Achieving Excellence Through Retrofitting: Collaboration with Abhijat Equipment Pvt. Ltd.
Introduction
In a world where manufacturing excellence is key to staying competitive, Abhijat Equipment Pvt. Ltd. turned to Tulja Hi-Tech Automations Pvt. Ltd. to restore their aging Mitsubishi HMC to peak operational efficiency. The collaboration resulted in remarkable transformations, addressing issues of downtime, quality, and productivity while demonstrating Tulja Hi-Tech’s expertise in machine reconditioning and retrofitting.
Client Overview
Name: Abhijat Equipment Pvt. Ltd.
Location: Satara, India
Sector: Machine Manufacturing
Product: High-performance machinery
Machine: Mitsubishi HMC with ATC and APC, operational for over three decades
Before
After
Challenges
1. Operational Breakdown
- Frequent machine breakdowns with a failure rate of 20%.
- Non-functional automatic systems, including ATC and APC.
- Spindle noise at high RPMs, disrupting production schedules.
2. Quality Compromise
- Geometrical inaccuracies causing frequent errors and high rejection rates.
- Inconsistent output affecting client trust and profitability.
3. Impact
- Production: Reduced capacity and delivery delays.
- Profitability: Increased rejection rates and dependency on skilled operators led to financial strain.
- Customer Trust: Hesitancy from clients to assign critical tasks due to reliability concerns.
Vendor Selection Criteria
Abhijat Equipment sought a partner with:
- Over two decades of retrofitting expertise.
- Proven track record and client testimonials.
- Cost-effective yet high-quality solutions.
- Comprehensive technical know-how.
- Timely execution and excellent service support.
Tulja Hi-Tech met all these requirements, becoming the obvious choice for this critical project.
Solutions Delivered by Tulja Hi-Tech
Phase 1: Assessment and Planning
- Comprehensive Inspection: The machine was dismantled and thoroughly inspected,
documenting all worn-out components and potential areas for improvement. - Client Collaboration: A detailed report was shared, and approvals were secured for
the proposed upgrades.
Phase 2: Execution
- Mechanical Restoration:
1. Replaced X, Y, and Z axis LM guideways, ball screws, and bearings.
2. Overhauled the spindle with new bearings to ensure high-speed accuracy. - 2 System Upgrades:
1. Installed the latest Fanuc CNC system with updated drives and motors.
2. Rewired the control panel and machine with modern components. - Servicing and Calibration:
1. Restored APC, ATC, hydraulic power pack, and coolant systems to optimal functionality.
2. Verified geometrical accuracies to meet OEM standards. - Visual and Structural Enhancements:
1. Repainted the machine with durable PU paint for a refreshed look and corrosion resistance.
Phase 3: Testing and Delivery
- Conducted successful job trials to validate performance under real-world conditions.
- Installed and commissioned the machine at the client’s facility.
- Provided exhaustive documentation, including electrical diagrams, system backups, and spare part details, ensuring operational independence.
Results
- Quantifiable Achievements
1. Restored Precision: Machine accuracy rivalled that of a new unit.
2. Enhanced Productivity: Output doubled, reducing lead times by 50%.
3. Cost Savings: The retrofitting project was completed at 25% of the cost of a new machine.
4. Reduced Rejections: Job rejection rates dropped from 15% to under 1%. - Client Impact
1. Operational Independence: Comprehensive training and documentation empowered the client’s team to manage routine maintenance.
2. Profitability Boost: Higher productivity and reduced downtime led to increased profitability.
3. Client Satisfaction: The client acknowledged the transformation as a game-changer for their operations.
Why Tulja Hi-Tech Stands Out
- Specialized Expertise: Over 21 years of experience in retrofitting and automation projects.
- Comprehensive Services: From conceptualization to commissioning, Tulja Hi-Tech offers end-to-end solutions.
- Client-Centric Approach: Focused on delivering value through cost-effective and sustainable solutions.
Client Testimonial
“The transformation of our aging Mitsubishi HMC was beyond our expectations. Tulja Hi- Tech not only restored the machine but enhanced its capabilities, making it an integral part of our production line.”
— Operations Manager, Abhijat Equipment Pvt. Ltd.
Conclusion
The collaboration between Tulja Hi-Tech Automations and Abhijat Equipment Pvt. Ltd. demonstrates the transformative potential of machine retrofitting. By addressing key operational, quality, and productivity challenges, Tulja Hi-Tech delivered a solution that underscores their commitment to quality, innovation, and customer satisfaction.
Call To Action
Ready to optimize your operations? Discover how Tulja Hi-Tech can transform your
manufacturing processes. Contact us at 9822627554 for a consultation. Also visit our
website www.tuljahitech.com
