Case Study: Denso Manufacturing Czech boosts leak testing throughput with Visual Components simulation

Denso Manufacturing Czech boosts leak testing throughput by 70 parts per hour with Visual Components

Denso Manufacturing Czech, a producer of automotive heater exchangers, faced inefficiencies and bottlenecks on its helium leak testing line. The previous manual routing system, which assigned specific product variants to dedicated testing stations, was inflexible and led to underutilized equipment. To address this challenge, the company turned to vendor Visual Components and its 3D manufacturing simulation platform to create a digital twin of the production line.

Using Visual Components, the team simulated and optimized a new dynamic routing logic that directed parts to any available tester. This virtual testing de-risked the implementation and proved the solution would boost throughput. The results showed a significant increase in automated tester utilization, with the busiest station able to process an additional 70 parts per hour. Visual Components provided the simulation needed to achieve a smoother production flow and greater line stability before any physical changes were made.

Denso Manufacturing Czech