In-House Programming Development

Challenge

The production line required new equipment programs to support product variant production. Initial vendor quotes for program development, traceability mapping, and implementation came in at approximately $5,000 with extended lead times that would delay product launch schedules. The dependency on external vendors for routine programming work represented both a cost burden and a flexibility limitation for future product changes.

Solution

Developed comprehensive equipment programs in-house using existing control software and programming expertise. The project involved analyzing product geometries, creating optimized processing paths for efficient cycle time, integrating programs with existing traceability systems, and validating all programs through systematic testing with production units.

Created detailed traceability mapping to ensure proper tracking of all product variants through the production process, maintaining full compliance with automotive quality standards. Developed documentation and training materials to enable future in-house program modifications without vendor assistance.

Technical Approach

• CAD analysis of product designs to determine processing path requirements
• Equipment program development with optimized sequences for cycle time efficiency
• Integration with vision system for product identification and traceability
• Quality validation through dimensional inspection of processed units
• Documentation of program logic and traceability mapping for future reference
• Operator training on new procedures and quality checkpoints

Technologies Used

• Equipment Control Programming
• Vision System Integration
• Traceability Database Mapping
• CAD Software for Product Analysis
• Quality Inspection Tools & Procedures

Results

• ~$5,000 cost savings by developing programs in-house versus vendor quotes
• Faster implementation timeline enabling on-schedule product launch
• Established in-house capability for future program modifications
• Full traceability compliance maintained for automotive quality requirements
• Optimized processing paths achieved competitive cycle times
• Created documentation template for future program development

Key Takeaways

This project demonstrated the value of building internal technical capabilities rather than relying on external vendors for routine engineering tasks. By investing time in understanding equipment programming and traceability systems, the team gained flexibility for future product changes while achieving immediate cost savings. The documentation and training materials created during this project established a foundation for ongoing in-house program development, multiplying the long-term value beyond the initial savings.