PROVEN TRACK RECORD / CASE STUDIES

Real Engineering Challenges. Measurable Production Outcomes.

Explore how Draftdu partners with automotive OEMs, commercial vehicle manufacturers, and clean-tech leaders to eliminate production bottlenecks, achieve micron-level repeatability, and deliver turnkey automation that performs on the factory floor.

FEATURED PROJECTS

Engineering case studies & system buyoffs.

Client identities are withheld under non-disclosure agreements (NDAs); physical engineering constraints, station architectures, and measurable production metrics are documented below.

Turnkey Automated Assembly Cell for High-Volume EV Traction Motors

PROJECT 01

Electric Vehicles & Clean Mobility EV Powertrain / High-Volume Stator Assembly

Turnkey Automated Assembly Cell for High-Volume EV Traction Motors

Challenge:

A leading electric powertrain manufacturer required a multi-station automated line to assemble stator cores and insert pre-formed hairpin copper windings under a strict 45-second takt time.

The process demanded zero manual handling deformation, ±12 µm radial insertion clearance, and 100% inline electrical insulation resistance (dielectric) testing before downstream varnishing.

Measurable Outcome:

Cycle time was reduced from 68 seconds to 43 seconds (36% improvement), achieving consistent ±10 µm radial concentricity. Over 150,000 stator assemblies have been manufactured with zero field dielectric failures.

Multi-Model BIW Geo & Hemming Fixture Line for Automotive Closures

PROJECT 02

Automotive & Body-in-White (BIW) Passenger Vehicle Closures / Geo Framing Line

Multi-Model BIW Geo & Hemming Fixture Line for Automotive Closures

Challenge:

A tier-1 automotive supplier needed flexible geo-framing and table-top hemming fixtures capable of handling driver, passenger, and rear door assemblies across two vehicle platforms.

Key constraints included maintaining ±0.15 mm spatial tolerance on class-A surface flanges, achieving model changeover in under 2 minutes, and providing complete weld-gun accessibility for 14 robotic spot welds.

Measurable Outcome:

Delivered continuous serial production repeatability within ±0.12 mm across 120,000 cycles. Changeover duration dropped to 90 seconds, and robotic weld reach was 100% verified with zero prototype rework.

Zero-Gravity Ergonomic Manipulator System for 320 kg Engine Blocks

PROJECT 03

Heavy Equipment & Commercial Vehicles Commercial Powertrain / Sub-Assembly Station

Zero-Gravity Ergonomic Manipulator System for 320 kg Engine Blocks

Challenge:

In a commercial diesel engine plant, operators faced acute physical fatigue and collision hazards manually guiding 320 kg cast-iron cylinder blocks between a transfer conveyor, washing booth, and final crankshaft assembly station.

Traditional overhead hoists were too sluggish, causing a 75-second bottleneck that hindered plant production targets.

Measurable Outcome:

Completely eliminated operator physical strain and ergonomic injury risk, while reducing station transfer cycle time by 28% (from 75s to 54s). The system has operated for over 24 months with zero component drops.

Integrated Line-Side Kitting & Vision Gauging System

PROJECT 04

Consumer Appliances & Precision Manufacturing Compressor & Appliance Assembly / Line-Side Staging

Integrated Line-Side Kitting & Vision Gauging System

Challenge:

A high-speed refrigeration compressor manufacturer suffered high assembly defect rates (1.4%) caused by operators selecting incorrect internal valve plate variants and missing small seal rings during rapid line pacing.

Traditional manual checking at the end of the line caused high scrap and teardown costs.

Measurable Outcome:

Assembly defect rate dropped from 1.4% to 0.02%, operator walking distance was reduced by 40%, and component verification was achieved in under 2 seconds per kit without slowing the main line.

Multi-Stage Automated Performance & Helium Leak Testing Station

PROJECT 05

Consumer Appliances & Precision Manufacturing Electromechanical Appliances / Serial Quality Assurance

Multi-Stage Automated Performance & Helium Leak Testing Station

Challenge:

A modern domestic appliance manufacturer required 100% helium mass-spectrometer leak testing and electrical safety testing on sealed compressor circuits without disrupting their 30-second continuous conveyor takt.

Manual connection of hoses and cables was inconsistent and frequently damaged delicate copper tube ends.

Measurable Outcome:

Achieved 100% automated inline verification with leak detection sensitivity down to 10⁻⁵ mbar·l/s, completely eliminating false rejects and preventing tube flare damage.

Automated Press Safety Enclosure & Controlled Quench Cell

PROJECT 06

Industrial Manufacturing & Heavy Equipment Forging & Thermal Processing / Safety Compliance

Automated Press Safety Enclosure & Controlled Quench Cell

Challenge:

A 600-ton hydraulic forging press and adjacent rapid oil-quench tank presented severe safety hazards from oil mist, hot-metal splash, and pinch points.

The plant required complete Category 4 / PLe safety guarding that did not obstruct fast die changes or overhead crane loading.

Measurable Outcome:

Full compliance with ISO 13849-1 Category 4 / PLe safety standards, 100% containment of oil splashes and fumes, and a 45% reduction in die-change setup access time.

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