SPICER INDIA LTD. – Comprehensive Retrofitting of MORISEIKI SL25
Client Overview
Client Name: SPICER INDIA LTD.
Plant Address: MIDC, CHAKAN, Pune, Maharashtra
Sector: Automobile Component Manufacturing
Products: Automobile Parts, including precision-machined components for the automotive industry
Machine Involved: MORISEIKI SL25 (CNC Lathe)
Before
After
Challenges Encountered
1. Problem
- Aging Equipment and Wear
The MORISEIKI SL25 had been in continuous operation for over 15 years, leading to significant wear and tear. While the machine had originally been a high performer, extended usage had resulted in diminished accuracy and operational issues, necessitating a comprehensive overhaul. - Geometrical Accuracy Compromise
Over the years, the machine’s geometrical accuracy had degraded. This was particularly apparent in the X and Z axes, where alignment and precision were critical to maintaining high-quality production. Frequent deviations from expected standards caused constant production errors. - High Rejection Rates
The combination of mechanical issues and loss of accuracy led to a significant increase in product rejection rates. These issues often resulted in rework and delays in fulfilling client orders, tarnishing SPICER INDIA’s reputation for reliability and precision. - Increased Breakdown Frequency
The frequency of breakdowns had risen to a concerning 20%, disrupting production schedules. These failures were primarily due to the aging mechanical components, outdated electrical systems, and worn-out bearings. - Outdated Electrical Controllers and Drives
The electrical controllers and drives had become obsolete, making it difficultto find replacement parts. Furthermore, the lack of modern diagnostic tools and technical support made troubleshooting and repairs inefficient.
2. Significance
- These challenges were affecting the consistency and quality of production. As a result, the operational costs had increased, client satisfaction had declined, and there was a real threat to long-term business sustainability. To ensure continued success, addressing these issues was vital for improving the machine’s efficiency, reducing downtime, and restoring high-quality output.
3. Impact
- Reduced Production Capacity: The aging equipment reduced overall productivity and capacity to meet client demands.
- Quality Control Issues: Production inaccuracies caused frequent product rejections, impacting both timelines and client relationships.
- Skill Dependency: The complexity of the machine’s issues led to heavy reliance on skilled operators. With their unavailability, production further slowed down.
- Prolonged Downtime: Machine downtime increased due to frequent breakdowns, delaying production schedules and hurting delivery timelines.
- Client Hesitation: Due to the unreliability of the machine, existing clients were reluctant to assign new jobs, impacting future business opportunities.
- Profit Losses: The accumulated downtime, rejections, and maintenance costs significantly impacted profitability.
Vendor Selection Criteria
To address these critical issues, SPICER INDIA carefully evaluated potential vendors based on the following criteria:
1. Expertise in Retrofitting Complex Machines: Proven experience with similar retrofitting projects, especially in the automotive and precision machining sectors.
2. Industry Experience: At least 20 years of experience working in the field of CNC machine retrofitting and reconditioning.
3. Client Feedback and Reputation: Positive recommendations and a proven track record with previous clients in the industry.
4. Multidisciplinary Expertise: A vendor with comprehensive skills in both mechanical and electrical systems, ensuring effective retrofitting and reconditioning of complex machines.
5. Infrastructure Capability: Access to facilities and resources to handle large and intricate projects, including precision machinery handling.
6. Cost-Effectiveness: Competitive pricing, with a focus on providing a costeffective solution without compromising quality.
7. Service and Support: A vendor offering reliable after-sales support, including ongoing maintenance services and troubleshooting assistance.
8. Quality of Workmanship: Ability to meet or exceed industry standards for machine reconditioning, with high-quality craftsmanship.
9. Ethical Business Practices: Transparency, honesty, and fairness in all business dealings.
10. Commitment to Timely Delivery: Strong reputation for meeting project deadlines and delivering work on time.
Approach to Work
1. Receiving and Initial Assessment
The machine was carefully transported to the Tulja Hi-Tech facility, where it underwent a detailed assessment. The team dismantled all critical components, including slides, ball screws, the turret, spindle, guards, and other vital parts, to evaluate the machine’s current condition.
