The Problem

Being built in the early 1960s, the existing examining machine wasn't up to today's safety and quality standards. Over the years the plant had made some modifications making it very unsafe to operate, and giving unreliable results. Workers had to "eyeball" inspections, leading to inconsistencies.

The Solution

Stage 1: Conduct a feasibility study to analyze the current machines and production process. The primary goal was to help the client determine whether to pursue the project and identify what we don’t know about the processes or systems involved. The output of stage 1 was a fixed fee proposal to complete detailed design in stage 2.

Stage 2: Due to the dangerous nature of the product being inspected it was critical to have the client’s subject matter experts involved at all stages. This ensured the proposed design paths couldn’t lead to any unforeseen safety risks. Tusk had to create completely new methods to perform the necessary tasks, for which industry standard solutions would have been too dangerous. The product our system was inspecting had properties that make many of these typical solutions dangerous or unworkable. To successfully complete the project Tusk had to develop new technology and reinvent the wheel.

Stage 3: Once the detailed design was complete and determined to pass all necessary safety reviews, the machine was built and programmed. Thanks to the talented programming team at Tusk, the completed machine was soon examining the cord at ~300ft/min with incredibly responsive defect detection and tension control systems. The machine was fast, safe and effective. The customer was very impressed and the new examining machine was a success!

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