COMPANY INFORMATION Established : 1991 No. of employees : 300+ - - PowerPoint PPT Presentation

COMPANY INFORMATION

Established : 1991

• No. of employees : 300+

Certification : ISO/TS 16949 Turnover : 255 Cr Total number of Machines: 200+ Number of Cells: 25

Our Customers

Top management drive

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In 2016, Top management drive to implement TPM- Trak OEE monitoring solution, now being called as Industry 4.0 and digitization initiatives in our newly built state of the art factory at Pune to improve the efficiency of equipments

1st Month of Installation -22 Machines

For the Time period 1st-Jan-2016 to 31st –Jan-2016 For the Time period 1st-Mar-2016 to 31st –Mar-2016

Top 5 Reasons identified

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Break down: it is observed that most of the break downs occurred due to poor autonomous maintenance, improper training to operators

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New settings: Setting time was taking more due to improper planning

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Tool/Wheel change: Tool and wheel changing was taking more time

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No operator: working on other machines/absent

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Machining Time increase: causing less productivity

Countermeasures

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Break down: Developed strong autonomous maintenance schedules and trained operators and maintenance departments and keeping critical spare part in stock

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New settings: Setting time is reduced with SMED

• concept. Reduced by

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Tool/Wheel change: Provided proper training to

• perators, implementing tool life monitoring

methods and proper planning of tools

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No operator: By making them understanding the importance of delivery schedules and by developing customer centric culture

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Machining Time increase: identified and avoided minor stoppages occurring in between cycles, by locking original part program and speed, feeds and by educating the operators

Data Analysis

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Rij Engineering deployed TPM-Trak OEE monitoring on 21 machines – Phase 1

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Rij Engineering decided to work on improving efficiency of the equipments Machine hour rate

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For CNC INR 255

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For Shaping Machines INR 1,000

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For Leibherr Gear cutting machines INR 3,000 Observations from 1st month out come

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Identified top 10 low performing machines – 3,291 hr

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Which means 137 days

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Down time loss – INR 29,08,528 After optimizing the down time over Three months period

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Down time reduced to 1,784 hrs (74 days)

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Down time loss – INR 15,97,601

Losses avoided : INR 13,10,927

Asset utilization increase over Three Months Period on 10 machines

Machines Increase Asset Utilization (in Hrs) Increase Asset Utilization (in INR) CNC Machines 1039 2,64,957 CNC Shaping Machines 182 1,82,930 Leibherr Gear Cutting Machines 287 8,63,040 Total Hours saved & Profit

1508 13,10,927

1st Year increased profit on 22 machines – INR 158 Lakh ROI > 200%

Thank You