Case Studies

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.

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…

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

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 /…

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…

Project initiation date 15/07/2008 to 20/10/2008 Challenge Wheels India ltd has a separate manufacturing unit for Forged Aluminum wheels catering to various truck segments abroad. Aluminum alloy wheels are single piece flow wheels without any welding operation involved. Critical success factors…

Productivity Improvement in HX25W Compressor housing machining cell to meet a 100% increase in customer demand (from 7100 Nos/month to 15900 Nos /month) without additional investment   Project initiation date 10/08 to 12/08 Challenge  We are Single source to Customer. Delay…