Manufacturing Support Equipment Build

Project Overview

Designed and built a complete support station for a production line to control environmental exposure during critical assembly operations. The project required rapid delivery to support product launch schedules while maintaining cost constraints typical of manufacturing support equipment.

Challenge

Products required controlled environment handling to prevent contamination during specific assembly steps. The production line needed a dedicated station to maintain product quality, but traditional procurement of new equipment would exceed both time and budget constraints. The challenge was to deliver a functional solution within 8 days and under $1,000 budget while meeting all technical requirements for process control and production workflow integration.

Solution Approach

Developed a cost-effective station by creatively retrofitting components from decommissioned equipment and utilizing available facility resources. Designed the station layout to integrate seamlessly with existing production line workflow, ensuring operators could efficiently transition units through the controlled process without creating production bottlenecks.

The design utilized a combination of retrofitted structural components, standard pneumatic fittings, and available process control equipment. Custom fixtures were designed to hold products during the process, with consideration for ergonomic loading/unloading by production operators.

Key Design Elements

• Retrofitted structural frame adapted from decommissioned line equipment
• Custom holding fixtures designed for product geometry and operator accessibility
• Pneumatic system integration for controlled process cycle timing
• Operator interface with clear process indicators and safety interlocks
• Integration with existing production line layout and workflow patterns
• Quality checkpoint procedures for process control verification

Implementation

Completed the station build in 8 days through efficient project planning and resource utilization. Coordinated with maintenance teams for installation, conducted functional testing to verify process control performance, and trained production operators on proper station operation and quality checkpoints.

Results

• Under $1,000 total cost using retrofitted components and creative resource utilization
• 8-day delivery from concept to production-ready installation
• Successful process control meeting product quality requirements
• Seamless integration with production line workflow and cycle time
• Established model for rapid, cost-effective support equipment development
• Positive operator feedback on station ergonomics and ease of use

Impact

This support equipment project demonstrated effective problem-solving through creative engineering and resourcefulness. By leveraging retrofitted components and existing facility resources, the project delivered required functionality at a fraction of traditional equipment costs. The rapid development approach prevented production delays and established a template for future support equipment needs. The success of this project highlighted the value of cross-functional knowledge of facility equipment and spare parts inventory for creative problem-solving.