Project initiation date: 02/10

Challenge

Burr problem was observed at customer end during first time development & supplies of Oil Ring with Nodular Cast Iron (Ductile) for prestigious American customers.

24 nos. found during sample inspection of P/N 7N7078 & 15 nos. found during sample inspection of P/N 9S7788(D22-3).

It was noted that inspite of 3 stage burr removal process (ultrasonic cleaning,+Id burshing+inspection) there were customer observations.

Extensive manpower had to be deployed to manually re-inspect and remove the burr by knife edge file, as the productivity was very less, only 300 rings per shift.

Manual removal of burr had following problems:

1. No fool proofing. Even single burr in a lot of rings not acceptable.
2. Safety of operator- First aid incidences of cut in finger from the blade
3. High lead time due to slow manual burr removal process
4. Rusting on rings required to be removed by brushing.
5. Low productivity
6. Quality issues of peel-off/ distort the ring

Engineering solution to global customer was important to make foot print in technologically advanced & huge potential US market (Sales 2011-12: 5 million US$).

Project initiation date: 04/11

Challenge

Chinese entry into Indian Market created a severe competition in the plastics processing industry. Chinese machines were offered at 20-30% lower prices and the delivery time was only the shipping time i.e., 4 weeks (1 month) whereas Indian manufactures were offering the machines at 8 weeks delivery time.

LTPML considered it as a severe threat for its survival and decided to come out with a solution to regain its regime in domestic market. In 2008-09, China imports market share and turnover was similar to LTPML i.e., 23% and Rs.85 crores during 2008-09 (as shown below).

Project initiation date: 06/2009

Challenge

Hazardous sludge generation

Conventional pretreatment technology of zinc phosphate (trication) leads to generation of phosphate sludge as by-product & since it contains heavy metals, the sludge is treated & disposed as hazardous waste.

High energy cost- The process of pre treatment works at 48deg – 2 deg C (Essential for process)

Data Collection

Collection of Hazardous waste (phosphate sludge) generation per year.

Project initiation date: 05/2010

Challenge

To meet the projected customer demand of painted 5000 sets/day (April’ 11) against the present capacity of 2900 sets/day (March’ 10)

Data Collection

OEE Losses data was collected by TPM methodology to evaluate the present capacity of Plastic Paint Shop.

Analysis and Solution Development

To achieve the customer demand of 5000 sets/day, following alternatives solution were evaluated.

It was decided to achieve the target

Solution

By doing activity on OEE Loss side – i.e. down time reduction to achieve design capacity of 3280 sets/day.

By doing activity on Improvement side – increase production / hr to achieve the target of customer demand 5000 sets/day.