Julio García Sánchez’s relentless passion for mitigating the challenges faced by his clients had stood the test of time since he was part of the launching team of an automotive plant in Valencia around 45 years ago—a time when computers were science fiction. Since then, Sánchez has been at the helm of Integrale Consulting (IC) as the General Director, leading the company in the task of coaching organizations in adapting manufacturing processes to the “new wave” of assuring quality, not controlling it. Sánchez’s business acumen has led IC to transform clients’ reactive mindset to a proactive one, in its journey of overseeing simple engineering inspections to the most complex repairs of vehicle components and engines. “It is important for any new project to be based on profound industry knowledge and optimal technical performance, rather than competing in the market for high profits. Efficiency follows automatically,” points out Sánchez.

An industry veteran, Sánchez knows what it takes to resolve manufacturing challenges within a business. “Most businesses struggle to reach the highest first-time-through manufacturing rate and optimal overall equipment efficiency (OEE). Besides, non-quality costs and not preventing their negative impacts are the main hurdles hindering profitability,” elaborates Sánchez. Bringing Machine Vision into play, IC leverages its vast experience on Quality Operating Systems (QOS) and Lean Manufacturing processes in an attempt to address these problems.

IC’s strong relationship with the local Universities has helped the company successfully complete projects pertaining to pattern recognition for façade and internal architecture designs, hyperspectral vision systems for the food market, and ‘neural networks vision algorithms’ for the leather industry.

IC has also served clients in the food and beverage industry, reducing human intervention via automation, thereby eliminating errors while segregating food bags. “We aim to reduce the time and money invested by a client, simultaneously enhancing the work efficiency by clubbing manual labour with machine accuracy,” explains Sánchez.

What makes IC a go-to service provider for most companies is its extensive use of modern tools, automation capabilities, and Machine Vision Technology in solving the most complex problems for its clients. IC exhibits full commitment toward its clients, right from the top management to the ground level executive. With a 45-year experience in ‘root cause investigation,’ PCAs proposal and problem-solving activities, IC is equipped to assess a multitude of constraints faced by its clients while they operate machinery, thereby eliminating problems right from their sources. Added to that, the team at IC is adept at conducting tasks in alignment with Ford’s language and procedures. “Clients hugely benefit from IC’s regular updates on the progression of work; our customers’ trust keeps us on the top of the benchmark,” states Sánchez with pride.

We aim to reduce the time and money invested by a client, simultaneously enhancing the work efficiency by clubbing manual labour with machine accuracy

In an instance, IC recently helped two engine plants resolve a dispute that frequently occurred over the quality of camshafts. IC’s simple Machine Vision station detected and assessed defects as per the engineering standards, linked the 2D matrix of the component with pictures, and displayed the calibrated size of defects, thereby maintaining traceability of the same.

Scripting similar success stories, IC has already established its branch in Romania and has similar expansion plans to India. The company is currently working on crack detection by means of laser heating and utilizing thermographic cameras, reducing the time consumed in production lines. “Integrale is constantly working on newer technologies and ideas, with an aim to empower clients with better business conducting services,” concludes Sánchez.