Manufacturing Engineering Services (MES)

Process planning in manufacturing is a pivotal and comprehensive phase essential for ensuring the efficiency and cost-effectiveness of production processes. This multifaceted approach encompasses a wide array of crucial considerations, serving as the guiding force that directs manufacturing operations. At its core, process planning aims to optimise every facet of production, from the definition of assembly processes and simulation of part flows to the creation of detailed station plans.

In this process, assembly processes are precisely outlined, specifying the steps, tools, and techniques required to seamlessly assemble components into the final product. Advanced simulations are employed to visualise and enhance the movement of parts within the manufacturing environment, promoting material flow and overall production efficiency. Station plans serve as blueprints for individual workstations, guaranteeing that equipment and tools are thoughtfully organised for maximum productivity.

Moreover, process planning encompasses critical aspects like weld spot studies, ergonomic evaluations, production volume calculations, and cycle time assessments. It involves meticulous part sequencing, clamping plans to secure workpieces during processes, and careful layout designs to optimise floor space and safety.

Cost estimation and the creation of station-specific Bills of Materials (BOMs) ensure budget adherence and minimise downtime, while controlled build documentation maintains consistency and quality. In essence, process planning is the linchpin of manufacturing, orchestrating these diverse elements to drive efficient, cost-effective, and high-quality production processes, from initial assembly to the final product’s delivery to customers.

TECOSIM is a specialised provider of services in the field of process planning, renowned for its expertise in optimizing manufacturing operations. With a deep understanding of each of these crucial aspects, TECOSIM offers tailored solutions to streamline processes, reduce costs, and enhance the overall efficiency and quality of manufacturing operations, making it a trusted partner in the industry.

• • Planning

    • • Assembly Process Definition
    • • Part Flow Simulation
    • • Station Plans
    • • Weld spot Study
    • • Weld Gun Selections
    • • Ergo Study

• • Part Study − Panel Build Sequence

• • Production Volume − Cycle Time Calculations

• • Clamping Plans

• • Layout

    • • Line Layouts
    • • Conceptual Plant Layout
    • • Cable Tray Layout

• • Estimation and Costing

    • • Station wise BOM
    • • Line CBD

• • Documentation

TECOSIM specialises in providing comprehensive solutions in the realm of manufacturing and engineering, catering to various critical aspects of the production process. One of our core areas of expertise lies in the development of specialised tools and fixtures for geometry stations, including both spot welding and arc welding applications. These fixtures are meticulously designed to ensure precision and reliability in welding operations.

In addition to welding fixtures, we excel in the creation of re-spot fixtures, hemming fixtures, and in-line checking fixtures. These fixtures play a vital role in maintaining product quality and dimensional accuracy throughout the manufacturing process.

TECOSIM’s proficiency extends to the design and development of geo grippers, material handling grippers, and combo grippers, which are instrumental in material handling and manipulation tasks within the production environment. We also engineer deposit stands and passing tables, as well as conveyor pallets and take-out trolley tooling, to streamline material flow and enhance operational efficiency.

For welding operations, we offer pedestal welding, stud welding, and gluing stands, which are crucial for ensuring the integrity and precision of assembly processes. Our services also encompass the creation of comprehensive manufacturing drawings and Bills of Materials (BOMs), providing a clear roadmap for production.

Furthermore, TECOSIM assists in the initial stages of manufacturing by providing preliminary manufacturing and purchase information, helping clients make informed decisions regarding production resources and processes. Additionally, we offer support in preparing shim plans, ensuring accurate and efficient adjustment of components.

TECOSIM’s commitment to precision, innovation, and efficiency makes us a trusted partner in the manufacturing industry, delivering tailored solutions to optimise production processes and drive success in every project.

• • Geometry Stations (Spot Welding / Arc Welding)

• • Re-Spot Fixtures

• • Hemming Fixtures

• • In line Checking Fixtures

• • Geo Grippers / Material Handling Grippers / Combo Grippers

• • Deposit Stands & Passing Tables

• • Conveyor Pallets & Take-Out Trolley Tooling

• • Pedestal Welding, Stud Welding & Gluing Stands

• • Manufacturing Drawings & Bill Of Materials (BOM)

• • Preliminary Manufacturing and Purchase Information

• • Preparing Shim plan

TECOSIM offers a diverse spectrum of robotic simulation services, tailored to optimise various facets of manufacturing and automation. Our expertise encompasses a wide array of joining technologies, such as spot, arc, and laser welding, as well as screwing, riveting, clipping, hemming, and gluing. Through meticulous simulation and fine-tuning, we ensure that these processes not only meet rigorous quality standards but also operate with maximum efficiency.

We excel in defining and validating process flows, leaving no detail unexamined to optimise manufacturing operations. Our services extend to layout validation and optimization, where we craft work cells tailored precisely to your requirements. We aid in evaluating and finalizing essential resources, including robots, welding guns, tip dressers, conveyors, fixtures, and all accompanying accessories, with a focus on resource efficiency and cost-effectiveness.

TECOSIM’s robotic simulation services extend further to cycle time validation and optimization, driving reduced lead times and increased throughput. We offer comprehensive support for offline programming (OLP) and online programming, ensuring your robotic systems align seamlessly with your production needs. Our expertise includes payload checks and optimization, resource collision mitigation, system integration for new variants (especially in brown-field projects), and in-depth human simulation studies that assess safety, accessibility, and feasibility. With TECOSIM, you can harness the full potential of automation and robotics in your manufacturing processes, leading to enhanced efficiency and safety across the board.

• • Joining technologies like Spot/Arc/Laser welding, Screwing/Rivetting/Clipping, Hemming & Gluing.

• • Defining Process flow, validation & optimization

• • Layout validation & optimization and Work cell building

• • Resource requirement evaluation & finalization e.g. Robot, Gun, tip dresser, Conveyor, fixture & All accessories

• • Cycle time validation & optimization

• • OLP attributes and online programming support

• • Payload Check and optimization

• • Resource collision check & optimization.

• • System integration for new variant (Brown-field Projects)

• • Human simulation – Safety, Accessibility & feasibility, ergonomic study.

Our aerospace tooling CAD design team excels in creating precision tooling solutions specifically tailored to the aerospace industry. We combine creativity and technical proficiency to design jigs, fixtures, transportation trolleys, and assembly platforms that meet the industry’s stringent requirements for accuracy and reliability.

TECOSIM provides comprehensive design documentation, including detailed drawings that serve as invaluable references throughout the manufacturing and assembly processes. Our detailed drawings ensure that every component of the aerospace tooling aligns precisely with the design specifications.

We understand the importance of legacy tooling within the aerospace sector. Our team specialises in legacy tool conversion, modernizing and optimizing existing tooling designs to meet current industry standards. This conversion process enhances the longevity and performance of legacy aerospace tooling, aligning it with modern aerospace requirements.