Revitalizing AMS VMC 400 for Concentric Pumps India Pvt. Ltd.
Executive Summary
Concentric Pumps India Pvt Ltd., a leading manufacturer of Pumps, faced significant operational challenges due to the aging AMS VMC 400 Vertical Machining Centre. With over 20 years of service, the machine’s performance had deteriorated, leading to decreased productivity, increased rejection rates, and frequent breakdowns. Tulja Hi-Tech provided an innovative, cost-effective reconditioning solution, restoring the machine’s accuracy, efficiency, and reliability. This case study highlights the approach, solutions, and results achieved, demonstrating Tulja Hi-Tech’s expertise in complex machine reconditioning.
Client Overview
Client Name: Concentric Pumps India Pvt. Ltd.
Location: Nagar Road, Pune.
Industry Sector: Pump.
Products: Pump manufacturing.
Machine: AMS VMC 400 Vertical Machining Centre.
Before
After
Challenges Faced
1. Key Problems
- The AMS VMC 400 had been operational for over 20 years, leading to significant wear and tear.
- Geometrical accuracies had deteriorated, compromising production quality.
- Frequent errors during Automatic Tool Changer (ATC) operations caused tool drops and accidents.
- High rejection rates and frequent machine breakdowns disrupted operations.
- The machine’s performance efficiency had decreased to 50%, affecting profitability.
2. Significance of Addressing the Challenges
- Ensuring consistent production quality to maintain client confidence.
- Improving operational efficiency and reducing reliance on skilled operators.
- Minimizing downtime and avoiding prolonged disruptions to delivery schedules.
3. Impact of the Issues
- Reduced production capacity and increased operational costs.
- High rejection rates led to frequent rework and resource wastage.
- Prolonged breakdowns and maintenance downtime hindered timely order fulfillment.
- Loss of machine trust due to inconsistent quality and reliability.
Vendor Selection Criteria
Concentric Pumps India Pvt. Ltd. chose Tulja Hi-Tech based on the following criteria:
- Proven expertise in reconditioning & retrofitting complex machinery.
- Over 20 years of industry experience.
- Positive feedback from existing clients.
- Comprehensive knowledge of operations, electronics, and mechanical systems.
- Robust infrastructure and resources.
- Cost-effective solutions with uncompromised quality.
- Reliable after-sales support and service.
- High-quality workmanship and adherence to ethical business practices.
- Transparent communication and fair business policies.
- Commitment to meeting project deadlines and maintaining timelines.
Approach to Work
1. Receiving and Initial Assessment:
- The machine was dismantled at Tulja Hi-Tech’s facility, with all critical components— slides, ball screws, ATC, spindle, guards, and others—disassembled for thorough evaluation.
2. Cleaning and Inspection:
- All components were cleaned meticulously to remove debris and contaminants.
- A detailed inspection was conducted to assess wear and damage, with findings documented in a comprehensive report.
3. Status Reporting and Recommendations:
- The inspection report and Tulja Hi-Tech’s professional recommendations were shared with the client for review and approval.
4. Work Execution:
- Proceeded with reconditioning based on the client’s approval.
- Maintained detailed records and photographs at every stage for transparency.
Solutions Provided
1 Restoration of Geometrical Accuracies:
Precision grinding and realignment of X, Y, and Z-axis slides.
2 Replacement of Key Components:
Installed new, high-quality ball screws and bearings for X, Y, and Z axes.
3 Spindle Overhaul:
Replaced spindle bearings to improve performance and longevity.
4 System Servicing:
Conducted comprehensive servicing of the ATC, hydraulic power pack, and coolant system.
5 Electrical Overhaul:
Rewired the machine and control panel using modern, reliable components.
6 Machine Repainting:
Repainted with durable PU paint for a refreshed appearance and protection.
7 Geometrical Accuracy Verification:
Verified alignment and accuracy according to the original machine tool builder’s standards.
8 Job Trials and Validation:
Conducted and validated job trials to ensure optimal machine performance.
9 On-Site Commissioning:
Installed and commissioned the machine at the client’s facility.
10 Documentation Handover:
Provided spare parts and both hard and soft copies of electrical documentation to the client.
Results Achieved
1. Restored Accuracy:
Geometrical accuracies were restored to 95% of a new machine’s standards.
2. Enhanced Productivity:
Productivity levels doubled, significantly improving operational efficiency.
3. Reduced Rejection Rates:
Job rejection rates were minimized to almost zero.
4. Resolved ATC Issues:
ATC tool-dropping problems were completely eliminated, ensuring safer operations.
5. Increased Profitability:
Improved productivity and reduced rejection rates contributed to higher profitability for the client.
6. Customer Satisfaction:
The client expressed high levels of satisfaction with the project.
Client Testimonial
“Tulja Hi-Tech has done an exceptional job in reconditioning our AMS VMC
400. The machine’s performance has improved significantly, and we’ve seen
a noticeable increase in productivity and reduction in rejection rates. Their
professionalism and expertise are commendable.”
– Concentric Pumps India Pvt. Ltd.
