Client: EPTEC, a leading manufacturer of defence products
Industry: Industrial Manufacturing
Objective: To improve the efficiency of the painting process for large, complex components by designing a modular girder system.
Background
EPTEC was facing significant challenges in its painting process for large defence products, which involved extensive manual handling. This not only increased labour costs but also posed safety risks to employees. Additionally, the fixed nature of the existing painting setup led to inefficient workflows, as products needed to be manually transported between different painting stations, causing delays.
Challenges
- Inefficiencies in Manual Handling: The current process required significant manual effort, leading to higher labour costs and increased safety hazards.
- Lack of Mobility: The existing painting stations were stationary, which disrupted the workflow and prolonged project timelines.
Solution
Our team embarked on a project to design a modular girder system that addressed the inefficiencies in EPTEC’s painting operations. The key features of our solution included:
- Modular Design: The girder system could be easily assembled and disassembled to accommodate different product sizes and shapes, ensuring versatility.
- Strength and Stability: Engineered to support heavy loads while maintaining precision during painting, the girder was capable of withstanding the demands of the operation.
- Rail-Based Mobility: A significant innovation was the integration of a rail-based mobile option, allowing the girder to move effortlessly between painting booths. This greatly reduced the need for manual handling and minimised downtime between stages.
Methodology
Our approach began with a thorough analysis of EPTEC’s current painting operations, which involved:
- Site Visits: We conducted on-site assessments to understand the existing workflow and identify pain points.
- Interviews: Engaging with key personnel provided insights into the challenges faced during the painting process.
The information gathered was instrumental in developing several conceptual designs. Through iterative prototyping, we refined these designs, followed by virtual simulations to test the structural integrity and mobility of the girder under various conditions. This rigorous testing ensured that the final design adhered to the highest standards of safety and performance.
Results
Although the project was not moved to implementation due to budget constraints and stakeholder readiness, the final design was met with enthusiasm from the EPTEC team. The modular girder system demonstrated our capability to create practical and innovative solutions for complex industrial problems.
Conclusion
The EPTEC girder design project is a testament to our expertise in industrial design and our commitment to addressing real-world challenges. By focusing on efficiency, safety, and adaptability, we developed a solution that, while currently on hold, underscores the importance of thoughtful design in industrial manufacturing. The ideas and designs from this project have been stored as valuable assets, ready for future implementation as EPTEC’s needs evolve.
Call to Action
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