Industrial and Simulated Manufacturing Projects
The below manufacturing examples are taken from work completed at the University of Portsmouth, and Caterpillar.
Projects cover: manufacturing-system design, production optimisation, digital-twin modelling, vision systems and production support.
N.B. Examples of manufacturing projects completed at Hevasure can be found under "CAD > Hevasure Aquila 2".
Academic project
A hybrid flow manufacturing system was developed for an aluminium-housing hydraulic disc brake caliper assembly. The proposed system combined parallel CNC machining, manual assembly and in-line pressure-decay testing.
The system was designed around a target output of 1,000 units per day and assessed using takt-time analysis, capacity calculations, line balancing, reliability inputs and defect-recirculation logic.
The production system was modelled in Enterprise Dynamics. The model included parallel CNC resources, manual assembly, leak testing, rework routing, internal logistics, palletising, an RFID gate and COBOT-assisted handling.
A live Excel dashboard layer was used to record quality and production KPIs without changing the routing logic of the simulation.
CNC machining was identified as the governing constraint. Under the model assumptions, availability improvements produced a greater output increase than further reductions in downstream cycle times.
The project demonstrated that targeted Industry 4.0 deployment should focus on fault detection, maintenance response and availability recovery at the governing resource rather than applying digital monitoring uniformly across the line.
The public report records the system-design process, capacity basis, simulation structure, scenario testing and final conclusions.
Industrial project · Caterpillar Inc.
Redesign of an axle value stream to support the transition from two shifts to one shift while retaining production throughput.
The work included planning and de-risking the relocation of an IPV vision-system station, production-station setup, tool configurations and the installation of large-screen production reporting linked to the manufacturing execution system.
Industrial project · Caterpillar Inc.
Production support for newly introduced image-inference software used by site vision systems. The work involved investigating production issues, supporting software patches and developing a standard configuration and installation package for site-wide upgrades.
The project combined manufacturing support with IT networking and cybersecurity awareness. Internal configuration details are intentionally excluded from the public portfolio.
Industrial project · Caterpillar Inc.
Consolidation of two production lines into a single line capable of supporting two separate products.
The project included production-station setup and design, health-and-safety sign-off activities, manufacturing-execution-system configuration, fixture design and the preparation of standard work.
