Installation of new EMS carrier in an existing EMS system

Industry:
Automotive Manufacturing

About the Customer:
A well-known automotive brand with origins in Britain, this company was revitalized by a leading Chinese automotive corporation and entered the Indian market in 2017. The company has established itself in the Indian automotive industry with a range of popular SUVs manufactured at a facility in Halol, Gujarat, which was acquired from a previous automaker. This plant now serves as the primary production site for the company’s SUV lineup, including some of the most popular models in the Indian market.

The Backdrop:
The Halol facility, originally built over 15 years ago, operates with legacy systems that have become increasingly inefficient, prone to frequent breakdowns, and challenging to maintain. The production line, particularly for one of the brand’s key SUV models, utilized an outdated Electrified Monorail System (EMS) carrier, which had been adapted from its previous use. While the EMS system was modified to accommodate the new model’s body-in-white (BIW) dimensions, frequent issues with carrier alignment and part wear led to costly downtimes and production inefficiencies.

Specific challenges faced included:

  • Frequent EMS Carrier Failures: Misalignment issues led to significant wear on wheels and current collectors, causing frequent breakdowns.
  • Obsolete Components: The old hoists used in the EMS system had limited availability for spare parts, complicating repairs and increasing maintenance delays.
  • Non-Standard Design Elements: The system used a mix of wheel sizes, leading to high inventory costs and logistical challenges in managing spare parts.

In addition to resolving these issues, the customer aimed for a solution that could integrate with the existing EMS track to avoid major structural changes while still meeting modern operational requirements.

The Challenge:
To improve operational efficiency and reduce downtimes, the company needed a reliable solution to upgrade the EMS system, particularly the carrier, while retaining as much of the existing infrastructure as possible. The main challenges included:

  • Alignment and Component Wear: Misaligned carriers caused excessive wear on wheels and current collectors, leading to frequent breakdowns.
  • Compatibility with Existing Systems: The new EMS carrier needed to seamlessly integrate with the existing main control panel for operational consistency.
  • Aesthetic and Functional Modernization: The solution needed to provide a visually appealing and efficient system upgrade to meet both operational and aesthetic standards.

The Solution:
The company awarded the contract to Sparkline to replace and test one EMS carrier, with an option to expand the solution to additional carriers based on the initial results. After assessing the site, Sparkline identified misalignment as the primary cause of excessive wear on wheels and current collectors, leading to frequent system failures.

To deliver an optimized solution, Sparkline implemented the following actions:

  1. Supply and Installation of New EMS Carrier: Sparkline provided a new EMS carrier designed to meet the required load specifications, equipped with a custom control panel, and supported by two new hoists rated at 1200 kg to ensure a safe margin, with a maximum working load of 800 kg.
  2. Integration with Existing EMS Controls: The control panel for the new carrier was integrated with the EMS main control panel, enabling seamless operation within the established system framework.
  3. Modernized Technology and Standardized Components: The updated carrier used advanced controls and standardized parts, eliminating the need for multiple wheel sizes and reducing inventory costs. Sparkline designed, supplied, and installed the system within a compact timeline—supply in less than 10 weeks and installation in one week.

By reusing the existing overhead tracks, Sparkline provided a cost-effective solution that addressed the operational issues without requiring a full overhaul of the EMS system.

How the Customer Chose Sparkline:
The customer’s trust in Sparkline was reinforced by previous successful engagements. In particular, Sparkline had previously addressed vibration issues in the EMS system of another SUV production line, which used a twin-hoist EMS setup. Sparkline’s prompt response and successful resolution of these issues demonstrated their technical expertise and commitment to customer satisfaction. Additionally, the paint shop at the facility utilized an EMS system with components from various vendors, and Sparkline’s maintenance support had kept this system running reliably for nearly a decade with minimal intervention.

A Statement of Overall Benefit:
Sparkline’s solution provided a reliable and efficient EMS upgrade, enhancing the functionality of the production line while significantly reducing maintenance requirements. By leveraging existing infrastructure and minimizing installation time, Sparkline ensured the customer could maintain production continuity and reduce operational costs.

Benefits:

  • Cost-Effective Solution: By utilizing the existing track, Sparkline avoided the expense of a complete system replacement, delivering a more economical solution.
  • Reduced Maintenance and Spare Part Costs: The new, standardized EMS carrier design reduced spare part inventory needs, resulting in cost savings and streamlined maintenance.
  • Quick Project Turnaround: Sparkline met the supply timeline within 10 weeks and completed installation in a week, minimizing production delays.
  • Reliable Long-Term Support: Sparkline’s proactive approach and established relationship with the customer ensured long-term support and confidence in system reliability.

With Sparkline’s effective EMS upgrade, the customer achieved a cost-efficient, reliable solution tailored to their operational needs, supporting both current and future production demands.