Objective: Production of 30000 Nos. of ICU Ventilators progressively within 3 months.

COVID spread in INDIA from March 2020 necessitating requirement of large no of ICU grade Ventilators to provide respiratory support to patients hospitalized.

Challenges faced while  executing the project:

• BEL entering into manufacturing of critical care medical equipment for first time without prior experience, domain knowledge and infrastructure.
• Import Procurement of components from OEMs due to export restrictions and overseas domestic demand.
• Dynamic pricing and uncertain lead time.
• Timeline of delivery is very challenging.
• Subcontracting of work packages from MSMEs due to the nation-wide lockdown.
• Logistics issues due to cross border traffic closure, etc.
• Concurrent production model adopted as CV200 Ventilator newly launched.
• Clinical validation and approval to be obtained at AIIMS-Delhi in a short span of time.
• Certification : ISO 13485:2016 for Ventilator manufacturing
• TUV Certification for CV200 Ventilator

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Tata Motors vision is to give sustainable mobility solutions for customers. Tata Motors entered in EV Segment in FY20-21 with Nexon EV and leading the EV Mobility with 90% Market share.
Its Flagship products include Nexon EV, TIGOR EV & Recently Launched High Range Nexon EV Max. This Project is conceived & executed in TML, Pune Plant where Nexon EV are being Produced.

EV Shop was originally Planned for Capacity 8/day in 3 shifts .With Increased customer Demand due to good market response we needed to improve the productivity & hence the capacity of Shop. This Project was to improve the Capacity of EV Shop focussing on special Levers.

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Brief Description of the project:
To adhere 100% Preventive maintenance in PASRS, our available time for PASRS stacker crane was 183Min/crane/Month and MTTPM for that was coming around 202min/crane/month, hence we did time study for each checkpoint assembly wise and found HTA as major contributing factor for high PM time. Hence to eliminate the HTA we analyzed that we need to convert TBM checkpoints to CBM checkpoint so that it can be monitored online and we don’t have to check it during preventive maintenance. We created CBM network with the help of IOT devices customized for our requirement and through which data is transferred to CBM server and we in-house developed the dashboard in our WMS software and displayed the critical parameters on that dashboard.

Trigger for the project:
Global Parts Center (GPC) is an IT enabled, Automated End to End Integrated Warehouse at Neemrana. It has state of art facilities (ASRS, Conveyors, Unishuttle, Sorter system, Packaging lines) and digitally integrated software Warehouse Management System (WMS). The WMS is the nerve center of GPC as it sends all information to all the equipment, resources and system.

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In the presented case study, the customer is producing Cabin Latch unit for different OEMs at global locations, there are different variants of latch that need to be produced specific to customer requirement, the core function of the product remains same but there are dimensional variances in the component across variants.

Machinery that the customer was using in production was 20 years old and was lagging in the latest technological development.

The Requirement floated to us for the project was to provide an assembly and testing solution for the latch meeting the quality and productivity requirements. Another challenge in the production line was to accommodate all the variants of the latch keeping the change over time minimum.

The Old line also didn’t have any provision for data collection, handling and processing which had to be incorporated in our proposal.

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