welcome to the “cii – ap tqm forum members”
DESCRIPTION
Welcome to the “CII – AP TQM FORUM MEMBERS”. Agenda: Our Company– 5 Minutes Thoughts Sharing on Low Cost Automation– 10 Minutes LCA Projects in Amara Raja Batteries– 15 Minutes Question & Answer Session– 5 Minutes. Core Purpose. - PowerPoint PPT PresentationTRANSCRIPT
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Welcome to the “CII – AP TQM FORUM
MEMBERS”
Agenda:
Our Company – 5 Minutes
Thoughts Sharing on Low Cost Automation – 10 Minutes
LCA Projects in Amara Raja Batteries – 15 Minutes
Question & Answer Session – 5 Minutes
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Core PurposeCore Purpose
To transform our spheres of influence and to improve the quality Of life by building institutions that provide better access to better opportunities, goods and services to more people….all the time.
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Amara Raja
InnovationExcellence
EntrepreneurshipExperiences
Responsibility4
Vision 2025Vision 2025
Through the Amara Raja way, and through enduring progressive partnerships, we will be a global leader in batteries and battery technologies and dominant player Indian Ocean Rim
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Quality systems certifications• ISO-9001 in Feb 1997• QS 9000 in May 1999• TS 16949 in Jan 2004
• Re certifications – Jan 2007, Jan 2010 Environment management systems
• ISO 14001- certification in May 2002• Re certifications - May 2005, May 2008 & May 2011
Occupational Health & Safety Management system OHSAS 18001:2007 - Certified in Aug 2010
Six Sigma initiation in the year 2002 5 S Practices from the year 2004 Total Productive Maintenance initiation in the year 2007 Quality Control Circles initiated from 2007
The Journey….The Journey….
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The Amara Raja Group
Amara Raja Batteries Ltd
Amara Raja Power Systems Limited
Mangal Precision Products Limited
Amara Raja Electronics
Limited
Galla Foods Ltd
Amara Raja Infra Pvt Ltd
Amara Raja
Industrial Services Pvt Ltd
Industrial & Auto
Batteries Power Electronics
Fasteners & Battery Parts
PCBs/ Home Invertors
Fruit Processing
Karakambadi
Karakambadi
Karakambadi / Petamitta
Dighuvamagam
Putalpattu-Chittoor
Karakambadi Karakambadi
26% Galla Family 26% JCI
48 % Public
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Amara Raja Batteries Ltd.
Ownership: Public Limited Company Joint venture with JCI, USA Share holding of 26% each - JCI & Gallas
Size and scope of business: Total Land area : 195 acres Built up area : 50,000 sq mts Direct Employment. : 3000 + people Total investment --Mar08 : Rs. 3000mn ( USD 60 Mn) Sales 2005-06 : Rs. 4458 Mn (USD 100 Mn) Sales 2006-07 : Rs. 7451 Mn (USD 166 Mn) Sales 2007-08 : Rs. 13500 Mn (USD 300 Mn) Sales 2008-09 : Rs. 15840 Mn (USD 352 Mn)Sales 2009-10 : Rs. 16904 Mn (USD 382 Mn)Sales 2010-11 : Rs. 20765 Mn (USD 464 Mn)
Under the present regime of globalization and liberalization - Quality enhancement and Cost reduction are two major steps to enhance productivity when many factors (economic recession , slump in demand , risk , lack of funds with long gestation period) make heavy investment not possible.
One of the very practical, safe, economical and rewarding strategies is the application of Low Cost Automation.
INDIAN SENARIO
Introduction of simple machinery like pneumatic , hydraulic ,mechanical and electrical devices into existing production…
WHAT ?
