Industrial Engineering - Test Cell Redesign

Problem Statements

• Existing end of line test equipment was not up to industry standards
• Test cell data output had to be recorded by hand and manually entered into spreadsheet for tracking purposes
• Too much variation in test results that were not controllable
• Inaccurate and unreliable test data caused risk of losing industry certification
• Existing end of line equipment lacked flexibility to allow testing of all models across single test stand, thus creating potential production bottlenecks

Solution

• Researched and implemented Best Practices and Standard Work for new test control plan
• Developed a new control strategy for automating the process
• Redesigned/upgraded existing test cell
  • Complete electrical rewire of test cell to facilitate implementation of new controls and equipment
  • Implemented Allen-Bradley hardware for control, monitoring and reporting results of test stand/test area (previously used hard relay logic and pneumatic logic with analog readouts)
  • Redesigned test cell plumbing to facilitate new flow rate measurement devices
  • Implemented higher accuracy torque and vibration measurement devices
• Managed and coordinated all mechanical and electrical modifications

Results

• Redesigned test cell was capable of testing product variations that previously ran through 2 different test stands
• More accurate, reliable and real time CFM, torque and vibration measurements being logged and tracked automatically
• Test data automatically captured into electronic test information repository
• End of line test equipment is now up to industry standards