Introduction To Incotech Ltd

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Introduction To Incotech Ltd
SPRAYMATION Ltd. Unit 9, lion industrial
park Northgate way Aldridge West midlands WS9
8rl Phone [phone] Fax [phone]
452288 E-mail sales_at_spraymation.co.uk Web
www.spraymation.co.uk
Incotech Ltd. Unit 9, lion industrial
park Northgate way Aldridge West midlands WS9
8rl Phone [phone] Fax [phone]
452288 E-mail sales_at_incotech.co.uk Web
www.incotech.co.uk
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About Us

• Incotech are a centrally based U.K company,
  established in 1992, with an impressive record of
  design and supply of automated assembly machines
  and test systems for the automotive and
  manufacturing industries. We have worked with
  many major manufacturers over a number of years
  and have demonstrated our commitment to
  excellence of service at all stages of projects
  we are awarded. In particular, we at Incotech
  pride ourselves on offering the best possible
  quality and response in after-sales support.
• In 2008 the company moved to a new level
  following an employee buyout from the retiring
  owner of fifteen years. This was a real landmark
  for the longstanding and loyal employees who are
  all highly motivated and have a genuine ambition
  to take Incotech forward with goals to increase
  customer base and turnover through a controlled
  realistic business plan.
• We would like to highlight to your company the
  services we at Incotech can offer you. We hope
  this document demonstrates our ability and
  working philosophy to engineer innovative
  solutions to any automation and production task
  solution your company may be looking for from
  initial concept through to design and manufacture
  and final commissioned systems.
• We at Incotech are proud of our workforce and the
  disciplines and services we can offer our
  customers. We pride ourselves on customer
  satisfaction throughout a project and after sales
  service.
• We sincerely hope that Incotech has an
  opportunity to work with your company in the near
  future and that you would also like be a part of
  Incotech future growth
• We hope you find this short presentation
  introducing Incotech to your company interesting
  and informative. If you have any comments
  regarding our services and presentation we would
  very much welcome your comments as this feedback
  enables us to continually enhance and improve our
  services and marketing

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• Spraymation Limited is a sister company of
  Incotech and has been trading since 1999.It
  compliments the service offered by Incotech
  predominantly in product finishing and as proved
  a very successful business since its conception.
• Spraymations business area and expertise lie in
  the design and manufacture of paint finishing
  systems, machines and equipment. Customer areas
  include plastic, metal, wood and even food. We
  also pride ourselves in providing an efficient
  after sales support to our customers.

• Just some of the key services offered
• Complete turn key special purpose machinery
  project control
• Mechanical Electrical design
• Electronic solutions
• P.C Solutions
• Production data acquisition and production of
  traceability reports
• Electrical Pneumatic Panel Build
• Mechanical build and service
• Plant Maintenance services
• Breakdown call out
• Complete turn key finishing plant project control
• Paint Plant Machinery
• Wet Paint Powder Spares (ITW, Nordson, Graco,
  Sames)
• Fluid level monitoring and measurement
• Automatic reciprocating machines
• Equipment servicing

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TYPICAL CUSTOMERS

• Include
• JCB (UK and India)
• Caterpillar (UK, USA and India)
• GKN Driveline
• Webasto Roof Systems
• Airbus Industries
• Metzeler APS
• Turner Powertrain Systems
• Pianoforte Plastics
• McKechnie Vehicle Components
• PSA Peugeot Citroen
• Johnson Johnson
• Lucas EMS
• Trelleborg Automotive
• Grayson Thermal Systems
• Baxi Potterton
• Lander Carlisle
• Federal Mogul

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INDUSTRIAL SYSTEMS AND SOLUTIONS
Incotech Limited specialise in production
automation. Drawing on many years of experience,
Incotech can provide custom mechanical and
electrical design, manufacture and installation
of bespoke systems. This includes production
line component test and assembly machines, poke
yoke fixtures component measurement,
identification and detection, computer and PLC
based control systems. Within our systems we can
offer the customer full process reporting for
component traceability Our sister company
Spraymation Limited provide specialist paint
automation equipment and systems along with spare
parts and backup.
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Automation, Assembly and Testing Machinery

• Our Capabilities include the following
• 2D and 3D Mechanical Design
• Mechanical build and fitting
• Electrical Design
• Control panel manufacture and installation
• PLC Programming
• P.C Controlled systems data acquisition

