Mahle Anand Filter System Pvt. Ltd. Redesign Solution for Rotary Oven to Boost Productivity
Executive Summary
Mahle Anand Filter System Pvt. Ltd., a key player in the automobile industry, was facing a serious production bottleneck. Although they had invested in an imported Rotary Oven from South Korea to modernize their process, it became evident that this single machine could not meet growing customer demands. The cost of importing another unit was approximately ₹65 lakhs with a 12-month lead time—unacceptable given the urgency of the situation.
To solve this critical problem, Tulja Hi-Tech Automations Pvt. Ltd. proposed a complete redesign and indigenous development of a Rotary Oven system. The approach included detailed study of the existing oven, precision 3D/2D system design, in-house manufacturing, PLC-integrated electrical panels, and on-site commissioning—all within significantly shorter timelines and at half the cost of the imported model.
The outcome was transformative:
- Daily output doubled from 4,000 to 8,000 pieces
- Lead time and cost were cut dramatically
- Operational efficiency and customer satisfaction improved
- The client gained the capacity to scale and fulfill rising demand effectively
Client Overview
Client Name: Mahle Anand Filter System Pvt. Ltd.
Location: MIDC, Pirangut, Pune
Industry: Automobile Manufacturing
Product Focus: Rotary Oven Special Purpose Machine (SPM)
Machine Involved: Rotary Oven
Challenges Encountered
a) Problem
Mahle Anand Filter System faced a major challenge in scaling production. Their imported Rotary Oven could not support increasing demand, and options to purchase another came with two major roadblocks:
- High Cost: ₹65 lakhs per unit, unaffordable for scale-up
- Long Lead Time: Estimated delivery of 12 months
- This created a serious limitation in capacity and risked missed customer commitments.
b) Significance
- Addressing this issue was critical for the client to:
- Increase Production Capacity to handle rising demand
- Improve Operational Efficiency and reduce bottlenecks
- Ensure Timely Deliveries and maintain service-level agreements
- Stay Competitive by scaling output while controlling cost
c) Impact
- Daily production capped at 4,000 pieces
- Inability to meet demand caused delays and bottlenecks
- Risk of losing customers to more agile competitors
Vendor Selection Criteria
Mahle Anand Filter System evaluated potential vendors based on the following criteria to ensure the best possible solution:
1. Expertise in Manufacturing Complex Machines: Proven ability to handle complex Machine projects in a similar domain.
2. Industry Experience: A minimum of 20 years in the machine Manufacturing and reconditioning industry.
3. Client Feedback: Positive reviews and successful track records with previous clients.
4. Multidisciplinary Expertise: Experience in mechanical, electrical, and automation systems for reconditioning complex machinery.
