"I had never built this assembly before. The Dirac instructions had everything I needed."

-Pedro, Assembly Manufacturing Engineer, Spudnik Equipment

Challenge

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Spudnik's lower boom assembly (Model #880) could only be reliably built by a single operator with 15 years of experience. That expertise was never formally documented.

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2.5x Longer build time

• New operators required 15 hours to complete builds that an experienced operator finished in 6 hours.

2+ hrs Rework per incident

• A single skipped bolt early in the assembly sequence triggered hours of costly disassembly and rework.

~200 Questions per build

• New operators relied on constant expert guidance, creating bottlenecks and slowing production.

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Engineering BOMs were structured for design, not manufacturing, and there was no tool to translate EBOM to MBOM. Production forecasts depended entirely on operator availability.

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For a company scaling heavy equipment builds, production resilience hinged on undocumented knowledge held by a single person.

Solution

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Spudnik deployed Dirac's platform to automatically generate animated, model-based work instructions directly from the 3D product model.

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From purchase to live instructions on the floor: one week.

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Dirac enabled Spudnik to:

• Digitize expert tribal knowledge into standardized workflows.
• Guide new operators through complex assemblies with animated sequencing.
• Eliminate sequencing ambiguity that caused costly rework.
• Restructure EBOMs into manufacturing-ready MBOMs.
• Empower manufacturing engineers to adapt designs for real-world assembly.

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Operators no longer depended on proximity to experience.

Execution became embedded in the system.

Impact

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33% Faster build time

• New operator built time dropped from 15 hours to 10 hours after a single training cycle. Throughput improved immediately with fewer errors and less stress on the floor. Build time became predictable regardless of operator experience level.

60% Less rework time

• A recurring 2+ hour rework incident was eliminated through clear, animated sequencing. Animated sequencing removed ambiguity and prevented repeat errors.

99% Faster operator ramp

• Guidance that took ~1.5 days now takes just 5-10 minutes with Dirac. New operators completed the lower boom assembly independently within a week of initial Dirac deployment. Questions per build dropped from ~200 to ~20. Ramp-up shifted from shadowing experience to executing a documented, model-driven process.

Spudnik transformed a single-operator dependency into a scalable production system. Critical knowledge is now institutionalized, build time is predictable, and rework is prevented before it happens. Throughput no longer depends on who is present.

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About Dirac

Dirac is a manufacturing technology company building the AI-driven system of record for production orchestration. Their product BuildOS is the first AI-driven work instruction platform that replaces document-driven manufacturing with an AI-driven, dynamic, model-based system. Dirac’s mission is to rebuild the industrial capacity of the West by turning manufacturing facilities into context-aware, adaptive, dynamic environments.

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