Facing & Centring SPM – Ghatge Patil Industries Ltd.
1. Executive Summary
Ghatge Patil Industries Ltd., a leading player in the automobile industry, faced operational challenges with its manual Facing & Centring Special Purpose Machine (SPM) used for facing and centring operations. The company struggled with manual adjustments, reliance on skilled labor, inefficiencies, and outdated technology, leading to inconsistent production quality and high rejection rates.
Through a tailored approach, the problems were resolved with innovative solutions, including mechanical system upgrades, modern electrical integration, and thorough documentation. The results were transformative—delivering enhanced precision, higher productivity, reduced rejections, and significant cost savings. This case study outlines the journey and highlights the role of effective retrofitting in ensuring sustainable manufacturing excellence.
2. Introduction
Client Name: Ghatge Patil Industries Ltd.
Sector: Automobile Parts Manufacturing
Plant Address: MIDC, Kolhapur
Products: Shafts and Crankshafts
Machine Type: Facing and Centring SPM (Make: HMT)
Ghatge Patil Industries Ltd. specializes in manufacturing automobile components using advanced machinery. However, one of their critical machines—responsible for facing and centring—encountered performance and operational challenges that affected production efficiency and output quality. This case study documents how these issues were addressed and the outcomes achieved.
3. Challenges
a) Problems Identified
- Manual Adjustments: The component settings were adjusted manually, resulting in inconsistencies in production quality.
- Dependence on Skilled Labor: The operation required experienced operators, making the system vulnerable to errors and production downtime in their absence.
- Excessive Setup Times: The machine required frequent, time-consuming setup processes, reducing overall efficiency.
- High Rejection Rates: Inconsistent centring led to defective products and increased rejections, impacting profitability.
- Outdated Technology: The machine relied on old electrical controllers, making maintenance and repair difficult due to limited availability of support.
- Frequent Positioning Errors: Manual adjustments caused misalignment of the components, further degrading precision and quality.
b) Significance of the Challenges
These issues affected Ghatge Patil Industries Ltd.’s ability to maintain consistent production quality, meet customer expectations, and ensure operational efficiency.
c) Impact of Challenges
- Production capacity was reduced due to inefficiencies and downtimes.
- Frequent product rejections led to financial losses and lowered profitability.
- The company became highly dependent on skilled labor, increasing risks during operator unavailability.
- Setup times delayed production schedules, causing missed deadlines and reduced throughput.
4. Vendor Selection Criteria
To resolve the challenges, Ghatge Patil Industries Ltd. sought a vendor with specific expertise. The selection criteria included:
- Proven expertise in retrofitting and modernizing complex machinery.
- At last 20 years of experience in the relevant industry.
- Positive client feedback and references.
- Multidisciplinary skills in electronics, mechanics, and control systems.
- Adequate infrastructure to manage the project scope.
- Cost-effective solutions without compromising on quality.
- Reliable after-sales support.
- High-quality workmanship and adherence to ethical business practices.
- Strong commitment to timely project delivery.
Before: Photos highlighting manual adjustments and outdated systems.
After: Visuals of the redesigned system, upgraded components, and improved production workflows
While Assembly of Parts.
5. Approach to the Project
Step 1: Problem Observation and Analysis: A thorough analysis of the machine was conducted to identify root causes. This included studying the manual adjustment mechanisms and the machine’s electrical architecture.
Step 2: System Design and Proposal: A customized solution was developed, addressing mechanical and electrical challenges. The proposed design incorporated automation and precision-enhancing technologies.
Step 3: Client Presentation: The proposed solutions were presented to the client through a detailed presentation, explaining how the challenges would be addressed.
Step 4: Recommendations and Approval: A detailed report with professional recommendations was submitted for client review. Upon approval, the implementation phase began.
Step 5: Execution of Work: The team implemented the proposed upgrades systematically, minimizing disruptions to the client’s operations.
6. Solutions Implemented
Mechanical System Redesign
- A new dual-slide system with a lead screw mechanism was installed to automate positioning.
- Slides were ground on a precision grinding machine.
Component Upgrades
- High-quality lead screws and bearings replaced outdated components, ensuring smoother operations.
- Motors were serviced, and their bearings were replaced.
Electrical Panel Overhaul
- A modern electrical panel with an advanced Siemens PLC controller was designed and implemented.
- Comprehensive rewiring improved system functionality and reduced maintenance complexity.
Job Trials and Validation
- Rigorous trials were conducted under real-world conditions to validate the upgraded system’s performance and reliability.
On-Site Commissioning
- The upgraded machine was seamlessly integrated into the production workflow, ensuring minimal downtime during commissioning.
Comprehensive Documentation and Handover
- A detailed user manual was provided, along with system backups in both hardware and software formats.
- Maintenance guidelines and operational insights were shared to empower the client’s team.
- This documentation ensures the client’s independence in selecting vendors for future maintenance activities and enhances understanding of the machine’s functions.
7. Results Achieved
- Restored Precision: The machine achieved accuracy levels comparable to new equipment, ensuring consistent production quality.
- Enhanced Productivity: Productivity doubled due to automation and reduced setup times, boosting operational efficiency.
- Reduced Rejection Rates: Rejection rates dropped to nearly zero, leading to significant cost savings and improved profitability.
- Increased Customer Satisfaction: The client was highly satisfied with the results, expressing confidence in the upgraded system.
- Business Growth: Enhanced efficiency and quality contributed to increased production output and profitability.
- Simplified Operations: Job settings were deskilled, reducing the reliance on skilled operators and streamlining workflows.
8. Lessons Learned and Future Scope
Key Takeaways: This project demonstrated the importance of systematic analysis, tailored designs, and robust documentation in addressing complex industrial challenges. Retrofitting proved to be a cost-effective alternative to replacing equipment, offering long-term value.
Future Scope: Regular upgrades and proactive maintenance can sustain machine performance. Additionally, implementing IoT-enabled monitoring systems could further optimize operational efficiency.
9. Conclusion
The project at Ghatge Patil Industries Ltd. highlights the transformative potential of retrofitting and automation. By addressing the challenges with precision and a customer-centric approach, the company achieved significant operational improvements. This case study underscores the importance of modernizing legacy systems to remain competitive in the dynamic manufacturing landscape.
The successful collaboration demonstrates how innovative solutions can drive efficiency, reduce costs, and enhance customer satisfaction. With proper maintenance and periodic upgrades, the client is well-positioned for sustained growth and excellence.
