Case Studies

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 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…

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…

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…

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 &…

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…

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…

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…

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…

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.