mfsi chairman award pune revised [compatibility mode]
DESCRIPTION
Award wining project presentation on Continuous ImprovementTRANSCRIPT
1 © MAHLE
MFSI Recommendation
Chairman Award 2008
Plant - Pune
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MR. Rajesh KakkarDirector Plant Operation Project Guide
MR. Kishore PatilManager Mfg. Engineering
MR. Uday DeshmukhAsst. Manager Mfg. Engineering
MR. Suryakant PalandeTechnical Head
Chairman Award Nomination
Project Team
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Nominee Name : Team : Suryakant Palande / Kishore Patil / Uday Deshmukh
Under Guidence of : Rajesh Kakkar
Age : 44 / 35 / 32
Designation : Technical Head / Manager ME / Asst. Manager ME
Deptt : Manufacturing Engineering
Experience : 24 / 15 / 11 Years
Project Undertaken : Inhouse Refurbishment of discarded / written off machine
( Hot Melt Extruder )
Project Started : October – 2007
Project Ended : February – 2008
Cost Recovery : Rs 7.0 M would have cost for a new equipment.
Spent Rs 1.5 M on refurbishment.
Nomination
Chairman Award Nomination
Executed new Business worth 60 M and Saved Rs 5.5 M
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Issue
Hot Melt glue dispensing machine required for new “Panel Type” PU Air filterswith cured media and co-polyester hot melt. Most crucial factor was MELTINGTEMP of 225°C as against normal temperature of 180°C.
Customers
TATA Motors (2.2 CRDI and ACE) / MARUTI SUZUKI (Swift diesel)
Impact
• Able to acquire and execute new business worth Rs. 60M
• Capex Saving Rs. 5.5 M
• Maintained competitive advantage in Air filter segment
Year 2008
Trigger
a. New business opportunity
b. Capex limitation. Poor Pay back with initial volumes
c. Availability of written off asset and in-house skill set
Project Details
Chairman Award Nomination
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Process Adopted
In view of the CAPEX constraints and not to loose potential business with prime OEs like TMLand MUL an old non-moving (written off) extruder (MELTEX German make) was identified forrefurbishment under guidance of Mr Rajesh Kakkar.
German counterpart strongly recommended to scrap the extruder and go for new Investment.
Extruder manufacturer refused to provide any type of technical help / support.
There was a potential risk of loosing investment of 1.5 M in case of failure however the teamtook the challenge.
Chairman Award Nomination
Project Details contd....
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Chairman Award Nomination
Project Details contd....
Before
Refurbishment
Extrusion screw found damaged
Gear box of Main Motor was found to be worn out
Conventional 8 segment temperature controller for hoses,
application heads and screw zones were non functioning
Screw and Pump motor drive found to be non functioning
Electrical panel was beyond repair due to unavailability
of spares as the model was out dated
Electrical and mechanical parts were checked
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Chairman Award Nomination
Project Details contd....
After
Refurbishment
Electrical hard wiring was minimised by using Siemens S7 300 PLC
with solid state relays for heaters
Control panel was made user friendly by using Siemens OP207 touch screen panel.
This helps in problem diagnosis and controlling of various parameters.
PID control loop was used for min-max glue pressure setting.
This dispenses constant and equal glue quantity.
Pleating machine and extruder pump were synchronised (Tacho-generator
feedback) to achieve metered glue dispensing quantity w.r.t. paper pleating speed.
Man and machine safety inter locks were added
which were not there on the original equipment.
New Lenz drives were installed for screw and pump motor
Extrusion screw and gear box repaired. Parts were manufactured
locally by taking reference from damaged sample parts.
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Chairman Award Nomination
Project Details contd....
Project Status
Equipment is in use for production on 2 shift basis since March 2008
Production Capacity
3800 filters / shift
Output
Machine has produced more than 480,000 PU elements since March 2008 till date
Delivery
100 % delivery against customer requirement in 2008
Quality
Metered glue dispensing resulted in consistent quality and reduction in Internal scrap
(COPQ)
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Special Thanks to; - Lenze Mechatronics India - Kletti Germany- Siemens India- Swaraj Automation
Project Details contd.... After
Chairman Award Nomination
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Recommendation
The Nominee team :
� Took challenge to refurbish old extruder in-house because Meltex, Germany / Nordson, Indiarefused for reconditioning of Extruder and strongly recommended to go for a new one.
� Noteworthy efforts were taken for restructuring of Electrical & Electronic Hardware as everycomponents had special purpose application.
� Hybridization of Critical Imported components with Indian branded product for costoptimization.
� Mechanical parts for Extrusion screw / Gear box were manufactured locally.
� Several experiments / trials were conducted for synchronization of Signal converters for Hotmelt Pressure & temperatures.
� Efforts were taken to achieve precise control for process parameters like uniform hot meltdispensing quantity at constant pressure.
� All experiments / trials / fine tuning were possible only in hot condition of machine.
� Latest technological hardware's – Like Siemens PLC / Siemens Touch screen / Lenze driveensured safety / user friendly operation / cycle time reduction & quality improvement.
� Achieved ease of operating and PM of equipment. Also resulted in increased productivitywith minimum internal scrap.
Chairman Award Nomination
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Thank You
Chairman Award Nomination