Achal Industries’ Transformation with Tulja Hi-Tech Solutions
Executive Summary
Achal Industries, a prominent gear manufacturer catering to the automotive sector with a production capacity of thousands of units per month, faced significant challenges with their traditional gear-cutting machines. These manual machines were heavily reliant on skilled operators, prone to breakdowns, and caused quality inconsistencies and production delays. To address these issues, Tulja Hi-Tech Automations Pvt. Ltd. proposed a cost-effective solution involving retrofitting a used CIMA 6-axis gear hobbing machine with advanced Siemens CNC technology. The result was a remarkable improvement in productivity, quality, and operational efficiency, enabling Achal Industries to achieve higher profitability and client satisfaction.
Background Information
Client Name: Achal Industries
Industry Sector: Automotive Component Manufacturing
Products: Gears
Location: MIDC, Bhosari
Before
After
Challenges Faced:
- Heavy reliance on skilled operators.
- Manual operations leading to delays and inefficiencies.
- High rejection rates and inconsistent quality.
- Frequent breakdowns causing significant downtime.
- Reduced client confidence and hesitation to assign more work.
- Financial impact due to low production and profitability.
Challenges Faced by the Client
Operational Issues:
- Manual settings required extended setup times, averaging 90 minutes per setup before the retrofit, compared to just 20 minutes post-retrofit.
- Machines were prone to major breakdowns, halting production.
Quality Issues:
- Inconsistencies in the finished product due to manual operations.
- High rejection rates, leading to resource wastage.
Production Issues:
- Low production output, affecting client delivery timelines.
- Dependence on skilled operators meant production was at risk if operators were unavailable.
Financial Impact:
- Reduced profitability due to inefficiencies.
- Client hesitation to assign more components for machining.
Evaluation Criteria for Solution Provider
Achal Industries sought a partner with:
- Extensive experience in retrofitting complex machines.
- Proven expertise with over 20 years in the field.
- Positive feedback from existing clients.
- A thorough understanding of operations, electronics, and mechanical systems.
- Cost-effective solutions that offered value for money.
- Strong service support and quality workmanship.
- Commitment to timely delivery and fair business practices.
Proposed Solution
Overview of the Approach
Tulja Hi-Tech proposed retrofitting as a cost-effective alternative to purchasing new machines. The approach focused on leveraging advanced CNC technology to deskill operations and enhance productivity.
Steps Taken
1. Recommendation for Used Machine:
- Suggested purchasing a high-quality used machine instead of a new one to save costs.
2. Machine Selection:
- Identified and inspected several options from various vendors.
- Finalized a CIMA 6-axis gear hobbing machine from a Delhi-based vendor.
3. Reconditioning and Retrofitting:
- Brought the machine to Tulja Hi-Tech’s factory for comprehensive mechanical work.
- Retrofitted the machine with a Siemens 6-axis CNC Package (828D).
4. Documentation and Training:
- Provided a detailed user manual and system documentation, including:
- System backups in both hardware and software formats, ensuring data security and system recovery options.
- Maintenance-related documents to support ongoing operations, enabling the client’s production and maintenance teams to gain a deeper understanding of the machine.
- This documentation empowers the client by reducing dependency on external vendors for routine maintenance and troubleshooting, while also allowing for informed decision-making when selecting future vendors if required.
- Documentation designed to empower the client’s production and maintenance teams to operate and maintain the machine independently.
5. Validation:
- Conducted successful job trials to ensure machine performance met client requirements.
Results and Outcomes
Cost Savings:
- The used machine was procured and retrofitted at 30% of the cost of a new machine.
Productivity Gains:
- Production output doubled, reducing average delivery timelines from 10 days to 5 days, significantly enhancing client satisfaction.
Quality Improvements:
- Rejection rates reduced to below 0.5%, ensuring consistent quality and nearly eliminating resource wastage.
Operational Benefits:
- Reduced dependency on skilled operators.
- Comprehensive documentation enabled independent maintenance and operations.
Financial Impact:
Higher profitability and enhanced client confidence.
Visual Documentation
Conclusion
Tulja Hi-Tech’s innovative approach to retrofitting provided Achal Industries with a cost-effective and efficient solution to their operational challenges. By replacing traditional manual processes with advanced CNC technology, the client achieved significant improvements in productivity, quality, and profitability. Additionally, the detailed documentation and training empowered the production and maintenance teams, ensuring long-term operational independence and success.
Call To Action
This case highlights the importance of retrofitting as a viable solution for small and medium enterprises looking to optimize their operations without incurring high costs.
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📩 Email: arunumane@tuljahitech.com
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