Problem Statements
Explore the problem statements from Sakthi's diverse industrial sectors and choose the one that inspires you. Build innovative solutions for a better tomorrow.
Problem Statements (36 Found)
Smart Export Packing Verification and Poka-Yoke System
Export packing is currently vulnerable to manual errors such as interchange of LH and RH parts, placement of an incorrect component in the packing box, and excess or short quantity during packing. These errors may not be detected immediately and can result in rework, dispatch delays, customer complaints and traceability issues. The challenge is to develop an intelligent packing verification system that confirms part identity, LH/RH orientation where applicable, correct component-to-box matching and required quantity before a box is released for dispatch.
Automated QR Labeling and Appearance Verification System
QR code labeling is currently performed manually, and a dedicated team carries out 100% appearance inspection and records QR code data for verification. This process is manpower-intensive and creates opportunities for labeling errors, unreadable codes, missing records and variation in visual inspection. The challenge is to develop an integrated automated system that applies or verifies the QR label, checks code readability and appearance requirements, and records the verification result digitally for each part.
Automated In-Machine Runout Inspection for SX1 Differential Case
In the SX1 differential-case process, as-cast runout is currently checked manually inside the machine. The activity is operator-dependent, consumes inspection/cycle time and can introduce measurement variation or allow abnormal parts to be missed. Performing the check inside the machine also creates ergonomic and safety concerns. The challenge is to develop an automated in-machine or integrated runout inspection solution that measures the as-cast component consistently, identifies abnormal runout and provides an immediate decision without manual measurement intervention.
Pre-Machining Detection of Casting-Induced Bore Size Abnormalities
Rough castings can exhibit bore-related dimensional variation that subsequently contributes to under-size or over-size conditions during machining. Detecting unsuitable castings only after machining results in avoidable processing cost and rejection. The challenge is to develop a pre-machining inspection or prediction method that identifies casting-related bore abnormalities before value-added machining begins.
Automatic Alloy Addition Calculation from Spectrometer Composition
During melting, spectrometer results indicate the actual chemical composition of molten metal. Determining corrective alloy additions requires calculations based on target chemistry, melt weight and recovery factors. Manual calculation can introduce delay and variation. The challenge is to develop a system that automatically recommends alloy additions from spectrometer results.
AI-Based Induction Furnace Power Optimization System
Induction furnace parameters such as power, current, voltage, temperature, charge weight and melting time are monitored separately, making it difficult to determine the optimum power profile for each heat. The challenge is to use real-time and historical heat data to recommend power adjustments, predict melting time, target temperature and energy consumption, and improve process efficiency.
Development of a Data-Driven Dynamic Soybean Procurement Strategy for ABT-CPD
Soybean is the primary raw material for ABT-CPD, and its market price is highly variable. Soybean is available through both domestic and international markets, with significant variations in price, seasonality, availability and procurement economics. Historical domestic and international soybean price data, along with ABT-CPD’s procurement data, provide an opportunity to develop a scientific and data-driven procurement strategy. The challenge is to develop a decision-support system that can analyze historical and current market trends and recommend when to buy, how much to buy, and whether domestic or international sourcing is economically preferable, while considering inventory, lead time, landed cost and business requirements. The objective is to reduce procurement cost and price risk while ensuring uninterrupted availability of quality soybean.
ABT-CPD Zero Customer Complaint – AI-Based Complaint Analytics, Root Cause Identification & Prediction System
ABT-CPD has accumulated approximately 19 years of customer complaint records, covering different products, customers and types of quality and service-related complaints. Complaints include product quality deviations, physical defects, packaging issues, contamination/foreign matter, infestation, sensory characteristics, weight/quantity issues, process-related defects and other customer-specific concerns. At present, the historical data represents a valuable but largely untapped source of information. The challenge is to analyse this historical database using data analytics and AI to identify recurring patterns, major root causes, high-risk products/processes, ineffective or recurring corrective actions and early warning indicators. The ultimate objective is to develop a system capable of identifying the probability and likely nature of future customer complaints and recommending preventive actions before the product reaches the customer.
Automated Loading and Unloading System for Fragile Foundry Cores
Loading and unloading foundry cores between production and subsequent processes requires careful handling because cores are fragile and geometrically complex. Manual handling creates operator dependency, ergonomic concerns and variation. The challenge is to automate safe transfer and accurate positioning while preventing damage and maintaining production cycle time.
Battery-Operated Smart Trolley for Pattern Transportation
Heavy patterns, moulds and dies need to be transported within the foundry/manufacturing facility. Manual movement increases physical effort and material-handling risk. The challenge is to design a safe, manoeuvrable and cost-effective battery-operated trolley suitable for industrial aisles and heavy pattern movement.
Quick-Change Ergonomic Fixture Loading System for Setup Change
Fixture loading and unloading during setup change is difficult and can require significant manual effort and time. Heavy or awkward fixtures can create ergonomic and safety concerns while increasing machine setup duration. The challenge is to develop a quick-change fixture handling solution that assists loading, positioning, clamping and removal while reducing setup time and operator effort.
Smart Detection and Monitoring of Hydraulic, Coolant and Oil Leakage
Hydraulic oil, coolant and other fluid leakages or scrap-related spillage around machines can create safety, housekeeping, environmental and maintenance concerns. Leakages may remain unnoticed until they become visually significant. The challenge is to develop an early-detection and monitoring system that identifies leakage/spillage, indicates the affected location and supports timely corrective action.