• What We Do
• Special Purpose Assembly Machines
• Special Purpose Test Machines
• Production Machines
• Project Management
• Control Systems and Panels
• Jigs and Fixtures
• Machine Modifications and Upgrades
• Painting Systems (Spraymation Limited)
• Component Detection and Identification

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PROJECTS COMPLETED
GKN Driveline
Prop shaft Assembly Machine Components Vehicle
Drive-shafts for Landrover Purpose To assemble
CV joints onto prop shafts, whilst providing a
range of checks to ensure correct assembly from
start to finish
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Webasto Roof Systems
1.
2.
Webasto Roof Systems Birmingham Sunroof
Assembly Rigs Components Vehicle Sunroofs 1. Pad
Application Machine 2. Grease Application Rig 3.
U-blend Machine
3.
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Lander Carlisle
Lander Carlisle Birmingham Leak Detection
Machine Components Vehicle radiator plastic
moulding Purpose Test plastic mouldings for
leaks by automatically sealing component
orifices, pressurising with air and monitoring
the pressure decay rate
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Transmissions Test Machine
JCB Fastrac Gearbox Final Test Rig
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J.C.B Transmissions
The 24 Forward speed and 9 reverse semi automatic
gearbox is used in this vehicle
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J.C.B Transmissions
Oil filtration during testing Oil flow
measurement ISO particle measurement
Auto drive spline engagement Calibrated Pressure
monitoring DC regen servo controlled 90kW motor
Custom Panel PC controlled automation Customer
ECU control via CAN bus Integration by Incotech
Pneumatically Braked Output Shafts Speed
detection Adjustment for future projects
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Turner Powertrain
Turner Power-Train Wolverhampton Gearbox Test
Rig Components Vehicle Gearbox Purpose To
provide a range of tests including gear change,
ratio test, clutch set up, etc. prior to despatch
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Caterpillar U.S.A
Caterpillar USA Gearbox Test Rig Components
Caterpillar Vehicle Gearbox Purpose To provide a
range of tests including gear change, ratio
test, clutch set up, pressure checks, etc. prior
to despatch
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G.K.N Driveline
GKN Driveline Aldridge Drive-shaft Assembly
Machine Components Vehicle Drive-shafts for
Landrover Purpose Semi-automatic assembly of 2
piece vehicle drive shafts
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Webasto Roof Systems
Webasto Roof Systems Birmingham Sunroof
Assembly Rigs Components Vehicle
Sunroofs Purpose Sun roof assembly providing a
range of checks to ensure correct assembly
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Axle Testing
Ege Industries - Turkey Differential Axle Test
Machine Components Axle Differential Purpose To
check for correct gear ratio meshing under load
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G.K.N Driveline
2.
3.
GKN Driveline Aldridge Drive-shaft Assembly and
Test Machines Components Vehicle
Drive-shafts 1. Flinger Assembly Press 2. CV
Joint Force Test Fixture 3. Gaiter Stretcher
1.
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Control Projects
3.
2.
Control Panels and Systems 1. Effluent Treatment
Plant Control O.E.S. Process Control 2.
Automatic Paint Plant Control System - F.C.
Brown 3. Pneumatic Control PSA Peugeot Citroen
1.
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Fixtures / Jigs
3.
2.
Special Machines and Fixtures 1. Tapping Machine
PC Control System Slack Parr 2. Gearbox Work
Trolley Turner Powertrain 3. Automatic Shimming
Machine Turner Powertrain
1.
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Mechanical Fixtures
2.
Special Machines and Fixtures 1. Commercial
Vehicle Radiator Assembly Rig Grayson Thermal
Systems 2. Conveyorised Solution Spray Machine
Johnson Johnson
1.
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G.K.N Driveline
GKN Driveline Aldridge Complete Drive-shaft
Assembly Cell Components Vehicle Drive-shafts
Fiat Panda 4WD Purpose Assembly of CV joints
onto vehicle prop shafts, providing a range of
checks to ensure correct assembly. Approx 90secs
floor to floor time per machine.
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Process Analysis
Air Screw Sequence Counter
Air Screw Sequence Counter
Air Screw Sequence Counter
Simple Low Cost Air Leak Detection Unit
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PROJECTS COMPLETED
Metzeler APS - Dunstable Paint Spray
Facility Components Vehicle Door Seals Purpose
To automatically mix a 3-component paint and
apply it automatically via vertical reciprocating
machine
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Paint Line Control
McKechnie Vehicle Components - Pickering Closed
Loop Flow and Colour Change System Components
Vehicle Interior Parts Purpose To provide
accurate closed loop flow control and
multi-colour/multi-solvent colour changes to
automatic spray guns
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Reciprocating Machines
3.
2.
Electronically Controlled Reciprocators 1.
Vertical Reciprocators - Superior Paint Powder
Coatings 2. Heavy Duty Vertical Reciprocator -
F.C. Brown 3. Horizontal Reciprocator -
Flexitallic
1.
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Paint Line Supply
3.
2.
Paint Circulation Systems 1. Sonneborn
Rieck 2. Baxi Potterton 3. Metzeler APS
1.
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Gear Pump Test
Volvo Cars - Sweden Gear Pump Test
Machine Components Precision Gear Paint
Pumps Purpose To run in and test refurbished
gear pumps over a timed cycle, checks flow
tolerances and provides a printed test report
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Product Measurement Mixing
Link 51 Brierley Hill IBC Transfer
System Components Storage Shelving Purpose To
automatically transfer paint from an IBC into a
paint mix tank (PCS), monitoring paint levels and
providing fault alarms
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Complete Paint Booth
Camcal - Stornoway Steel Plate Spray
System Components Wind Turbine Support
Columns Purpose To automatically coat upper and
lower surfaces of steel plates
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Rotary Spray Machine
Anochrome Czech Republic Single Spindle
Automatic Painting Machine Component Oven
Trolleys Components Brake discs Purpose To
automatically coat hub edge of brake disc
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Cleaning Machine
Volvo Cars - Sweden Bell Cup Washing
Machine Components High-Speed Atomiser Bell
Cups Purpose To automatically flush paint
residue from bell cups. Fully pneumatic
controlled.
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Monitoring Mixing Systems
3.
2.
1.
Various paint systems 1. Part marking system 2.
Automatic dye mixing system 3. Paint tank
level/load monitoring
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INCOTECH DESIGN PRINCIPLES

