Barry-Wehmiller Network
Equipment Design Solutions

Project Profiles

Please see the below Project Profiles representing Design Group Equipment Design Solutions.

  • Incremental Innovation - Special Purpose Tool For OEM

    Incremental Innovation: Special Purpose Tool for an OEM

    Client Profile:
    The client is a leading manufacturer of machinery and equipment for paper processing industry.

    Project Scope:

    • Custom design of special purpose tool to perform grinding of anvil drum used in rotary die cutters, instead of using an Original Equipment Manufacturer (OEM) solution at a royalty fee

    Design Group Approach:

    • Brainstormed alternate ways for material removal, generated 31 ideas
    • Shortlisted 7 potential ideas, developed conceptual designs for conducting Proof of Concept trials for evaluating material removal precision
    • Followed a retrofittable design approach, enabling upgrading of existing field machines, for generating After Market Revenue 
    • Delivered 3D models, 2D manufacturing drawings, Exploded View Drawings, Bill of Materials, Controls System Architecture, Schematics

    Results:

    • Use of a lifetime wear resistant cutting tool helped in reduced maintenance cost (by 95%) and eliminated machine downtime 
    • Enabled continuous use of the rotary die cutter, by dressing the anvil cover periodically, thus eliminating the need for cover rotation, performs cleaner cuts and longer blade life
    • Royalty fee saved

  • Redesign of Electric Girdle Handles for OEM

    Redesign of Electric Griddle Handles for an OEM

    Client Profile:
    The client is a leading food equipment manufacturer in the USA.

    Project Scope:

    • Redesign the handles of electric griddle for reducing failure of grill handle in field during usage

    Design Group Approach:

    • Reviewed and baselined existing design, and studied competitor products for benchmarking 
    • Examined product usage conditions and variations in food being grilled
    • Re-designed opening and closing mechanism for various sandwich heights
    • Performed FEA Analysis to determine load withstanding capability of redesigned handle
    • Delivered 3D models, 2D fabrication drawings and BOM

    Results:

    • Field failure completely eliminated
    • Added benefit of ensuring parallelism in the sandwich from changes made in the opening and closing mechanism

  • Redesign - Special Purpose Machine For Equipment End-User

    Redesign - Special Purpose Machine for an Equipment End-User

    Client Profile:
    The client is a leading American multinational company and one of the largest chocolate manufacturers in the world.

    Project Scope:

    • Design a special purpose machine for automating broken mint replacement in an existing mint production line for improving uptime and throughput of line

    Design Group Approach:

    • Conducted Discovery Phase onsite - to understand existing manual process and develop conceptual layout design
    • Carried out Proof-Of-Concept trials for validating proposed design 
    • Developed preliminary design and detailed design including safety review of the design for eliminating safety hazards and provision of enclosures 
    • Delivered 3D models, 2D fabrication drawings and BOM

    Results:

    • Eliminated manual “Short Count Fill” issue with this automated refill design 
    • Increased line productivity of 20%

  • Retrofit: Custom Design of Top Printer Module for OEM

    Retrofit: Custom Design of a Top Printer Module for OEM

    Client Profile:
    The client is a leading manufacturer of paper finishing equipment.

    Project Scope:

    • Design and development of a top printer module to use with an existing bottom printing unit of a paper finishing equipment

    Design Group Approach:

    • Standardized existing bottom printer unit parts and assemblies wherever possible, for ease of manufacturing and maintenance
    • Created retrofittable design to enable selling to existing field machines

    Results:

    • Existing brand identity of the equipment retained
    • Supported in designing a ‘first in the market’ top and bottom printable finishing equipment for the corrugated board industry, for improved throughput
    • Retrofittable design with the following features: 
      • Single and multi-color printing
      • Additional dryer option allowing for faster print times

  • Retrofit: Safety Guarding Design For Soap Manufacturing Line​

    Retrofit: Safety Guarding Design For Soap Manufacturing Line

    Client Profile:
    The client is a leading consumer goods company having products in Personal Care, Home Care, Foods and Refreshments.

