Productivity Portal » 2011

Roll forming in spigot type weld screws

admin — Fri, 13 Mar 2015 09:20:08 +0000

Project initiation date: Sep’09

Challenge

The generic process flow for spigot type weld screw consists of (1)Raw material (2) Forging(3) Spigot machining (4) Threading (5) Heat treatment (6) Surface finishing (7) Pack & dispatch.

This product has a unique entry profile which is a functional and customer specific requirement, which is currently being machined in a SPM.

Productivity improvement by resolving quality problem in Lub oil pump assembly

admin — Fri, 13 Mar 2015 07:14:45 +0000

Project initiation date: July 2010

Challenge

Delivery commitments getting failed due to the rejection of the pumps after assembly

Used bar chart & ABC analysis for identification of the problem.

Innovative Up gradation of Pegard CNC Boring machine

admin — Fri, 13 Mar 2015 05:31:16 +0000

Project initiation date: Aug 2009

Challenge

Pegard CNC Horizontal Boring m/c commissioned in the year 1983 (29 years old). Problem was selected to improve Productivity, to improve maintainability, to improve Process capability and to improve internal customer satisfaction.

Tools like Pareto diagram, MTBF & MTTR chart and quality control charts and Productivity charts(OEE) were used

Reduction of Frame Body boring bar change over time for 6 models thru SMED

admin — Fri, 13 Mar 2015 04:29:14 +0000

Project initiation date: 20.10.10

Challenge

Weld shop Machine wise production data collect Last six month Avg. (Mar-Aug-10) Fine Boring production is less (25/Shift) then other Machine’s

Design by Edit process to enhance Design Productivity

admin — Fri, 13 Mar 2015 04:09:00 +0000

Project initiation date: 02/09

Challenge

Problem was selected to reduce design lead time, Design variability & deviations due to design.

As per annual business plan (ABP) number of projects to be executed from 113projects/Year (2007-08) to planned 200 projects / Year (2008-09)

The learning curve for New Designers to become experts was three years. These resources are not easily scalable for catering to fluctuations in load condition.

Every year additional skilled Die Designers are required, who have sound knowledge in Die designing principles and also expertise in 3-D modeling software, to meet the growth planned in ABP.

Productivity Improvement in Medium voltage (11 Kv to 33 Kv) Vacuum Circuit Breaker manufacturing line

admin — Fri, 13 Mar 2015 03:35:02 +0000

Project initiation date: 01/10

Challenge

Circuit Breaker is the sub-assembly for the main product – The Switchgear panel. Every customer order is considered as a project of “switchboard” which consists of a number of interconnected switch gear panels. The size of the board varies from 2 panels to 200. Hence the “On Time delivery In Full” (OTIF) of Circuit Breakers is important for the total throughput.

In our Circuit Breaker line, the following factors inhibited the capacities which affected internal customer satisfaction.