About the Client
Client is India’s leading air conditioning and commercial refrigeration company. The company has modern manufacturing facilities, producing over vast range of models across many product lines. The Company’s mainstay of product development has been energy efficiency, coupled with sustainable products.
Client required a turn-key end-of-line test facility to test Indoor Unit (IDU) & Outdoor Unit (ODU) of an Air Conditioner (AC) test machine to the given specifications. Test Facility should be capable of identifying process defects and ensure the product meet the company standard. Test system should precisely monitor and analyze the product during run test with minimal human interaction while taking considerably less test time than current testing system. The solution should include easy to use Graphical User Interface (GUI) based testing system with advance visualisation. It should be easy to use and configure, generate test report and perform analysis on past test data.
The product has to go through complex manufacturing process hence increasing the error possibility. Considering the number of models client manufactures, adds the complexity to test and validate the product. In addition to that, at a time, client manufacture only one part of the product either IDU or ODU, this makes the closed loop coupled testing more expensive and time consuming. Hence the test machine should be smart enough to automatically simulate other part of the system. It should be flexible enough to add new models of same product family with minimum configuration and can analyze the equipment under test automatically.
Optimized solutions has developed a most favorable solution considering all primary requirements of client, as well as future possibility of IDU& ODU Testing. Optimized solution has designed Application Software controlled test system which provide GUI to conduct the tests on the IDU and ODU.
Test system primarily consist of data acquisition device and application software running on industrial PC. Application software acquires data from the Unit Under Test (UUT) through data acquisition device and perform analysis based on pre configured parameters automatically. It provides advance visualization of various parameters of the UUT in real time, helps user to better understand the product functioning.
Test system perform closed loop testing by simulating IDU or ODU depending on UUT being tested. The electronic simulation allows a UUT to behave in a closed loop environment like a real working scenario. This helps in identifying all the faults at factory level even before they occur on the site. After test is completed system generates the test report and stores all the test data in the database which can later be analyzed to find key insight of the product design and manufacturing process.
Having user friendly interface leads to a very simplistic way to use the system which has reduced operator training time. Having a single GUI for multiple tests, lower down time and less maintenance makes the test system more cost efficient.
The new test system has considerably reduced the testing time which helped client to reduce cycle time of product line by significant amount with respect to current testing system. New test system has helped the client to achieve high cost saving and increase production capacity of manufacturing facility.
- Very simplistic user friendly test system.
- High speed reliable and accurate data acquisition, monitoring and analysis of the equipment.
- Significant reduction in cycle time of the assembly line.
- Lower maintenance of the test system.
- Less down time due to testing facility.
Benefits Against Alternatives
- GUI based testing system
- Advance Visualization
- Lower testing time
- Lower maintenance cost and downtime
- Less development time to add new feature
Our Value Addition
- With technological innovations, Optimized Solutions challenge the traditional approach to functional testing that truly addresses the ever-changing needs of the customer.
- Working with large organizations in multiple industries, Optimized Solutions deliver unmatched services and offer some of the best value in the industry.