    Project Scope:

    • Develop safety guarding design for mitigating hazard risks reported in the Risk Assessment for a soap manufacturing line

    Design Group Approach:

    • Modeled machine from measurements taken at site, understood site requirements and limitations, generated ideas for guarding that met both requirements – hazard mitigation and site limitation
    • Reviewed and shortlisted idea, detailed design, design reviews for ease of implementation, ease of maintenance and ease of manufacturing
    • Delivered 3D models, 2D detailed drawings and Bill-of-Material

    Results:

    • Delivered an ergonomic design of the guards, complying with Machine Safety requirements identified in the Risk Assessment report
    • Design optimized for weight for cost benefits

  • Cost Optimization - Material and Manufacturing for an OEM

    Cost Optimization - Material And Manufacturing Cost for an OEM

    Client Profile:
    The client is a leading manufacturer of manufacturer of products for the consumer goods industry.

    Project Scope:

    • Optimize material and manufacturing cost of an existing hook tape unwind system

    Design Group Approach:

    • Developed conceptual design for providing the required function – unwinding of hook tape; instead of optimizing existing design for cost benefits
    • Opportunity for re-design was used for understanding and addressing chronic field issue – tape jumping off the rollers
    • Delivered 3D models, 2D fabrication drawings, Bill of Material
    • Engineering support for manufacturing, testing, installing and commissioning

    Results:

    • Part count reduced by 50%
    • Material and manufacturing cost reduced by 85% 
    • Significant reduction in foot print of the new design in comparison to existing design
    • Added functionality enhancements including: Easy tape thread-up; Enhanced operator access to rolls; Elimination of tape dislocation out of rolls; Better tape control due to shorter tape path

  • Line Automation - Automated Food Preparation Line for an OEM

    Line Automation - Automated Food Preparation Line for an OEM

    Client Profile:
    The client is a leading manufacturer of food preparation equipment and smallwares.

    Project Scope:

    • Develop an automated conveying system for automating a food preparation line

    Design Group Approach:

    • Brainstormed ideas for each requirement, ranked ideas using PUGH matrix and shortlisted potential ideas for a Proof of Concept trials
    • Created conceptual designs for precise food dispensing to the container on a custom designed pallet  
    • Performed cycle time calculations, simulations for optimizing dispensing
    • Reviewed design for sanitation and food handling requirements
    • Finalized design and detailing engineering, and released 3D assemblies, 2D drawings and Bill of Material

    Results:

    • Increased productivity due to Takt time improvement
    • Improved crew productivity due to ergonomically designed layout

  • Automated Assembly Line

    Line Automation – Automated Assembly Line

    Client Profile:
    The client is a major pharmaceutical company specializing in the development and manufacturing of biopharmaceuticals.

    Project Scope:

    • Conceptual design for automating the unpacking of components, for feeding them to an assembly line to eliminate human touchpoints and improve hygiene

    Design Group Approach:

    • Examined current state and desired future state - upstream and downstream activities, deriving specifications for the future state automated line 
    • Identified off-the-shelf solutions, developed custom designs for realizing the future state and for removal of packing materials from the line 
    • Identified and integrated AGVs for component transportation
    • Integrated all the above solutions into a conceptual design  
    • Validated conceptual design through trials
    • Provided budgetary estimates for design and manufacturing of conceptual design

    Results:

    • Provided a fully automated solution (zero touchpoints) to integrate into the existing floor plan, with the following benefits: 
      • Just-In-Time supply to the assembly line
      • Less than a 12-month ROI
      • Automated handling of packaging material for compacting and disposal

  • Lifting Tool Design

    Manufacturing Automation - Custom Lifting Tool Design For Truck OEM

    Client Profile:
    The client is a leading manufacturer of forklifts.

    Project Scope:
    • Design and develop a lifting tool for handling transmission component at different stages in a truck assembly line

    Design Group Approach:

    • Understood existing process and baselining
    • Brainstormed alternatives for handling Transmission component, generated 12 ideas; PUGH matrix to review and shortlist one idea for conceptual design
    • Created conceptual layout design, preliminary and detailed designs for shortlisted idea whose key features included:
      • Ergonomic design with simple locking systems
      • “POKA YOKE” to avoid unlatching while handling components
      • Simple replaceable mechanical parts to reduce machining cost and complexity of the tool, avoided weldments
    • Design Reviews and Finite Element Analysis for design validation
    • Delivered 3D models, 2D fabrication drawings and Bill of Materials (BOM)

    Results:

    • Cycle time (latching and unlatching of tool) reduced about 50%
    • Enhanced safety and optimized material, manufacturing costs

  • Manufacturing Automation - Redesign Of Postal Delivery Trucks

    Manufacturing Automation - Redesign of Postal Delivery Trucks

    Client Profile:
    The client is a manufacturer of customized commercial Trucks and Trailers.

