• DENSO, founded in 1949, is one of the world’s largest supplier of parts to the automotive industry. DENSO also supplies automotive aftermarket parts, production robots, and portable air-conditioning units.

• The company has firm Japanese roots, and has 187 subsidiaries globally, and employs over 38,000 associates.

• In 1989 DENSO purchased a company in Shipley, West Yorkshire called IMI Radiators Limited. The company which manufactured automotive radiators was renamed as DENSO Marston Ltd. Now, the company manufactures cooling systems for the off highway markets.

• DENSO Marston are committed to the investment of R&D and cutting-edge technology, whilst leading the way in high quality and competitive products. Moving forward, DENSO are planning a high level of investment in targeted areas such as the environment and sustainability.

• DENSO provide Charge air cooling components to customers , but on occasions the products received were defective and did not meet the necessary product specification.

• A key requirement was to provide a solution to the specific quality issue and to ultimately increase quality standards and reduce the number of defective products sent out to customers .

• The existing quality control system involved operators checking the number of plates in the component by using jigs. If it adhered to the product specification a label was then placed on the part identifying the individual component. In this system risk of skipping the jig check and incorrect identification was present.

• DENSO required a system which ensured process adherence with greater accuracy, increased visibility, and one that would eliminate the risk of operator error contributing to costly product recalls.

A Vision of Success:

“ Low cost vision system development is a key initiative in DENSO Marston Ltd. Our approach has been to replace manual inspection methods with vision inspections.

For the Fuel cooler vision system we required a low cost solution that can be developed quickly and works efficiently. The main objectives were to improve quality control and

achieve 80% cycle time reduction from our existing vision system. Cimlogic was an obvious choice to partner us in this project due to our experience from previous vision systems.”

CASE STUDY

How Cimlogic Captured Quality Improvements at DENSO Marston Ltd

Company Profile The Business Requirements

Vineet Verma - Head of Quality, DENSO Marston Ltd

Cimlogic Ltd, 11 Baildon Mills, Baildon, Shipley, West Yorkshire BD17 6JYe: enquiries@cimlogic.co.uk t: 01274 599 955 f: 0870 762 5559

www.cimlogic.co.uk

• Cimlogic developed and installed a bespoke vision system for DENSO. The system was set up in one day and provided instant improvements in visibility and quality control.

• The system incorporated a camera, which would take a picture of individual parts produced. The camera would detect whether or not the part met the correct standards.

• Operators no longer had to inspect quality manually, as the image would match the part against predefined standards to determine whether it passed or failed the inspection.

• If the part passed the inspection, the system would automatically produce a label to accompany the part. This entire process took seconds to perform, and ensured that all products delivered to DENSO’s customers were of the highest quality.

• The system also included a reporting feature, which evaluated the number of parts that had passed and failed over a specified time period. This historical data will aid decision making and present clear areas of improvements within the production process.

• Simplified quality process, which saved operator time and reduced the risk of human error.

• DENSO now have improved visibility and accuracy of product quality which, helps to reduce customer concerns, has increased production efficiency and reduced costs.

• DENSO have formed better working relationships with their customers as a result of improved product quality.

“The Project was successfully executed and delivered on time by Cimlogic. We achieved our

targets for cycle time reduction and improved quality control. Application developed by Cimlogic is easy to use

for Shop floor associates and very effective in providing information and traceability of results.

This is first of our low cost vision system development together with Cimlogic and we are confident that next

projects will be completed on time successfully.”

Vineet Verma - Head of Quality, DENSO Marston Ltd

The Cimlogic Solution

The Benefits

Outstanding manufacturing solutions