Navyug Engineering
Client Overview
Plant Address :- MIDC,Ahemadnagar.
Sector :- Induction Motor Mfg.
Products :- Motor stator Manufacture
Machine :- 3 Axis Milling SPM.
Before
After
Challenges
1. Problem
- The machines have been in operation for over 15 years, resulting in significant wear and tear.
- Geometrical accuracies are compromised, leading to frequent errors in production.
- High job rejection rates due to quality issues.
- Machine breakdown frequency has increased .
- Electrical control Panel outdated, making repairs difficult due to limited support availability.
- Slide are driven by Induction motor and Clutch.
- Spindle Noise at high rpm.
2. Significance
- Addressing these challenges is critical to ensuring consistent production quality, operational efficiency, and customer satisfaction.
3. Impact
- Reduced production capacity.
- Quality control issues, resulting in frequent product rejections.
- Heavy reliance on skilled operators; machine downtime increases when operators are unavailable.
- Prolonged machine breakdowns affecting delivery schedules.
- Clients are hesitant to provide additional machining assignments due to reliability concerns.
- High rejection rates contribute to significant losses in profitability.
Vendor Selection Criteria
1. Expertise in Retrofitting Complex Machines: Proven experience in handling retrofitting projects of similar complexity.
2. Industry Experience: A minimum of 20 years of experience in the same field.
3. Client Feedback: Positive reviews and recommendations from existing clients.
4. Multidisciplinary Expertise: Adequate experience in operations, electronics, and mechanical systems, specifically for reconditioning and retrofitting complex machinery.
5. Infrastructure: Adequate facilities and resources to handle the scope of work effectively.
6. Cost-Effectiveness: Competitive and economical solutions without compromising quality.
7. Service Support: Reliable after-sales support and service capabilities.
8. Quality of Workmanship: Demonstrated ability to deliver high-quality work.
9. Ethical Business Practices: Transparency and fairness in all business dealings.
10. Commitment to Timely Delivery: A strong track record of meeting deadlines and maintaining project timelines.
Approach to Work
1. Receiving and Initial Assessment:
Upon receiving the machine at our facility, we begin by dismantling all its components, including slides, ball screws, ATC, turret, spindle, guards, and other critical parts.
2. Thorough Cleaning:
All dismantled parts undergo a comprehensive cleaning process to ensure they are free from debris and contaminants.
3. Inspection and Status Reporting:
Following the cleaning, our expert team conducts a detailed inspection of the machine components, jointly with the client’s representative. A detailed report is then prepared, outlining the current condition of each part.
4. Recommendations and Client Approval:
The inspection report, along with our professional recommendations, is shared with the client for review.
5. Work Commencement:
Upon receiving client approval, we proceed with the necessary reconditioning, retrofitting, or repairs as outlined in the approved report.
Our Solutions to Address the Problem
1. Restoration of Geometrical Accuracies: Perform slide grinding Guideways to restore alignment and accuracy.
2. Replacement of Key Components: Modified slide with Servo system Ball screws and bearings with high-quality units.
3. Spindle Overhaul: Installed new bearings for the spindle to enhance performance.
4. System Servicing: Conducted comprehensive servicing of the hydraulic power pack, and coolant system.
5. PLC and Servo Drives Retrofitting: Retrofitted the machine with the latest Fuji Make PLC and Servo Drives system, including new drives and motors.
6. Electrical Overhaul: Completed rewiring of the machine and control panel with modern, reliable wiring
7. Machine Repainting: Repainted the machine using durable PU paint for a refreshed appearance and protection.
8. Geometrical Accuracy Verification: Verified all geometrical accuracies against the machine tool builder’s standards.
9. Successful Job Trials: Conducted and validated job trials to ensure optimal machine performance.
10. On-Site Commissioning: Installed and commissioned the machine at the client’s facility.
11. Handover of Documentation: Provided the client with spare parts and both hard and soft copies of electrical documentation.
End Results
1. Restored Accuracy: The machine achieved precision comparable to that of a new machine.
2. Enhanced Productivity: Productivity levels doubled, significantly improving operational efficiency.
3. Reduced Rejection Rates: Job rejection issues were minimized to nearly zero.
4. Customer Satisfaction: The client expressed high levels of satisfaction with the results.
5. Business Growth: Increased productivity contributed to higher profitability for the company.
