 microns.

CHALLENGE

  • Achieving ≤ 2 µm spindle runout under operating conditions.
  • Maintaining high structural rigidity of spindle, column, and base assemblies.
  • Minimizing vibration and resonance affecting machining accuracy.
  • Reducing machine weight without compromising strength.
  • Using standard components wherever possible to improve manufacturability and accuracy.
  • Meeting customer-defined cycle time and functional requirements.

APPROACH

  • Studied customer inputs, functional parameters, and runout requirements.
  • Developed optimized machine arrangement and spindle architecture.
  • Designed Base, Column, Spindle, Expansion, Fixture, and Guard Assemblies.
  • Performed FEA for structural strength validation.
  • Conducted weld strength and modal analysis to eliminate resonance issues.
  • Incorporated customer feedback through iterative design improvements.
  • Generated manufacturing drawings, BOM, and machine documentation.

2 Micron Runout Achievement for high-precision honing operation

20% Machine Weight Reduction

5% Material Cost Reduction

33% Faster Design Cycle (Reduced from 6 Months to 4 Months)

25% Improvement in Structural Rigidity

100% Structural Validation through FEA

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