Lean, Fast-Track Test System

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Lean, Fast-Track Test System

Using Fast-Track Development, AeroSpec was able to design, fabricate, build and test this solution in under a month meeting all customer requirements.

With a compressed schedule, small budget and the need for increased capacity, AeroSpec’s Fast-Track Project Team fulfilled the customer’s every requirement from delivery requirements to an increase in production. As you’ll read below, we met the customer’s schedule, bought off the equipment and increased capacity four-fold over the course of a month. While the short schedule is not representative of every project, the dedicated, cross-departmental team ensured that the project was a success, on-budget and on time.

CUSTOMER CHALLENGE

Due to an unexpected surge in demand, the Solar Energy Client experienced difficulty with its testing capacity in mapping the efficiency of an optical component critical to the overall performance of the end product.  Existing test equipment fabricated by in-house personnel was designed for limited production runs.  A lean, but extremely robust solution need to be validated and in production within three weeks.

AEROSPEC’S APPROACH

AeroSpec engaged a Fast Track Project team consisting of Mechanical, Electrical and Software Engineers, Manufacturing Specialists, Integrators, and a Project Expeditor.

Within a day the concept was finalized and approved by the Client.  As delays were not an option, all development and manufacturing were performed in parallel.  Power up, final debug and trial validation was accomplished with the client present in order to provide hands-on training without impacting the schedule.

SOLUTION IMPACT

Two Production Semi-Automated Test Stations were completed on schedule.

The First Article, delivered within three weeks, provided a 400% productivity gain over the existing in-house equipment.  The client could now focus attention on balancing the throughput for other processes on their production system.

As AeroSpec learned the end game for the client was to increase product output approximately 5000% over the next year without increasing head count or floor space significantly, a migration path to a fully automated system was presented incorporating testing technology and tooling developed during the Fast Track effort.

SOLUTION GALLERY

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