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Case Studies

Home Case Studies

Improve productivity by ensuring end to end pull system in M&M bolero assembly

  • March 14, 2015
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  • 2013, Award Winners, Case Studies
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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…

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Productivity improvements in oil pumps assembly & testing

  • March 13, 2015
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  • 2013, Award Winners, Case Studies
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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…

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To Achieve Zero Rejection in Crank Shaft Right due to Grinding Operation

  • March 13, 2015
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  • 2013, Award Winners, Case Studies
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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…

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Productivity and flexibility enhancement of refrigerator plant through flow manufacturing

  • March 13, 2015
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  • 2013, Award Winners, Case Studies
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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…

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Innovative Burr Removal Green Technology For Piston Ring

  • March 13, 2015
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  • 2012, Award Winners, Case Studies
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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 &…

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Single Piece Flow/Moving Line for Building Injection Molding Machines (IMMs)

  • March 13, 2015
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  • 2012, Award Winners, Case Studies
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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…

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Optimizing metal process – Elimination of hazardous waste generation in motorcycle fuel tank painting process.

  • March 13, 2015
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  • 2012, Award Winners, Case Studies
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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…

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Productivity Improvement In Plastic Paint Shop

  • March 13, 2015
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  • 2012, Award Winners, Case Studies
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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…

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Roll forming in spigot type weld screws

  • March 13, 2015
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  • 2011, Award Winners, Case Studies
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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…

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Productivity improvement by resolving quality problem in Lub oil pump assembly

  • March 13, 2015
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  • 2011, Award Winners, Case Studies
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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.

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