Generating Smart Engineering Impact
In today’s globalized world, Original Equipment Manufacturers (OEMs) and product engineering companies face constant challenges in shortening New Product Innovation (NPI) cycles, reducing development costs, and meeting the demands of emerging markets with the new products. Compounding the problem is a shortage of experienced engineers with the depth of industry knowledge.
For 15 years Genpact Engineering Services has been helping manufacturing enterprises foster product innovation and reduce time to market with our strong talent pool of highly experienced engineers. Their collective knowledge spans aerospace, energy, power generation, transportation, telecommunications, healthcare, and a host of other industries in markets around the world.
Since our beginning as a captive of GE, Genpact has leveraged the power of our deep Lean Six Sigma heritage to empower what we call intelligent enterprises—innovative companies capable of keeping up with change. Built on Genpact’s proprietary Smart Enterprise Processes (SEPSM) framework of smarter processes, detailed analytics, and targeted technologies, Genpact Engineering Services enable our clients to minimize product development costs, enhance capacity, and reduce time to market.
We provide end-to-end design and engineering solutions ranging from new product development and introduction, technical documentation, and engineering design and analysis, to support for technical infrastructure such as product lifecycle management (PLM) and computer aided design (CAD) tool customization.
Genpact helps our engineering clients more clearly define product offerings to cut material costs, manufacturing times and costs, and overall program management timelines and expenses. From tool design to reverse engineering, our highly trained engineering staff bring new perspectives to your projects to augment your institutional knowledge, speed development, and drive savings from end-to-end of the development process. Offerings include:
- Product design and development (mechanical, integration engineering)
- Tool design and development
- Verification and validation support
- NPI/NPD support
- Reverse engineering
- Programmable logic controller design/Supervisory control and data acquisition
- Product development management
- Technical marketing
- Program management
- Electrical, electronics
Genpact supports our clients with a variety of engineering documentation in aerospace, energy, and industrial. Our engineers assist with all areas of your documentation from regulatory compliance to certification support. Our best practices reduce product development time and cost, and ensure ongoing compliance. In the area of documentation, Genpact offers the following services:
- Product regulatory compliance (ROHS, WEEE, REACH and FAA)
- Technical documentation
- Bill of Material management
- Engineering change management
- Plant/Process layouts
- Program management from concept to field
- Certification program management
- FAR 33 certification support
Genpact supports computer aided engineering (CAE) and non-CAE analysis for our clients in the energy and aerospace industries. Our highly skilled resource pool possesses deep domain knowledge and works on a variety of engineering analyses to arrive at accurate results. You achieve optimized products you can take to market faster, at less cost. Genpact offers the following services:
- Value engineering
- Design for manufacturing and reliability
- Finite element analysis
- Computational fluid dynamics
- Mold flow analysis
- Installation reliability
- Thermal analysis
Manufacturing Engineering Support
Genpact supports our clients with years of experience in manufacturing engineering support, applying our diverse industry knowledge to help our clients reduce product development time and management costs. Offerings include:
- Product development management
- Business program plans
- Program scheduling
- Hardware tracking
- Design hardware changes
- Product improvements
- Spare and retrofit
- Hardware kitting
- Final engine assembly support
- Capacity reviews
- Tooling capabilities
Engineering IT (CAD and PLM)
Our highly skilled team helps our clients reduce product management costs with CAD customization, design automation, and PLM simplification, reducing product design time and cost and speeding time to market. Offerings include:
- Solution design
- Data migration
- Test support
- Component and engine test support
A major aircraft engine manufacturer lacked sufficient resources to meet the schedule on time and within budget for a new engine design program. Genpact provided value engineering services that helped the client reduce engine design cycle time and deliver faster to the end-customer. Genpact also developed new and improved design for manufacturability leading to long-term continuous improvement for the client.
A global energy OEM wanted to improve the efficiency and performance of gas turbines by redesigning its combustion system (the trapped vortex combustor, TVC). With the client, Genpact conducted detailed research on the TVC technology and then conceptualized, designed, developed, tested, and delivered the new product design. This resulted in a two-month decrease in design cycle time leading to faster time to market.
A leading energy equipment manufacturer had to manage equipment outages more effectively, at a lower cost, and thus serve customers better and faster across the globe. Genpact helped develop and deploy an integrated solution for smarter sourcing processes and effective transactional procurement activities. This value engineering solution resulted in US$8.72 million savings, higher availability of direct materials, and improved sourcing effectiveness.
A U.S. based global solar photovoltaic (PV) manufacturer was aggressively expanding into new markets in India, Africa, Australia, South Europe, and the Middle East. However, the company lacked the ready resources to rapidly design to local standards and meet cost pressures from increasing competition. Genpact helped this client with “intelligent” value engineering services by putting in place smarter sourcing and design processes that improved the current design, decreased time to market by four months, and produced more than US$4 million in annual savings.
A market leader in aerospace fluid fittings wanted to optimize its investment in manufacturing tooling and save costs. Genpact enabled design for manufacturability by applying design modularity principles across different pipe fitting families and developed a detailed analysis of tolerance stacks across part families and tool groups. This resulted in 82% jaws optimized, and machine setup time was reduced by 30%, which led to an overall business impact of US$1.6 million.
A global aerospace engine manufacturer required crucial technical documentation updates in its engineering operations and maintenance (O&M) manuals to align with the assembly process. Genpact provided complete engineering support from understanding the assembly process to data inputs to final delivery of accurate documentation. This led to improved manufacturing productivity and operations safety, and near elimination of rework and rejection.