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Success Story: Effectiveness & time savings in test sequences - savings of up to 80 % of the previous throughput time

Project content and brief description

As part of this project, our team developed and implemented an innovative system solution for the comprehensive testing and commissioning of construction machinery. The aim was to digitalise previously manual quality inspections to significantly improve quality assurance (QA). The focus was particularly on the flexible design of test sequences to ensure smooth commissioning of the complex assembly variants. The solution also needed to be expandable in order to seamlessly integrate future requirements and additional construction machines and their components.

Customer requirements

  • Development of a system solution for comprehensive testing and commissioning of construction machinery.
  • Digitalisation of quality inspections to improve quality assurance.
  • Flexibly definable test sequences for a large number of assembly variants.
  • Expandable solution for integrating additional construction machinery and components.
  • Coverage of the operator's test stand and end-of-line tests for all hydraulic excavator components

Solution

Our team developed a software solution consisting of two main components: the TestSuite and the runtime system.

  • TestSuite - Definition of test sequences:
  • User-friendly interface for defining test sequences for different test benches.
  • Pre-defined test benches and affiliations.
  • Customisable test plans with modules, test steps, variants and various measured variables.

Runtime system - execution of the check:

  • Execution of the test plans for the respective construction machine.
  • Identification and generation of the test plan from the central SQL database using a unique manufacturer number.
  • Initialisation of all necessary hardware components for measured variable acquisition.
  • Central storage and logging of test results for further analyses.

Value for the customer

The introduction of the new system solution led to considerable benefits for the customer:

  • Time saving: Savings of up to 80 % of the previous manual processing time of test procedures, which corresponds to a reduction of 175 man-days per year.
  • Digitalisation: Improved quality assurance through digital processes and automated workflows.
  • Automation: Automation of previously manual testing and commissioning, minimising sources of error and increasing efficiency.
  • Quality improvement: Ensuring high quality and reliability of construction machinery by analysing and diagnosing faulty modules and components in detail.
  • Future security: Expandable solution that seamlessly integrates future requirements and additional construction machines and their components.Thanks to the successful implementation of this solution, the customer was able to significantly optimise its inspection processes and sustainably improve the quality of its products.