Production Line Retrofit Project

Project Overview

Coordinated a production line retrofit project to support next-generation product manufacturing. This project involved transitioning from legacy technology to advanced systems with improved performance capabilities for automotive applications.

Challenges

The updated product featured different designs, component specifications, and assembly sequences compared to previous generation products. The production line required equipment modifications, updated programming, new quality inspection procedures, and operator retraining—all while maintaining production of existing products during the transition period.

Retrofit Scope

• Equipment tooling modifications to accommodate updated product geometry
• Control system programming updates for revised assembly sequences
• Vision system reconfiguration for component recognition and traceability
• Updated quality inspection procedures and acceptance criteria
• New work instructions and operator training materials
• Validation testing and production readiness assessment

Technical Implementation

Worked closely with equipment suppliers and internal engineering teams to implement necessary hardware and software modifications. Modified assembly fixtures to accommodate component placement variations, updated control logic for new assembly sequences, and reconfigured vision systems for proper component verification and traceability tracking.

Developed comprehensive validation plans to ensure retrofit changes met production requirements before transitioning to full-scale manufacturing. Conducted systematic testing with pre-production units to verify equipment performance, quality inspection effectiveness, and cycle time targets.

Key Activities

• Requirements analysis comparing Gen 1.0 and Gen 1.1 manufacturing specifications
• Coordination with vendors and internal teams for equipment modifications
• PLC programming updates and testing for new assembly sequences
• Vision system reconfiguration and validation for Gen 1.1 components
• Quality procedure development and operator training delivery
• Production validation and launch readiness assessment

Results

• Successfully transitioned production line to next-generation manufacturing capability
• Maintained production schedule commitments during transition period
• Achieved quality targets from production launch
• Smooth operator transition with comprehensive training and support
• Established retrofit methodology applicable to future product transitions

Impact

This retrofit project demonstrated effective project coordination and technical problem-solving in a complex manufacturing environment. By managing the transition from legacy to next-generation technology, the project enabled the company to maintain competitive positioning. The structured retrofit approach and validation methodology established best practices for future product transitions, reducing risk and accelerating launch timelines.