• Incotech Ltd. Offer technical proposals which are
  fully compliant with our customers requirements
  and specifications.
• After detailed study of the specification and
  informative discussion with your technical
  representatives, we would present our proposed
  system design to meet or surpass all of your
  requirements, within the allowed project
  timescale.
• Of great importance at the early stage of any
  project definition is the understanding of the
  key requirements of that project, and their
  relative importance. Only in this way may the
  many and various design trade-offs be assessed
  for their effect on performance, cost,
  reliability, maintainability and other criteria.
  More particularly, each sub-system or component
  should be critically assessed for the risk that
  it represents to the achievement of the projects
  key requirements, and alternatives should be
  sought if the risk is considered unacceptable.
• From the customers specification and discussion
  we ascertain the key requirements for the
  project, i.e. lead time, accurate and repeatable
  production, and project cost. It is these key
  requirements that drive our conceptual design at
  every phase. The system that has resulted
  consists, in both a mechanical and a control
  sense, of the largest number possible of
  completely autonomous functions or sub-systems.
  The alternative approaches considered, and the
  reasoned arguments behind the eventual selection,
  are given in the following section.
• The benefits that result from breaking the system
  down into functionally independent sub-systems
  are
• The significant technical problems of a few large
  and complex systems that would threaten the
  delivery timescale are removed. They are replaced
  by simpler issues of project management.
• Once the functional requirements and general
  design objectives of each separate sub-system are
  established, the project can call upon a larger
  team of independent design, assembly and
  commissioning staff.
• The system as a whole becomes significantly more
  tolerant of individual failures and the
  production line will continue to work with minor
  levels of acceptable degradation, where more
  complex systems would stop completely.
• Fault finding and maintenance are simplified, and
  our customers dependence upon spares holding and
  external specialist technical support is
  minimized. With proper documentation and
  training, most maintenance work can be conducted
  in-house, if the customer so choose and the Mean
  Time to Repair are significantly reduced.

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CONTROL PHILOSOPHY

• Incotech Ltd. Provide full support to the
  Poka-Yoke philosophy asked for by many of our
  customers, and in some cases proposes to employ
  more sensors to confirm, for example, component
  and clamp positions than the specification
  strictly requires. However, this does lead to a
  large amount of discrete control information
  available within the system, when the majority of
  it is only needed locally.

