Portfolio

Work we have delivered

A selection of automation, test and data projects. Each one started as a conversation about a bottleneck rather than a specification document.

Automotive components

Semi-Automatic Test Bench for a Harness Line

Replacing a manual continuity check with a fixture that verifies termination, routing and polarity in one pass.

Challenge: Operators were checking harnesses by hand against a paper chart. Intermittent faults escaped to the customer line, and the check took long enough to be the bottleneck of the cell.
Approach: A purpose-built connector interface with a guided probe sequence, an editable test program per harness variant, and automatic logging of results against the barcode on the work order.
Outcome: The check moved from a manual chart to a recorded pass/fail result per harness, and the cell's inspection step stopped being the constraint on output.

Precision machining

Retrofitting cycle counting and downtime reason capture onto machines that had no monitoring built in.

Challenge: Availability and downtime figures were reconstructed monthly from shift registers. The data was late, and nobody trusted the reasons recorded at the end of a shift.
Approach: Cycle signals were tapped from existing PLC outputs, an operator panel was fitted at each machine with the plant's own downtime reason codes, and events were buffered locally before upload.
Outcome: Availability and downtime Pareto became available the next morning, and the reason list was built with the supervisors so the entries matched how the floor actually talks about breakdowns.

Plastics and molding

Moving from monthly capability reports to live control charts on the characteristics that actually drift.

Challenge: Capability was assessed once a month from an export. By the time the report appeared, a drifting process had already produced several non-conforming batches.
Approach: Control limits were baselined from existing data, digital gauges were connected so readings went straight into the charts, and run rules were agreed with the quality team before alerts were enabled.
Outcome: Drift now raises an alert while the batch is still in the machine, and capability evidence for customer audits is generated from the same data used to run the line.

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