WHY ?To Improve - Productivity ,Quality ,Safety ,Delivery , Ergonomics and reducing cost
High initial cost
Computerization is
required
Skilled labor is
required
Low Investment
Simple Machines can be used
Operation is possible with Semi-Skilled and unskilled labor
AutomationAutomation Low Cost automationLow Cost automation
ApplicationsApplications
• Loading
• Feeding
• Clamping
• Cutting
• Cleaning
• Insertion
• Crimpling
• Pneumatic
• Hydraulic
• Mechanical
• Electrical
LCA MethodsLCA Methods
Increases productivityHighly skilled labour is not requiredProduction time is reducedIncreases the quality of productsComputerization is not requiredCost of production is reducedBetter Utilization of materialLess rejectionsManufacturing Lead-time can be reduced
OLD METHOD:OLD METHOD:Operator has to collect fallen paste from floor and add into hopper in Pasting
CONSTRAINT:CONSTRAINT:
1 Manpower per shift 3 manpower per dayHigh operator fatigue leads to attrition5% Paste loss while manual loading
Developed U type inclined conveyor for loading paste into the hopper
PRESENT PRESENT METHOD :METHOD :
Conveyor system for Bottom paste addition
BEFORE
Benefit
Operator fatigue elimination3 Manpower savedPaste loss eliminationConsistant plate thickness
AFTER
Conveyor system for Bottom paste addition
Manual addition of bottom paste
OLD METHOD:OLD METHOD:Operator manually peel off the label and paste on the battery in batch flow of batteries at Finishing
CONSTRAINT:CONSTRAINT: 12 seconds per batteryLoss of adhesiveness due improper peel off Label damages while handling
Developed label dispenser for auto peel off labelPRESENT PRESENT METHOD :METHOD :
Label dispensing system
Improvement
LABEL DISPENSING SYSTEM
BEFORE AFTER
Benefit
Retention of adhesiveness Auto peel off sticker 9 seconds per label
OLD METHOD:OLD METHOD:Operator manually fixing the charge eye with mallet to the battery at assembly
CONSTRAINT:CONSTRAINT:Uneven orientation of Charge eye Improper fitment of charge eye
PRESENT PRESENT METHOD :METHOD :
CHARGE EYE FEEDING
Indicates the charging status of battery
Auto Charge eye fixing to the battery
1. Consistency in orientation2. Zero chance of improper fitting ( Automatic Operation )
CHARGE EYE FEEDING
BEFORE AFTER
Benefit
Consistency in orientation Zero chance of improper fitting ( Automatic Operation )
OLD METHOD:OLD METHOD: Battery type is hot punched on cover in Assembly
ONLINE ENGRAVING
PHASE :1PHASE :1Engraving battery type on cover by manually holding cover in offline
PHASE : 2PHASE : 2Engraving battery type on cover by clamping cover in offline
PHASE : 3PHASE : 3 Engraving battery type on cover by clamping cover in online
ENGRAVING AUTOMATION
BEFORE AFTER
Benefit
1. Holding the cover ,Movement of operator eliminated
2.No additional manpower is required add this activity to line operator
OLD METHOD:OLD METHOD: Shims are manually cutting using cutter in Plastics
CONSTRAINT:CONSTRAINT: Operator cut the shim 1 piece per cycle Unable to meet the requirement3 manpower per day is required
Automatic shim cutting will cut 4 pieces per cycle PRESENT PRESENT METHOD :METHOD :
SHIM CUTTING
SHIMCUTTING SETUP
BEFORE AFTER
Benefit
1 In single cutting we can produce 4 shims at a time.
2.Operator fatigue reduced. 3.Productivity raised by 134% 4.Manpower saved-3 No’s
OLD METHOD:OLD METHOD: Manual foam cutting using knife at Packing
CONSTRAINT:CONSTRAINT: 6 manpower per day Unable to meet the requirementOperator safety
Semiautomatic setup will cut the foamPRESENT PRESENT METHOD :METHOD :
FOAM CUTTING
FOAM CUTTING SETUP
BEFORE AFTER
Scale to measure length
Auto Cutting with hand valve
Easy to pull
Benefit
Minimize operator fatigue Optimum work content Good workplace management
OLD METHOD:OLD METHOD: Cables are scrapped due to lug damages in Formation process
CONSTRAINT:CONSTRAINT: 30000 cables are ready to scrap
Developed semi automatic set up for cut the lug of cable and crimple the new lug.
