Representation of Company’s Innovations and approach at National level helps in showcasing Company’s talent.

Presentation by various companies of diversified field and their breakthrough activity has given opportunity to improve wherever required.

A new technology already implemented and with proven results shown at Summit were eye opener and has given us a clear understanding of tech availability in and out of india.

National Productivity summit is one of best platform which enables company to utilize as where we stand in healthy competitive market .

As an individual I gained more self-confidence ,improved communication of presentation infront of huge nos of participants ,industrialist ,multitalented jury’s.

2. How does your company look at innovation and improvement? What are the steps taken by your company to continuously bring in improvements in its processes?

SKF has key platform for innovations and continuous improvement imbibed in Company’s vision and mission statement.

SKF Has various activities and approaches for continuous improvement may be through Kaizens in all categories safety ,quality ,cost ,productivity.

SKF drives all approaches of Innovations and continuous improvement through Business excellence a major platform .

Various analytical tools six sigma , TRIZ , DFSS ,application simulation tools ,new product development tools and tech are used to innovate and continuous improvement

SKF journey for innovation and improvement has started from day 1 of company’s startup which has led to a culture which is built at all levels from top to bottom and has become a daily owned job by each and every one in company.

Employee engagement and complete involvement is done at various forums in SKF internal competitions, external competitions,various showcase forums

Please send us the responses in 150-200 words per question.

Also, please send us a high-resolution image of yourself.

In order to meet production deadlines, please send us the inputs by December 30, 2015.

Along with this please send us a high-resolution image of the Spokesperson.

We started the day with enlightening key note session by Fraunhofer IWU Chemnitz, Germany on Vehicle Light-weighting employing Hollow Shaft Strategy, Hot Forming & Magnesium Forming and update on Fusion of various technologies.

Under the stream Design & Software the first session by Godrej and Boyace illustrated the new methodology of predicting and applying Spring-Back compensation for an HSS Component with associated benefits. The next presentation was from Fraunhofer IWU Chemitz, Germany on Alternative Heating Strategy and Process Chain for Hot Forming. It covered selective Heating and Cooling for localized tailoring of properties, it also threw up High Speed Impact Cutting post Hot Forming as an alternative to Laser Cutting for saving on energy cost.

Third presentation by Data M Sheet Metal Solutions, Germany discussed in depth the Simulation for Roll Forming influencing the Design of New Roll Forming Lines for 3D Forming typically for Long Member of Trucks.

The presentation by Fibro GmbH Germany spoke about use of Controllable Gas Springs with Wireless remote monitoring of pressure, it also showcased Hydro-cams for compact multifunctional Die Design. These concepts are poised to transform the Sheet Metal Forming Tools in near future.

Hatebur Switzerland presented interesting possibilities of Light-weighting of forgings like fasteners with use of Higher strength material, with optimized shapes and lower temperature forming for saving on energy cost.

Finally, the presentation from Simufact Germany scaled the depth of Simulation for Forging and Sheet Forming by use of advanced techniques covering the finer aspects.

The second stream on Equipment and Tools began with proxy presentation from Hexagon Metrology Intelligence Singapore about automation of in-line inspection of BIW line using combination of Robotized Scanning along with Gap and Flushness Gauging.

The presentation by DVB Design & Engineering India highlighted the benefits of using Progressive Dies even for medium and large components while clearing myths and detailing some special features of Progressive Dies and compatible presses.

Dreher Automation GmbH Germany presented some case studies where by retrofitting automation products on Transfer Presses and Blanking Lines a lot could be achieved in terms of increase in productivity and cost effectiveness.

Bharat Forge India presented their technology prowess in Analysis and Simulation of deflection and deformation in Hot Forging Dies using Finite Elements.

Electro-pneumatics & Hydraulics India presented the prospects of deploying Servo-electric technology in presses and metal forming industry for improving controllability and energy efficiency.

Last presentation from Rockwell Automation took us through the evolution of Safety Standards and how they have shifted stress on communication and control rather than stopping and how these are affecting presses, automation and subsystems.

In the stream Processes Electro-pneumatics & Hydraulics India presented how Tube Bending has become a field with diverse challenges and driven by stringent demands of economy and efficiency the machines and tools employed in this process have implemented many innovations.

This was followed by a presentation by Yamazaki Mazak Japan , the first part stressed on importance of controlled environment for manufacture of precision machines and the second part covered holistic automation with Laser Cutting Machine.

IIT Bombay presented a way of dealing with environmental issue of waste management. It was illustrated that Powder Metallurgy could be used to transform Grinding Sludge and Scales into useful recycled product thereby literally transforming waste to value.

Fagor Spain presented the equipment line up for Hot Forming and how the preference is shifting from Hydraulic to Servo-mechanical presses. Further they presented test reports with Hot forming, which lead to conclusion that Servo-mechanical presses are unfit for the process unless some special features are incorporated in their design.

Prof Karunakaran of IIT, Bombay explained the related terminology, latest trends, immense interesting possibilities and certain limitations associated with 3D Printing.

This stream was wrapped up by BalTec Switzerland covering the niche area of Riveting, highlighting the differences in riveting by forming, orbital riveting vs radial riveting. They gave an insight in available equipment and applications.

