Today, Directech QM-Systems are a world leader in the provision of automated and semi -automated production and test systems across many industries. In particular our in house developed, fully integrated, semi-automated production systems for engine and power unit build has opened new markets particularly within Outboard Marine applications. Over the last years we have partnered with companies like Cox Powertrain, Riccardo, Caudwell Marine and others to deliver innovative solutions for the unique field of Diesel Outboard Marine technology with some real success.
Directech QM-Systems – Marine Systems
Our Systems include:
- Short and long block engine assembly
- Engine marinization
- Transom and PTT assembly
- Steering system assembly
- Gearbox assembly
- Lower leg and Interim assembly
- Component marriage
- Final system dress
- Hot and cold engine test
- In process testing, e.g. Torque to Turn (TTT) testing of sub-assemblies
- Control unit programming
- Overall system control with our own proprietary Manufacturing Execution System (MES)
Diesel Outboard Manufacturing System
Directech QM-Systems partnered with a leading Diesel Outboard Marine start up to design, manufacture, install and commission a complete production system for a V8 Diesel Outboard motor. The production system is a semi-automated assembly process using a blend of automation, semi-skilled operators and In-process validation (IPV) and manufacturing control through use of an MES to manufacture the product using a ‘no fault forward’ manufacturing methodology.
The project consisted of 6 main sub projects.
Short Block Build
An assembly line with overlying MES to assembly the base level engine block consisting of pistons assembly, conrod cracking, crank and flywheel assembly, piston stuffing, shim measurement and selection, torque to turn testing with IPV.
Cylinder Head Assembly
An assembly line with overlying MES to assemble the complete cylinder head, consisting of valve insertion, valve spring assembly, conrod setting and fitting, fuel pump fitting and shim insertion, tappet shim measurement and fitment, valve popping station to bed in valve seats, final turn test with IPV
Engine Marinisation
An automated carousel-based assembly line to marry the short engine and cylinder heads together. Following the marriage process the engine assembly is driven from station to station to complete the Marinisation process where water pump, turbo units, fuel injection system, cooling system, exhaust and inlet systems end electronic systems are fitted to the Long Block. The Engine ECU is programmed at this point. The process is managed by the MES system with IPV including leak test interlaced where appropriate to ensure the unit is assembly correctly.
Lower leg build
A floor mounted carousel assembly line to manufacture the complete lower leg. The lower leg is an arrangement of input shaft, clutch, bevel gears, bearings, prop shaft, outer and inner casings, filters, water pump and intermediate housing. Similar to the Engine Marinisation assembly line the unit passes through a number of build stations situated around the carousel. The final station utilises a spin rig to run up the final assembled product to test for NVH and temperature.
PTT Transom
An assembly line to assemble and test the operation of the PTT. The PTT is a key part of the product that mounts the assembled outboard motor to the vessel and provides steering and angular trim functionality using hydraulic ram systems. The assembly line controls the assembly process via the MES control system and finally carries out functional test of the assembled PTT by communicating with the control module to drive and check for correct operation of the hydraulic steering and trim systems.
Product Marriage
The product marriage station is a lift-based station that enables the PTT, power unit and lower leg to be assembled or ‘married’ together to form the finished product. The system enables automatic and manual lift and rotate of the total weight of the final product to enable easy access by operators to all areas of the product. Final system dress occurs at this station with connection of final wiring harnesses and pipework. The final stage of the process is the fitment and alignment of all cowl assemblies and off load to shipping crate.
