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 (9 Found)
Integrated Digital Sand Quality Management and Rejection Analytics System
Routine sand parameters are tested hourly and chemical parameters shift-wise across D1, D2, D3 and D4 lines. Results and corresponding graphs are currently recorded manually, making historical retrieval, comparison, trend identification and rejection analysis difficult. The challenge is to digitize the existing sand testing format so entered values are automatically compared with specifications, classified as OK/Not OK, graphed online, stored historically and linked to rejection analysis.
Real-Time CMM Quality Dashboard with Automatic Non-Conformance Alerts
CMM inspection results are critical for dimensional quality control. When a CMM report indicates a Not OK condition, the concerned process needs immediate visibility so that corrective action can be initiated without delay. At present, consolidated real-time visibility of inspected quantity, OK/Not OK status and corrective-action closure is limited. The challenge is to develop an online CMM monitoring system that consolidates inspection results, provides actionable dashboards and automatically alerts the responsible process when non-conforming results are detected.
Automated Inspection Layout Generation from 2D Engineering Drawings
Inspection and process layouts are prepared using approved 2D engineering drawings to identify and organize dimensional and quality characteristics for inspection. Manual preparation can be time-consuming, particularly for drawings containing numerous dimensions and revisions, and may create risk of missed characteristics or revision mismatch. The challenge is to develop a digital solution that interprets an approved 2D drawing, assists in generating the required inspection layout and maintains the resulting layout with appropriate revision control and traceability.
Smart Storage and Traceability System for Gauges and Measuring Instruments
Gauges and measuring instruments are currently stored in cupboards using carton boxes, limiting visibility, organized access, preservation and quick identification of the required instrument. Inappropriate storage can also increase handling time and the risk of damage, misplacement or use of the wrong instrument. The challenge is to design a transparent, organized and smart storage system that enables easy identification, controlled storage and traceability of gauges and measuring instruments.
Wireless Measurement Data Integration with SPC Reports
Measurement results used for SPC reporting are currently entered manually by QC personnel. Re-entering values from measuring instruments increases reporting time and creates the possibility of transcription errors. The challenge is to establish secure wireless or equivalent digital connectivity between applicable measuring instruments and the SPC system so that measurement values are captured automatically in the correct report field and immediately available for statistical analysis.
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.