Enhancing Productivity and Precision at Mahle Anand Filter System Pvt. Ltd.
Client Overview
Client Name: Mahle Anand Filter System Pvt. Ltd.
Plant Address: MIDC, Pirangut, Pune
Sector: Automobile
Product: Glue Dispensing Special Purpose Machine (SPM)
Machine: CNC SPM
Challenges Encountered
a) Problem
Mahle Anand Filter System Pvt. Ltd. faced several critical issues with their glue dispensing CNC SPM, which impacted operational efficiency and production quality:
Manual Adjustments
Glue dispensing gun settings were manually adjusted, leading to inconsistencies in application and production.
- Skilled Personnel Dependency: Operations required skilled operators, increasing the potential for human errors.
- Excessive Setup Time: High setup times caused production delays and inefficiencies.
- High Rejection Rates: Poor quality control led to frequent product rejections, affecting profitability.
- Outdated Electrical Controllers: Legacy controllers were difficult to maintain, with limited support and spare parts availability.
- Disturbance in Glue Gun Positioning: Manual adjustments often led to positional disturbances, reducing precision and overall quality.
b) Significance
Resolving these issues was vital to:
- Achieve consistent production quality.
- Enhance operational efficiency and reduce dependency on skilled labor.
- Minimize downtime, setup times, and rejection rates.
- Meet production schedules and customer expectations.
c) Impact
The above challenges resulted in:
- Reduced production capacity, limiting the client’s ability to scale.
- Quality control issues, leading to increased rejections and reduced profitability.
- Heavy reliance on skilled operators, creating a bottleneck when operators were unavailable.
- Delayed production schedules due to long setup times.
- Significant financial losses due to rejected products and inefficient processes.
Vendor Selection Criteria
Mahle Anand Filter System evaluated potential vendors based on the following critical factors to ensure a robust and reliable solution:
- Expertise in retrofitting complex machines: Proven track record of successfully handling similar complex projects.
- Industry experience: Over 20 years of experience in machine reconditioning and retrofitting.
- Positive client feedback: Recommendations and positive reviews from existing clients.
- Multidisciplinary expertise: Skilled in mechanical, electrical, and automation systems for reconditioning complex machinery.
- Infrastructure capability: Adequate resources and facilities to handle the scope of the project effectively.
- Cost-effectiveness: Solutions that balance affordability with high-quality results.
- Reliable service support: Strong after-sales support and service capabilities.
- Quality of workmanship: Consistent delivery of high-quality work.
- Ethical business practices: Transparency, fairness, and integrity in dealings.
- Timely delivery: Proven ability to meet project deadlines and maintain schedules.
Approach to Work
To address the client’s challenges, a systematic approach was followed:
- Problem Observation and Analysis: The existing machine was thoroughly studied to identify root causes of the issues and determine suitable solutions.
- System Design and Proposal: A customized solution was developed, including the design of a new system tailored to meet the client’s specific needs.
- Detailed Client Presentation: A comprehensive presentation was delivered, explaining the proposed solution, its benefits, and how it would address the identified challenges.
- Recommendations and Client Approval: A detailed report with professional recommendations was submitted for the client’s review and approval.
- Execution of Work: Upon approval, modifications and retrofitting were carried out in line with the approved plan.
Our Solutions to Address the Problem
Design of a New System
- Developed a new mechanical system incorporating dual slides and a ball screw mechanism for automated glue gun positioning.
- Integrated a custom SIEMENS 828D CNC controller program for precise and repeatable operations.
Replacement of Key Components
- Upgraded the slides with servo-driven systems for enhanced precision and reliability.
- Installed high-quality ball screws and bearings to improve system durability and accuracy.
Electrical Panel Redesign with CNC Integration
- Redesigned the electrical panel with a modern CNC system for enhanced control and functionality.
- Comprehensive rewiring improved the system’s dependability and ease of maintenance.
Job Trials and Validation
- Conducted rigorous job trials to validate the machine’s performance, ensuring it met operational requirements under real-world conditions.
On-Site Commissioning
- Successfully installed and commissioned the upgraded machine at the client’s facility.
- Ensured seamless integration into the production workflow.
Documentation and Handover
Delivered spare parts and complete documentation, including electrical schematics, operational guidelines, and maintenance instructions in both hard and soft copies.
End Results
- Restored Accuracy: The retrofitted machine achieved precision levels comparable to a new machine.
- Enhanced Productivity: Productivity doubled, significantly increasing operational efficiency.
- Reduced Rejection Rates: Glue dispensing issues were resolved, reducing rejection rates to nearly zero.
- Customer Satisfaction: The client expressed high levels of satisfaction with the machine’s improved performance.
- Business Growth: The increase in productivity and quality contributed to higher profitability and business growth for the company.
- Deskilled Job Setting: Automation reduced dependency on skilled operators, making the system easier to operate and manage.
Conclusion
This project demonstrates how precise engineering and innovative retrofitting solutions can overcome complex production challenges. By leveraging expertise in automation, mechanical systems, and CNC integration, Mahle Anand Filter System Pvt. Ltd. achieved:
- Enhanced production capacity.
- Improved product quality and consistency.
- Significant cost savings and operational efficiency.
Through a tailored approach and commitment to excellence, we successfully
addressed the client’s challenges and delivered a solution that exceeded their
expectations.
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