With this we declare the seminar closed. Hope to see you in next ISFT in 2018

IMTMA had organized a series of successful National Productivity Summits in the past from 2006 to 2014. The ninth summit in the series was organized at Hotel Crowne Plaza, Gurgaon, on 20-21 November 2015.

Key highlights of the National Productivity Summit 2015 were the four inspiring keynote presentations, 4 interesting plant visits and 12 live case study presentations.

Plant visits:
Plant visits to 4 companies were arranged on 19 November, a preceeding the summit, to Hero Motocorp and Sona BLW Forging in Gurgaon and to Hitech Gears and Honda Motorcycles & Scooters India in Bhiwadi. A total of 80 delegates attended the plant visits, where various productivity improvement measures being practised on the shop floor were demonstrated.
Inaugural and Keynote Addresses :

Mr. L. Krishnan, President, IMTMA gave the welcome address. Dr. V. K. Saraswat, Hon'ble Member, National Institution of Transforming India (NITI) Aayog, was the Chief Guest for the event.

Speaking at the event, Dr.Saraswat briefed on the current Indian economic scenario, the challenges and opportunities lying ahead. He then impressed upon the importance of productivity and manufacturing to the growth of the nation, in conjunction with the drive of the government on Make in India campaign, to equip the Indian manufacturing fraternity scale to greater heights in the global arena.

Around 300 participants from 102 companies witnessed the keynote presentations by industry leaders from Maruti Suzuki, Honda Cars, Hitech Gears and Sartorius India Group, on innovative approaches to address productivity challenges, new ideas and concepts.

Case Study presentations:
Leading firms like Ashok Leyland, Bajaj Auto, Bosch, Keihinfie, Lucas TVS, Mahindra & Mahindra, Maruti Suzuki, Tata Motors, TVS Motor and Wabco India presented their case studies on productivity practices, all of which contested for IMTMA – Ace Micromatic Productivity Championship Awards 2015, that gave away cash awards of Rs.10 Lakhs.

Award Winners :
Towards the close of the event, Wabco India, TVS Motors, Bajaj Auto, Keihinfie, Lucas TVS and SKF India were adjudged the winners of the IMTMA-ACE Micromatic Productivity Championship 2015 Awards. Further, a Vox Populi Award was given to TVS Motors. This award was voted by the delegates at the summit as the most popular case study presentation.

National Productivity Summit 2016 :
The next edition of the National Productivity Summit will be held in November 2016, scheduled in Bangalore, for which entries on the latest productivity practices will be called for and evaluated to compete for the Productivity Championship Awards 2016.

Bajaj Auto, Chakan plant, achieved dramatic improvement of yield and cost savings by replacing forgings with sintered parts for balancer driven and idler gears. The sintered gears were near net shape with a yield of 95% against forgings with a yield of 70%. Process steps were also reduced, resulting in cost saving. The case study presentation will elaborate the approach used as well as the study carried out to address differences in the material properties of both processes.

Ashok Leyland found that the major contributor to their overheads was electrical power. Their case study highlights how they went about analyzing shop wise, line wise, and aggregate wise Energy monitoring with On-Line single screen view, and further re-grouping of entire energy load. Mobile alerts for demand management was an added benefit. This resulted in huge savings and more so when machines are idling.

Challenge

To meet sudden increase in Customer demand, Ford (430 to 560 Nos) & 7 LPM (340 to 450 Nos)

Gaps in meeting customer demand is identified by comparing the actual demand to the current capacity and by improving the major losses like Model changeovers in the current capacity.

Data Collection

Keeping minimum investment in mind focused on-Machine utilization / Line Balancing – Existing Line, Machine utilization / Line Balancing – other similar lines and Major losses in current condition.

Project initiation date: 07/12

Challenge

Project: Improve productivity by ensuring end to end pull system in M&M bolero assembly. To meet the customer demand and management policy we have selected the theme of creating an Integrated cell.

For selecting this project, PQ analysis was done and found IFS Lower has the highest volume in production.

Project initiation date: 07/12

Challenge

NTBC oil pump (Cummins) requirement increased from 500nos. to 1800nos. per month. Assembly & testing is the identified system constraint. Existing productivity of assembly & testing was 18 & 38 nos. per shift respectively. To meet the increased demand, it was needed to increase the capacity of assembly & testing. Since management policy does not allow to increase manpower, without increase in productivity (without fully exploiting the constraint). Capacity addition without improving productivity would have increased the cost of manpower, other expenses like power bill & other overheads. This would reduced bottom line.

Project initiation date: 07/11

Challenge

Zero rejection was targeted for machine shop and on data stratification

It was found that the steel phase was the top contributor of rejection. In steel phase rejection of Crank Shaft Line was very high and also affecting the overall productivity of the line. Project was taken and TPM (Total productive Maintenance) was used as a broad management tool and Figure of Eight methodology was adopted to eliminate the defects.

Project initiation date: 03/12

Challenge

The refrigerator market in India is highly seasonal and peaks during summer and festive seasons installed capacity to meet this peak demand.

But, in today’s competitive market, manufacturers are offering customers a range of features to suit their needs. This range includes different sizes, colors, designs, interiors etc and each such variant becomes an SKU for manufacturing. We at Godrej also increased our range by 25 nos. over last three years.

In order to produce the large number of variants and SKU’s, needed to produce in multiple lots and keep changing models on the production lines which resulted in productivity loss and inefficiencies in capacity utilization.