Engine Assembly
Customer : Leading Heavy Vehicle Manufacturer (OEM)
Project Description :
Facility planning for engine assembly (Green Field)
Scope :
Manufacturing facility planning for Engine assembly.
Area considered: - Input stores, assembly, Testing,
Finishing, Dispatch.
Key Considerations :
Productivity improvement, by Mechanization of assembly
process. Automatic transfer systems. Quality Improvements
by providing in process verification systems. Planning based
on LEAN manufacturing concepts. Flexibility to handle all var.
Output Delivered :
- Assembly Process Optimization – Line balancing.
- Equipment selections -RFQ documentation
- Equipment concepts for special purpose equipments
In-Plant Logistics
- Detail layout showing foot prints of the equipments
- Digital Factory showing 3D models, Walk through,
Process formation & Animation
- Work Place arrangement considering Ergonomics,
Poka-Yoke and Operator Safety
Quantified Benefits to the customer :
- Production increased by 186%
- Production capacity increased by 120% per Sq.mtr.
- Production capacity increased by 90% per direct labor hour
- Lead Time reduction by 50%
- WIP reduction by 50%
- Reduction in rejections and rework by 20%
- We went beyond the scope of the project to provided valuable design
recommendations.
Gear Box Assembly
Customer : Leading Heavy Vehicle Manufacturer (OEM)
Project Description :
Facility planning for Gear Box Assembly (Expansion)
Scope :
Manufacturing facility planning for Gear Box assembly
Area considered: - Input stores, assembly, Testing,
Finishing, Dispatch
Key Considerations :
Productivity improvement, by Mechanization of assembly
process. Automatic transfer systems. Quality Improvements
by providing in process verification systems. Planning based
on LEAN manufacturing concepts. Flexibility to handle all var.
Output Delivered :
- Final Assembly Process Optimization.
- Equipment selections (standard Equipments) & RFQ documentation
- Equipment concepts for special purpose equipments
In-Plant Logistics
- Final Layout showing foot prints of all the equipments
- Digital Factory showing 3D models, Walk through, Process formation & Animation
- Equipments detailed manufacturing drawings
Quantified Benefits to the customer :
- Production increased by 131%
- Production capacity increased by 54% per Sq.mtr.
- Production capacity increased by 78% per direct labor hour
- Lead Time reduction by 14%
- WIP reduction by 14%
Off Road Vehicle Axle Assembly Plant
Customer :Leading Heavy Vehicle Manufacturer (OEM)
Project Description :
Facility planning for Rear axle assembly (Expansion of existing facilities)
Scope :
Manufacturing facility planning for Gear Box assembly
Area considered: - Input stores, assembly, Testing,
Finishing, Dispatch
Key Considerations :
Productivity and process improvement by mechanization of assly.
process. Automatic transfer systems. Planning based on LEAN
manufacturing concepts. Flexibility to upgrade to a new product.
Output Delivered :
- Optimized Assembly Process.
- Equipment selections -RFQ documentation
- Equipment concepts, design and supply for special purpose equipments
In-Plant Logistic Planning
- Detail Layout showing foot prints of all the equipments
- Digital Factory showing 3D models, Walk through, Process formation & Animation
- Complete project management right from concept to installation, commissioning &
prove out
Quantified Benefits to the customer :
- Production increased by 500%
- Production capacity increased by 500% per Sq.mtr.
- Production capacity increased by 300% per direct labor hour
- Lead Time reduction by 83%
- WIP reduction by 83%
- Increase in ergonomics and safety by 80% (measured on RPN)
Axle Assembly layout
Customer :Leading LCV, passenger car manufacturer
Project Description :
Facility planning for Front and Rear axle assembly (Expansion)
Scope :
Manufacturing facility planning for Gear Box assembly
Area considered: - Input stores, assembly, Testing,
Finishing, Dispatch
Key Considerations :
Productivity and process improvement, by Mechanization of assembly process automatic transfer systems. Planning based on LEAN manufacturing concepts. Flexibility to handle all variants.
Output Delivered :
- Final Assembly Process Optimization.
- Equipment selections (standard Equipments) & RFQ documentation
- Equipment concepts for special purpose equipments
In-Plant Logistics
- Final Layout showing foot prints of all the equipments
- Digital Factory showing 3D models, Walk through, Process formation & Animation
- Equipments detailed manufacturing drawings
Quantified Benefits to the customer :
- Substantial reduction in Rework & Rejection due to material handling
- Reduction in Inventory cost by adopting JIT system.
- Cost and Time saving.
Core Making & Handling
Customer :Giant in Foundry Business
Project Description :
Facility planning for Core making, Storage, Handling & Delivery System
Scope :
Setting up the manufacturing facilities for 4 types of Cores
Designing of Core Storage system
Area considered: - Core Making, Buffer, Delivery to Mold Line
Key Considerations :
Improvement in Productivity by reducing the damages due to handling, Process Improvement, by Mechanization, Flexibility to handle all the variants and empty pallet (common pallet for all variants) management.
Output Delivered :
- Final Layout showing foot prints of all the equipments
- Equipment selections (standard Equipments) & RFQ documentation
- Equipment concepts for special purpose equipments
- In-Plant core handling & buffer storage system
- Digital Factory showing 3D models, Walk through Animation
Quantified Benefits to the customer :
- Substantial reduction in Rejection due to improved material handling system
- Balance between Core making lines & Molding Line because of effective Buffer System
Cost and Time saving.
- Operator Safety Environment & Less Fatigue due to effective handling systems
Manufacturing System Engineering for Bus Body Shell Plant, Digital Factory & Animation
Customer : Leading Global manufacturer of Commercial Passenger Vehicles
Project Description :
Manufacturing System Engineering for Bus Body Shell Plant & Digital Factory – Modeling & Animation
Scope :
Analysis of different part used in body shell
To decide the manufacturing facilities required
3D modeling and walk through animation of entire bus
Key Considerations :
To centralized part storage and sub assembly manufacturing for all other plants.
Output Delivered :
- Pa3D model of entire plant
- Walk through animations
- rts analysis report.
Quantified Benefits to the customer :
- Production increased by 131%
- Cost and Time saving
