Overview
Timeframe: 2024
Category: Manufacturing Systems / Capacity Engineering
Turned idle equipment into a multi-variant routing and labeling cell to cover 19 new products in one week.
The Problem
Production needed new variant routing fast, but capital and time were limited. Buying new automation would cost ~$200K and miss launch.
Constraints
- 7-day implementation window
- $800 budget, reuse existing hardware only
- No unplanned downtime allowed
- 19 configurations to validate
Approach
I drove the retrofit end to end:
- Reverse-engineered controls, wiring, and mechanics of the idle cell
- Rewrote PLC logic and added DataMatrix-driven routing
- Built new nests and modified shuttles for added variants
- Offline tested every configuration before production cutover
Tools & Technologies
PLC Programming
DataMatrix Scanners
Mechanical Design
Fixture Mods
Production Validation
Impact
- Expanded coverage with zero extra downtime
- Delivered 250:1 ROI versus buying new equipment
- Maintained throughput and traceability through the transition
Key Learnings
- Deep system understanding reveals reuse options fast.
- Offline prototyping protects production when timelines are tiny.
- Disciplined documentation keeps retrofits maintainable.