MECHANICAL DESIGN BUILD

• Our design team uses Pro Engineer to design
  projects in 3D this allows our customers to
  visualize the machine before it is manufactured.
  It also speeds up the design and detailing
  process enabling the machine drawings to reach
  the shop floor faster and more reliably than
  older methods. Customers are given colour 3D
  prints of the machine as well as 2D layout
  drawings which can be used to approve the design.
• We can produce detailed layouts of proposed plant
  to customers floor plan drawing.
• Modular aluminium frame construction is used were
  suitable along with the more traditional steel
  fabricated structures. All tooling fixtures will
  be designed in such a way as to avoid any form of
  damage to the components being assembled.

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PLANT MAINTENANCE

• At all stages of any project we place high
  priority on plant maintenance this ensures that
  the finished machine will be user friendly to
  maintenance personnel. We produce comprehensive
  plant layout diagrams that identify all
  diagnostic test points and terminal layouts which
  will assist maintenance personnel in quickly
  locating and diagnosing any problems. Full
  maintenance schedules are produce and supplied to
  the customer. We also offer mechanical
  electrical maintenance services on site.

P.C P.L.C PROGRAMMING

• All P.L.C programs conform to IEC 1131-3 and are
  structured with the use of Organization Blocks,
  Function Blocks, Program Blocks and Data Blocks
  as required. This will provide maintenance
  personnel with program listings that are well
  documented, cross referenced and broken down into
  readable blocks to specifically aid the
  de-bugging process and any subsequent fault
  diagnosis.
• P.C based applications utilize various
  proprietary software packages to suit customer
  requirements. We are a recognized application
  integrators for National Instruments hardware
  software systems
• Programs will be structured not only to perform
  the assembly tasks with Poke-yoke if your
  specification requires this, but will also check
  I/O inputs for all possible states of operation
  at all times throughout the process, thus
  ensuring correct process of information.
• Each Poke-yoke operation will be checked as
  required and will not step to the next process
  check until being fully compliant with your
  specification.

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DESIGN MANAGEMENT

• Each Poke-yoke operation will be checked as
  required and will not step to the next process
  check until being fully compliant with your
  specification.
• The management of the design process at Incotech
  is based upon BS7000 guide to managing product
  design and the quality requirements of ISO9000.
  It employs disciplines that are very closely
  allied to the overall project management and
  production of documentation, which are discussed
  in following sections.
• The conceptual design at the outset of a project
  will be done entirely in-house. There is now a
  clear legal requirement on all machine
  manufacturers to conduct detailed risk analyses
  at various stages throughout a design project.
  This analysis, and the conceptual design and
  configuration, will result in a detailed
  Functional Requirements Specification. This will
  be discussed with customers at an early
  Preliminary Design Review and will be issued to
  the design team along with the design concept and
  customers own Machine Purchase Specification,
  which identifies the general design and build
  requirements.
• Before the Critical Design Review, the original
  functional requirements will be translated into
  an Acceptance Specification. This details the way
  in which each part of the requirements will be
  tested before delivery, and what constitutes
  acceptable performance. It is a document that
  will be agreed by customers.
• This procedure of Functional Requirements
  Specification and Acceptance Specification can be
  followed though many levels of a project.
• All machine manufacturers are required to
  maintain a Technical Construction File, which
  details all aspects of the machines design.
  Hazard analysis is required for all phases of the
  machines life, from installation and
  commissioning, through normal operation and
  maintenance, to de-commissioning and removal. All
  failure modes considered have to be identified,
  and the design action taken to overcome safety
  problems has to be stated. In addition, all user
  manuals, parts lists, independent test
  certificates etc. are also kept as part of the
  Technical Construction File. These will be
  available for preliminary customers inspection
  at the time of the equipment acceptance at
  Incotech.

