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 Routing and Condition Monitoring for Electrical Cables and Pneumatic Lines
Improper routing of electrical cables and pneumatic air lines around machines can create safety, maintenance, accessibility and reliability concerns. Lines may become tangled, exposed to damage or interfere with movement and housekeeping. The challenge is to design a standardized smart routing solution that organizes and protects cables and air lines while enabling easy inspection and identification of abnormal routing or damage.
Predictive Tool-Life Monitoring and Optimization System
Cutting tools do not always achieve their expected life, leading to premature replacement, unplanned tool failure, quality variation and increased tooling cost. Fixed tool-change rules may not account for actual cutting conditions. The challenge is to develop a data-driven tool-life monitoring system that uses machining parameters and tool-condition signals to estimate remaining useful life and recommend an appropriate replacement point.
Smart Monitoring and Predictive Alert for DISA Machine Card Adjustment
DISA machine card adjustment is disturbed frequently, requiring repeated intervention and potentially affecting machine stability, moulding consistency and production availability. The challenge is to identify the operating conditions that lead to card-adjustment disturbance and develop a monitoring and predictive-alert system that detects abnormal deviation early and supports timely corrective action.
Digital FIFO and Ageing Control for Rough Castings
FIFO is not consistently followed for rough castings, creating the possibility of older stock remaining unused while newer castings are consumed first. This reduces inventory visibility and may contribute to excess ageing, identification difficulty and material-flow inefficiency. The challenge is to develop a digital FIFO control system that identifies casting batches, tracks receipt and issue sequence, highlights ageing stock and prevents or warns against out-of-sequence consumption.
Digital Machine Manual, Drawing and Spare Identification System
Machine manuals, electrical drawings and spare-part information are not always available through a single easily searchable source, making troubleshooting and spare identification slower. The challenge is to develop a digital machine knowledge system that organizes manuals and drawings and enables maintenance personnel to identify required spares, including through image-based search or drawing linkage where feasible.
Real-Time Critical Spare Inventory and Availability Monitoring
Critical spare availability needs continuous visibility to avoid prolonged machine downtime when failures occur. Inventory records that are not updated in real time can create uncertainty regarding available quantity, location and replenishment requirement. The challenge is to develop a live critical-spares monitoring system that tracks stock movement, minimum levels and replenishment status and generates alerts before stock reaches a critical condition.
Smart Ventilation and Air-Quality Improvement for Plant 4 & 5
Ventilation in Plant 4 and Plant 5 is inadequate, potentially resulting in heat build-up, poor air circulation and reduced workplace comfort. Without continuous environmental data, it is difficult to identify hotspots or optimize ventilation effectiveness. The challenge is to assess airflow and environmental conditions and develop an energy-conscious ventilation solution with measurable improvement in workplace conditions.
Digital Industrial Gas Consumption Monitoring and Analytics
Industrial gas consumption requires systematic digital monitoring to understand usage patterns, identify abnormal consumption and support cost and resource-efficiency improvement. Manual meter readings provide limited granularity and delayed visibility. The challenge is to develop a digital gas-consumption monitoring system that records usage by relevant plant/process and provides trends, alerts and consumption analytics.
Smart Disposal & Utilisation of Boiler Ash
Boiler ash generated during operation needs to be handled, collected, transported and disposed of safely and economically. The project should explore an systematic method for ash collection, storage, monitoring and possible value-added utilisation.
Fine Dust Control from Seed Preparation Aspiration System
Fine dust is generated during soybean seed preparation and is carried through the general aspiration blower system. Develop an efficient system to capture/arrest fine dust before it is released into the surrounding environment, while maintaining required air flow and process efficiency.
Recovery & Utilisation of Physical Waste from Seed Cleaning
Physical impurities such as stones, foreign materials, husk, dust and other waste are separated during soybean seed cleaning. Develop a system for effective collection, segregation, monitoring of these materials, reducing waste sent for disposal.
Automated Manufacturing MIS and Rejection Report Generator
Production and quality data is available in the existing PMS, but weekly Foundry/Machine Shop reports and monthly rejection reports require further consolidation and preparation. The challenge is to automate extraction, transformation and presentation of available PMS data into standardized management reports.