Engine Assembly Line

The straight six engine assembly line was a successful project for the client as well as Lewis Australia because it was delivered on budget and on time.

The project began when the engine manufacturer wanted to double its engine output due to market demands. The existing infrastructure was not capable of being upgraded to meet the new forecast volume requirements. The challenge was to conceptualise cost effective appropriate of automation to meet the client's objectives.

The proven Lewis process was applied to the challenge. The process started with brainstorms to find the appropriate level of automation to cost effectively assemble engines. Once a concept was identified, extensive testing was completed to verify the technical feasibility of the concept.

The client accepted the outcome of the test work which demonstrated a new type of modular conveyor system for the new assembly system. Flexibility, ease of upgrade and modification were the primary project objectives which were satisfied by this concept. The result was a flexible production system with a low production cost.

The design work followed once the concept was approved and final detail drawings were completed within six months of the design start. Construction followed when the client approved the detail drawings for construction.

The construction, assembly and testing of the machine took approximately six months. The machine underwent testing and was accepted by the client at Lewis Australia. It was then disassembled and shipped to the client's site by road freight.

Installation and commissioning took eight weeks to complete. The machine gave the client twice the production rate as the previous line at low operating costs.

The line has since been successfully upgraded three times to accommodate new changes for the engine and increases in production to meet new demands.