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PROJECT CONTROL

• Effective project control is essential to the
  technical and commercial success that both
  Incotech and our customers strive for.
• Incotech fully support our customers desire to
  procure a turn-key solutions from a single
  source taking full responsibility for its
  performance and delivery on time. However, for
  this to happen it is essential that our customers
  have confidence in the suppliers project
  management abilities.
• On all projects, Incotech will make extensive use
  of PERT analysis to predict and review progress.
  The attached GANTT charts are an example of the
  many already produced to provide us with the
  confidence we need to prepare any future
  proposal.
• GANTT charts show the expected timing of all
  elements of a project, and the required
  completion dates if the project overall is not to
  be delayed. Equally importantly, they show key
  dates when actions must be taken by our
  customers, such as component drawing release,
  approval of designs, acceptance on site etc.
• The Incotech project manager will review progress
  against these plans on a regular basis and take
  recovery action if delays or other problems are
  foreseen. Customers will be provided with regular
  project progress reports summarizing achievements
  so far, and key future dates. Attendance by the
  Incotech project manager at the customers site
  to for project review meetings and presentations
  to higher management can be provided.

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TRAINING, SPARES AFTER SALES SUPPORT

• No investment in capital production facilities is
  of value without full operator training.
• Incotech can offer training, not only to
  production staff who are concerned only with the
  correct operation of the plant, but also to
  supervisory staff, maintenance engineers etc. who
  need to understand how to handle failed
  components and cope with system faults.
• The training will be planned and lead by the
  Incotech project team.
• In our experience, if this training and contact
  with production operators is started early in the
  project, there is a useful return flow of
  information where operators can influence some
  aspects of the design of the production line.
  Feeling involved in this way often makes
  operators more receptive to the eventual formal
  training and to the introduction of the facility
  itself.
• Incotech is fully committed to effective
  after-sales support, and always work with the
  customer until all requirements are fully met
  after commissioning at your site.
• The Incotech design concept takes particular care
  to simplify the customers requirement, so as to
  make spares and repairs easier. This concept will
  be developed in detailed design, with an
  insistence to use locally available, standard
  common parts wherever possible. It is our
  intention to minimize the required spares holding
  as far as is practical.
• Incotech has a significant advantage in offering
  rapid response to any problems that our customers
  might have in operating the production line. Our
  geographical proximity to our customers based in
  the U.K is a valuable feature when an urgent
  call-out is necessary.
• Incotech Ltd. has a proven record of providing
  the highest quality of backup and support to all
  of its customers and on all of its supplied
  systems, for the complete life of that system.

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DOCUMENTATION

• Effective project control is essential to the
  technical and commercial success that both
  Incotech and our customers strive for.
• In addition to the technical and design
  management documentation mentioned earlier, and
  the normal project control reporting, Incotech
  provide full documentation for all major projects
  we undertake.
• This will include as a minimum
• A full set of installation instructions, operator
  instructions, setting instructions and
  maintenance fault finding guides
• Detailed drawings of all mechanical, pneumatic,
  and electrical installations, fully identified
  and to ISO standards in CAD format
• PC and PLC software and program listings with
  disk back-ups
• Floor plans can be provided showing mountings and
  responsibilities for providing services to the
  production line
• A full list of parts, suppliers and recommended
  spares
• Copies of all operating manuals supplied to
  Incotech for major bought-out items
• All necessary calibration and test certificates
• Full instructions and schedules for planned
  periodic maintenance
• CE certification and statements of compliance.
• In addition, all training materials used for any
  projects will be made available in hard copy
  format.

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SUMMARY

• Incotech greatest assets are the staff who are
  all long serving employees with many years
  experience there fields. The workforce skills
  compliment each other and at every stage work as
  a team to ensure that our customers always
  receive a First Class Service
• The Incotech design teams take pride in all tasks
  undertaken and at every stage work closely with
  the customer. We believe good communication is
  essential in insuring we provide our customers
  with a first class service.
• Through discussions with your technical staff we
  will form a clear view of the important criteria
  that govern any project we undertake
• In any proposal we are asked to provide we will
  present what we consider to be the integrated
  solution that offers the best possible
  availability, performance and cost combination.
• We have demonstrated our commitment to many
  prominent engineering companies over a number of
  years, both in project design and after sales
  service, and would be honored to add a company of
  your standing to our portfolio.
• Incotech represents a stable and reliable
  resource for customers seeking a complete
  turn-key solution encompassing a wide range of
  engineering principles
• Full confidentiality is essential between us and
  our customers and you can rest assured that we do
  not discuss any the customers requirements or
  working practices unless approved by the customer
  in a written letter of approval
• We all at Incotech look forward to having the
  opportunity of working your company in the
  future.