PRESENT PRESENT METHOD :METHOD :
RE USAGE OF CABLES
PURPOSE:PURPOSE: Cables are used to interconnect cells at charging process
Cable cost Rs 30
Lug cost Rs 1.25
Each cable has 2 lugs
BEFORE AFTER
CRIMPLING SETUP
Cable ready for reuse
Directly scrapping the cables in ABD,IBD & SBD formation after usage.
Lug(sleeve is open) damaged Cable after usage
Cable cutting
Benefit
Cable cost Rs 30 Lug cost Rs 1.25 Each cable has 2 lugs Cost saving by each cable Rs27.50, Savings/Annum Rs 825000
Cable crimpling
OLD METHOD:OLD METHOD: Hot number punching on Battery with Punching gun
Automatic setup for Number PunchingPRESENT PRESENT METHOD :METHOD :
NUMBER PUNCHING
PHASE 1:PHASE 1: Semi automatic setup for Number punching
CONSTRAINT:CONSTRAINT: 3manpower per dayUneven location of the punchOperator fatigue & punch visibility was not good ( Manual Operation)
BEFORE AFTER
AUTO HOTNUMBER PUNCH
1. Consistency in location of the punching 2. Visibility of the serial number is good ( Automatic operation ) 3. No operator fatigue 4.Work content reduced by 42%
Benefit
OLD METHOD:OLD METHOD: one manpower per shift is assigned to fix and release
bolts in post of the cell to check is it freely moving or
sulphation form in the cells at Finishing Sulphation is formed due to cell is not cleaned
after leak testing
Auto air pulsing is provided to eliminate sulphationPRESENT PRESENT METHOD :METHOD :
AUTO AIR PULSING
Water getting stayed on post threadsSulphation formed in threadsMore thread damagesManual cleaning of water in post threadsMore water spills on floor due to manual cleaning Additional man power to clean the post waterAir loss
CONSTRAINT:CONSTRAINT:
BEFORE AFTER
AUTO AIR PULSING
No sulphation observed(QA Approved).Elimination of thread damages due to sulphation.Elimination of manual cleaning of water droplets on posts.No additional man power required to clean water on posts.Elimination of repetitive thread inspection in finishing.
Benefit
OLD METHOD:OLD METHOD: Operator has to manually align the group in COS Operation in Assembly
Auto aligner will align the groups in COS OperationPRESENT PRESENT METHOD :METHOD :
AUTO ALIGNER
CONSTRAINT:CONSTRAINT: Manual alignment leads to operator Fatigue
BEFORE AFTER
AUTO ALIGNER
No operator fatigue
Benefit
OLD METHOD:OLD METHOD:
Manual lifting of around 60 kgs batteries is difficultHigh operator Fatigue2000 times bend and raise for 1000 batteriesDifficult to handle on conveyor2 manpower/shift totally 6 manpower day is required
PRESENT PRESENT METHOD :METHOD :
CARTON INSERTION
CONSTRAINT:CONSTRAINT:
Manual inserting the batteries in carton box in Finishing
Semi automatic setup for carton insertion .
BEFORE AFTER
No bend and raise Fatigue Reduction Easy to operate 3 Manpower per day is enough
Benefit
CARTON INSERTION
OLD METHOD:OLD METHOD:
Spillage/Wastage of oil
PRESENT PRESENT METHOD :METHOD :
NP OIL FILLING
CONSTRAINT:CONSTRAINT:
Manually filling of NP Oil on vent cap for lubrication purpose in Formation process
NP Oil filling on vent cap through saline bottle
BEFORE AFTER
NP OIL FILLING
No Spillage of NP Oil
Benefit
Saline bottle
OLD METHOD:OLD METHOD:
Difficult to insert
Operator fatigue
PRESENT PRESENT METHOD :METHOD :
GROUP INSERTION
CONSTRAINT:CONSTRAINT:
Groups inserted in to the container manually at Assembly
Pneumatic setup developed to insert the groups in container
BEFORE AFTER
GROUP INSERTION
Easy to insert Operator fatigue reductionBenefit
Open to
Questions, Suggestions, ……
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Thanks for the Opportunity….
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