5. Infrastructure Capability: Adequate resources and facilities to manage the scope of the project.
6. Cost-Effectiveness: Ability to provide cost-efficient solutions without compromising on quality or performance.
7. Service and Support: Comprehensive after-sales support and technical assistance.
8. Quality of Workmanship: Demonstrated ability to deliver high-quality work that meets stringent industrial standards.
9. Ethical Business Practices: Commitment to transparency and fairness in business dealings.
10. Timely Delivery: A strong history of meeting project deadlines and adhering to timelines.
Approach to Work
1. Study of Existing Machine
- In-depth analysis of the imported Rotary Oven
- Identification of design limitations and performance gaps
2.System Design and Proposal
- Custom solution design aligned with client goals
- 3D models and 2D manufacturing drawings prepared for every component
3.Client Presentation
- Detailed walkthrough of design and functionality
- Clear articulation of advantages, timelines, and cost-benefits
4. Recommendations and Approval
- Shared final drawings and improvement areas
- Received formal client approval to proceed
5.Execution of Work
- Manufacturing began with quality assurance at every stage
- Components fabricated with strict tolerance adherence
- Weekly project updates shared with the client
Our Solutions to Address the Problem
Designed and developed a new Rotary Oven system
- 3D/2D precision drawings ensured manufacturing accuracy
- Focus on boosting capacity and minimizing breakdowns
Efficient Manufacturing of All Parts
- Short lead time with strict inspection protocols
- Fabrication aligned to industrial quality standards
Dedicated Project Monitoring
- Taskforce deployed to oversee each stage
- Ensured timeline and quality compliance
Modern PLC-Integrated Electrical Panel
- Fully rewired control system for safety and easy operation
- Siemens PLC optimized oven performance
Job Trials and Real-World Validation
- Full-scale operational tests conducted at factory
- Performance benchmarked under production load
On-Site Commissioning
- Seamless integration into existing operations
- Zero disruption to ongoing production during setup
Comprehensive Documentation and Handover
- Electrical schematics, operating manuals, and spare parts list provided
- Digital and hard copies ensured long-term support readiness
Our Solutions to Address the Problem
Designed and developed a new Rotary Oven system
- 3D/2D precision drawings ensured manufacturing accuracy
- Focus on boosting capacity and minimizing breakdowns
Efficient Manufacturing of All Parts
- Short lead time with strict inspection protocols
- Fabrication aligned to industrial quality standards
Dedicated Project Monitoring
- Taskforce deployed to oversee each stage
- Ensured timeline and quality compliance
Modern PLC-Integrated Electrical Panel
- Fully rewired control system for safety and easy operation
- Siemens PLC optimized oven performance
Job Trials and Real-World Validation
- Full-scale operational tests conducted at factory
- Performance benchmarked under production load
On-Site Commissioning
- Seamless integration into existing operations
- Zero disruption to ongoing production during setup
Comprehensive Documentation and Handover
- Electrical schematics, operating manuals, and spare parts list provided
- Digital and hard copies ensured long-term support readiness
End Results
1.Significant Productivity Increase
- Production doubled from 4,000 to 8,000 pieces per day
- Bottlenecks were eliminated
2.Enhanced Operational Efficiency
- Reduced downtime
- Improved machine reliability and process flow
3.Substantial Cost Savings
- Indigenous solution delivered at 50% of import cost
- Massive reduction in capital expenditure
4.High Customer Satisfaction
- Client reported strong confidence in system performance
- Solution exceeded their expectations
4.Business Growth and Profitability
- Increased throughput enabled timely deliveries
- Client positioned to handle future growth and demand
Conclusion
The collaboration between Mahle Anand Filter System Pvt. Ltd. and Tulja Hi-Tech Automations Pvt. Ltd. is a testament to the power of indigenous engineering in solving high-impact industrial challenges. Faced with limited production capacity and costly import options, the client found a tailored, efficient, and scalable solution through complete redesign and in-house development of a Rotary Oven system.
The successful implementation not only doubled daily output but also eliminated operational bottlenecks, improved machine reliability, and delivered substantial cost savings. By blending mechanical precision with PLC automation and project discipline, Tulja Hi-Tech delivered a solution that exceeded expectations—enabling the client to grow efficiently and meet market demands confidently.
Call To Action
Is your production line held back by imported machinery or outdated equipment?
Tulja Hi-Tech Automations Pvt. Ltd. specializes in cost-effective machine design, reengineering, and automation that delivers enterprise-level results without the import price tag.
📞 Call us at: +91 9822627554
📩 Email: arunumane@tuljahitech.co
🌐 Visit: www.tuljahitech.com
Let’s design a smarter, faster, and more profitable solution—built right here in India.
Disclaimer
This case study is intended solely for informational and illustrative purposes. The results and outcomes described are specific to Mahle Anand Filter System Pvt. Ltd. and may vary based on equipment condition, process requirements, and operational context. All technical solutions are custom-developed and subject to detailed assessment. Tulja Hi-Tech Automations Pvt. Ltd. makes no representation that similar results can be guaranteed without a proper evaluation and proposal.
