OVERVIEW:
The project centered on delivering a high-performance software solution for a heavy duty diesel engine assembly line at a leading commercial vehicle manufacturer. With a mandate to streamline complex production processes, maintain continuous operations, and meet aggressive timelines, Actemium applied its proven methodologies and deep automation expertise to drive exceptional results. Through close collaboration with the customer and a focus on quality at every stage, the team delivered a fully validated, seamlessly integrated system that not only met requirements but set a new benchmark for reliability and efficiency.
BACKGROUND:
The customer required a dependable software solution to manage the complex operations of their engine assembly line. Our task was to design and commission software for 31 stations, while also supporting commissioning activities across certain parts of the assembly process. This work was essential to help the customer improve efficiency, minimize downtime, and ensure consistent performance at every station.
SOLUTION:
Utilizing Actemium’s standard methods and practices, the sequence of operations was developed and reviewed with both the customer and end user before software design began. Once approved, Actemium’s engineers used customer-developed software templates to create programs. All software was fully bench-tested using customer-supplied test equipment prior to on-site deployment, ensuring a smooth commissioning process. Key elements included standardized programming, pre-commissioning validation, and collaborative design reviews.
RESULTS:
The project was completed under a time-and-materials contract with exceptional efficiency:
- Software development: Completed with over 200 hours remaining from original estimates.
- Commissioning: Finished with over 100 hours remaining from original estimates. Both the customer and end-user expressed high satisfaction with Actemium’s performance, leading to additional production support requests after project completion.
The project highlights how structured methods, early stakeholder engagement, and rigorous pre‑testing can speed delivery, reduce risk, and ensure long‑term operational success—an approach applicable across industries.
