Sectors
Advanced Facilities
Sub Sectors
Advanced Manufacturing
Services
Digital and Advanced Technologies
Location
Chhattisgarh, India
The Automatic Film Loading and Stacking System (AFLASS) was developed to improve the efficiency, safety and consistency of radiography‑based non‑destructive testing used for critical defence components. Designed for a secure research facility in Jagdalpur, the system replaces time‑intensive manual handling with an automated process that significantly reduces inspection time while maintaining accuracy and safety. AFLASS supports both tangential and radial radiography and is engineered to operate reliably within constrained and safety‑sensitive environments.
TCE’s Scope
Tata Consulting Engineers led the engineering and delivery of the AFLASS system from concept through site commissioning. The scope included development of the complete system configuration, followed by detailed engineering of all mechanical, structural, electrical and motion‑control elements. The team supported manufacturing and assembly based on approved fabrication and general arrangement drawings, carried out inspections as per quality assurance plans, and conducted trials, testing and system validation. TCE also prepared operation, installation and maintenance manuals, and completed installation, commissioning and final handover at site.
Impact
The introduction of AFLASS has significantly improved the inspection process by reducing manual effort and enhancing safety and consistency. Inspection time per position has been reduced from around 50 minutes to approximately 10 minutes, while human exposure during radiography operations has been substantially lowered. The system delivers reliable repeatability and positioning accuracy for critical inspections, supported by integrated safety measures and a robust structural design. The project establishes a strong benchmark for automated non‑destructive testing in defence‑related applications.
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