Monday, November 18, 2013

India - Productivity Improvement Projects - Examples - 2012

Pune Productivity Council


Sr Case study No. Company Case Study Title


1 5 Tata Motors Limited, (Nano machine shop car plant-Pune.) Productivity improvement case study on machine availability improvement.
2 7 Tata Motors Limited, Nano machine shop car plant-Pune. Productivity improvement case study in nano machine shop car plant – Pune.
3 9 Tata Motors Limited, Nano Engine Assembly Car Plant-Pune. Need of production per shift to increase from 75 units to 100 units.
4 10 Minda Industries ltd (Switch Division) Pune. Productivity Improvement through losses elimination of left hand bar    switch assembly line and soldering line.
5 15 Mahindra & Mahindra Ltd. Nagpur. Productivity Improvement by 15% to meet the production requirement of 400 control valves in 2 shifts.
6 16 Mahindra & Mahindra Nashik. (Scorpio). To meet higher market demand at cheaper cost.
7 22 Bharat Electronics Limited Modification of alignment method of holder fixing through X-Ray Radiation to Optical Method for DRA1 X-Ray tube
8 30 Mahindra & Mahindra Ltd., Kandivali Plant. To improve utilization of resource i.e Man, Machine & Material.
9 32 Tata Blue Scope Steel Limited, Pune. Automation of stacker & conveyor on Trimdek Roll Forming Machine.
10 33 Tata Blue Scope Steel Limited, Pune. Optimum utilization of diesel generator power.
11 42 MGI COUTIER Exotech Industries Pvt. Ltd. Process Improvent in MFG Of Air Brake
12 31 Grindwell Norton – Saint Gobain Abrasives Ltd. Reduction in Rework & Customer Complaint for Small Wheel Sulphur Treatment product.
13 John Deere Capacity enhancement
14 John Deere Poka-yoke (Transmission)
Category -  Engg & Auto-   Associate
15 48 John Deere Energy conservation
16 49 John Deere Productivity improvement
17 50 John Deere Poka-yoke / Mistake proofing at Engine Assembly.

Sr Case study No. Company Case Study Title


1 47 Classic Auto Tubes Ltd. / Apollo Tyres Ltd. Reduce Scrap Cost due to Fly Loss
2 19 Mahindra Hinoday Industries Ltd. To meet 100% demand increase in induction cook top coils.
3 21 Maxtech Sintered Product Pvt Ltd. Receiving time reduction by VSM for product family Hego Boss.
4 4 Hindalco Industries Limited, Taloja. Improvement in Canron cold rolling mill speeds.
5 12 Hindalco Industries Ltd. Rolling emulsion bypass line modification.
6 1 Rashtriya Chemicals and Fertilizers Limited, Thal. Productivity improvement by steam saving. (Urea Plant)
7 2 Rashtriya Chemicals and Fertilizers Limited, Thal. Provision of Two Pressure Cooling water system by Cooling water Header Bifurcation
8 3 Rashtriya Chemicals and Fertilizers Limited, Thal. Productivity improvement by revamping Synthesis Gas Compressor Drive Turbine.
9 35 Tube Products of India Limited. Recovering the loss increasing increase in per shift output of 50 ton draw bench.
10 36 Tube Products of India Limited. Man power reduction by reducing material handling on new SINICO machine.


Sr Case study No. Company Case Study Title


1 8 Tata Motors Limited, Maval foundry. Energy conservation in melting shop.
2 11 Ashok Iron Works Pvt Ltd. Productivity improvement by reducing internal rejection.
3 20 Mahindra Hinoday Industries Ltd. To focus on preventive actions to eliminate equipment failures / breakdowns in order to ensure availability & reliability of equipments & to minimize cost of maintenance (TPM).
4 27 Mahindra Hinoday Industries Limited, Pune. Zero Breakdown Approach For Machine Availability up by TPM way.
5 28 Mahindra Hinoday Industries Limited, Pune. Improvement on G200TCI Flywheel Magnet (MHIL part no PD 1319) for crack & strength defect.
6 23 Excel Industries Limited, Roha. Productivity improvement case study by doing modification in ETP Slurry handling centrifugal Pumps & ETP Aerators for bioreactors.
7 37 Tube Products of India Limited. To eliminate manual tag cutting operation at SOOCO cutting machine to achieve 100% OTD in front fork.
8 38 Tube Products of India Limited. To eliminate wastage of abrasive cutting wheels by converting used abrasive cutting wheels into grinding wheels.
9 39 Epcos India Limited. Reduction in setting time and scrap during slitting of wave cut free margin profiles.
10 40 Epcos India Limited. Elimination of Excess consumption of Spray Wire.
11 41 Epcos India Limited. Reduction in setting time and scrap during slitting of wave cut free margin profiles.
12 45 SKF India Limited To improved productivity on bearing components machining.
SSI
13 6 BSA Facilities Limited Pune. Elimination of customer complaints in main wiring harness.
14 26 Seinumero Nirman Pvt. Ltd. POKA-YOKE (Mistake Proofing) of Tapped Holes missing on Magna-flanges.


Sr Case study No. Company Title


1 13 L.G Electronics, Pune. Error free operation in compressor model and circuit diagram fixing.
2 14 Essel Propack Ltd. Reduce changeover time lami tubes from 342 minutes to 60 minutes.
3 17 TATA TOYO Radiator Ltd. Productivity improvement of X3 Nano ECS assembly from 207 units / day to 347 units / day.
4 18 TATA TOYO Radiator Ltd. JD Radiator assembly quality improvement.
5 24 Godrej & Boyce Manufacturing Co. Ltd. Reduce vacuum forming process rejections by using Six-sigma methodology.
6 25 Mahindra & Mahindra Ltd (Automotive sector, Nasik). Capacity Enhancement & Manpower Optimization.
7 29 Tata Motors Limited, CVBU - Pune. KAIZEN Methodology for Breakthrough Improvements.
8 34 05 TATA Motors Limited, Pune. Uptime improvement in NANO engine testing car plant. Productivity improvement case study on machine availability improvement.
9 44 Kirloskar Brothers Development of UP & TB Pump  Improved Assembly process to increase productivity from 2 to 6 Pumps / man/shift.
10 46 Kirloskar Brothers Reduction in throughput time of large SCT thru bore Pumps from 14 Hrs to 8 hrs. By DFMA & Process Improvement.
11 43 Kirloskar Brothers Productivity improvement by reduction in manufacturing process time of SCT Pumps from 23 hrs per pump to 6 Hrs per pump. Discharge head quality improvement.
12 John Deere Equipment Pvt. Ltd. Vehicle shop capacity enhancement through lean.

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