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.