    Project Scope:
    • Conceptual design of an automated components’ unpacking system for feeding them to an assembly line to eliminate human touchpoints and improve hygiene

    Design Group Approach:

    • Baselined current design for redesign, material substitution and manufacturing processes
    • Created conceptual, preliminary and detailed designs for identified sub-assemblies
      • Latching systems, sliding doors, tray systems, lifting systems
      • Used standard parts for reducing material cost, leading to reduced manufacturing cost
      • Standardized aluminum extrusions resulting in reduced procurement cost 
    • Suggested alternate material for reducing material cost
    • Eliminated waste in manufacturing process resulting in reduced manufacturing cost

    Results:

    • Reduced material cost by 20% through standardization and material substitution
    • Reduced manufacturing cost by 25% through simplified design and process optimization

  • Assembly Animations

    Engineering Support - Machine Operation Animation Videos

    Client Profile:
    The client is a global manufacturer of flexible packaging machines that fill and bag numerous food and non-food products worldwide.

    Project Scope:
    • Develop animation videos to train operators on the working sequence and adjustment procedures for sub-assembly of Vertical Form Fill and Seal machine

    Design Group Approach:

    • Understood ‘sequence of operation’ of sub-assembly and arrived at “animation sequence”; Created story board and arrived at timing plan for animation sequence
    • Developed animation video in SolidWorks Composer as below:
      • Modified 3D CAD model of sub-assembly suitably for developing animation
      • Defined camera positions and angle for focus on key components
      • Added annotations and background audio as needed

    Results:

    • Animation served as effective training module/tool for operators as it clearly showcased functions and instructions for operator against traditional manual usage for operator trainings
    • Leveraged client supplied engineering 3D assembly models for optimizing cost and reduced turn-around-time

  • Release To Fab - Remote Engineering Design Support

    Release To Fab - Remote Engineering Design Support

    Client Profile:
    The client is a leading manufacturer of high-quality conveyor such as gravity conveyors, belt conveyors, chain driven conveyors, belt driven roller conveyors and accessories.

    Project Scope:

    • Remote engineering design support for releasing fab drawings to shop floor of Made-to-Order Conveyors from Sales Orders 

    Design Group Approach:

    • Oriented a dedicated team of engineers on client standards, manufacturing processes, raw-materials and limitations to support the client as a seamless team working remotely
    • Developed workflow for processing sales orders –  through product type, end client requirements and geographies 
    • Leveraged time difference of remote team in releasing fab drawings to shop floor

    Results:

    • Order to fulfilment turn-around time reduced by 30%  
    • Optimized use of shop floor machineries without any idle time

  • Redesign of medical devices

    Medical Devices: Redesign

    Client Profile:
    The client is a leading medical devices organization with over 100 products, including medical carts, table-top instruments, hand-held devices and single use/disposable medical devices.

    Project Scope:
    • Design and development support for multiple product lines to improve time to market by supporting client’s internal design team on redesign and custom equipment design projects

    Design Group Approach:

    • Baselined current design for redesign, material substitution and manufacturing processes
    • Created conceptual layout design, preliminary and detailed designs for:
      • Redesign of an existing equipment for providing additional features and functionalities
      • Custom engineering design from a given industrial design sketch of a medical device  
    • Conducted manufacturing reviews and tolerance stack up analysis 
    • Delivered 3D models and 2D fabrication drawings for prototype and for full scale production requirement 

    Results:

    • Achieved faster turnaround time from Concept to Production - Time to Market improved by 40%

  • Medical Devices - Automation Enables First-Time Right Bone Replacements

    Medical Devices - Automation Enabled First-Time Right Bone Replacements

    Client Profile:
    The client is a global medical device company focused on Extremities and Biologics.

    Project Scope:

    • Using SolidWorks API for developing first-time right custom implants for bone replacements 

    Design Group Approach:

    • Review of current manual process and samples for understanding the need
    • Develop SolidWorks API’s using a spiral model approach for automation
    • Review and fine tuning of the API based on tribal knowledge of the client

    Results:

    • Automated the process of generating the contact point curves for Femur and Tibia bones from point cloud data of the bones of individual patients for bone replacement
    • Productivity improved by 50% with the automation of modeling process using SolidWorks API
    • Early visualization of each patient’s limitations for providing ‘First-time-Right’ solution