2. Comprehensive Cleaning
All disassembled components were thoroughly cleaned to remove contaminants, debris, and grease build-up. This ensured that all components were in optimal condition for inspection and reconditioning.
3. Inspection and Status Reporting
After cleaning, the machine underwent a comprehensive inspection. The vendor’s engineering team, in collaboration with SPICER INDIA’s technical representatives, assessed each part. A detailed report was generated, outlining the current condition of the machine and highlighting the need for specific repairs or replacements.
4. Recommendations and Client Approval
Based on the inspection, the Tulja Hi-Tech prepared a list of necessary repairs, retrofitting, and upgrades, including component replacements, precision grinding, and electrical system overhauls. SPICER INDIA reviewed the report and provided approval to proceed with the proposed solutions.
5. Commencement of Work
Upon approval, the Tulja Hi-Tech began the retrofitting and reconditioning process, focusing on precision, efficiency, and quality.
Tulja Hi-Tech Solutions to Address the Problem
1. Restoration of Geometrical Accuracy
The X and Z slides were precision-ground to restore their alignment and accuracy, ensuring the machine could meet its original manufacturing tolerances.
2. Replacement of Key Mechanical Components
Both the X and Z axis ball screws and bearings were replaced with highquality, state-of-the-art units. This not only improved the machine’s performance but also extended its operational lifespan.
3. Spindle and Tailstock Overhaul
New bearings were installed in the spindle and tailstock assemblies, improving machining stability and enhancing the precision of the machine.
4. Comprehensive System Servicing
The turret, hydraulic power pack, and coolant system were thoroughly serviced to ensure smooth operation and reduce the risk of future failures.
5. CNC Retrofitting
The machine was upgraded with the latest Fanuc CNC system, incorporating new drives, motors, and control software to enhance performance and provide future-proof capabilities.
6. Electrical System Overhaul
The entire electrical system, including wiring and control panels, was updated to modern standards. New components were installed, ensuring better reliability and easier maintenance.
7. Repainting and Refurbishment
The machine was repainted using high-quality, durable PU paint, giving it a refreshed look while providing additional protection from wear and tear.
8. Geometrical Accuracy Verification
After retrofitting, the machine’s geometrical accuracy was meticulously checked and verified against the original machine tool builder’s standards, ensuring that it met or exceeded the expected performance levels.
9. Successful Job Trials
After reassembly, multiple job trials were conducted, testing the machine’s ability to perform various operations under typical load conditions. These trials were analysed to ensure that the machine was operating at optimal efficiency.
10. On-Site Commissioning
The retrofitted machine was reinstalled at SPICER INDIA’s facility, where it was thoroughly tested and commissioned. The team ensured the machine was fully functional and capable of meeting the company’s production needs.
11. Handover of Documentation
Full documentation, including electrical schematics, spare parts lists, and maintenance guidelines, was handed over to SPICER INDIA for future reference and ongoing machine care.
Why Tulja Hi-Tech Stands Out
1. Restored Accuracy and Precision
The retrofitting process successfully restored the machine’s accuracy to levels comparable to a brand-new unit, improving overall machining quality.
2. Enhanced Productivity
With its enhanced performance, the machine’s productivity doubled, enabling SPICER INDIA to meet customer demands more efficiently and with less downtime.
3. Reduced Job Rejections
The overhaul eliminated the quality issues that had previously led to high rejection rates. Product defects were minimized to nearly zero, boosting the company’s reputation for precision and reliability.
4. Customer Satisfaction
SPICER INDIA expressed immense satisfaction with the results. The company was impressed not only with the enhanced machine performance but also with the vendor’s professionalism, expertise, and commitment to quality.
5. Increased Business Growth
The improvements led to a boost in profitability. With reduced machine downtime, fewer rejections, and enhanced efficiency, SPICER INDIA saw a marked increase in production capacity and business growth.
This comprehensive case study highlights how a tailored retrofitting solution not only addresses the challenges of aging machinery but also leads to significant improvements in productivity, quality, and business growth. By partnering with an experienced vendor, SPICER INDIA was able to extend the life of their critical machinery, restore its performance, and ensure a more reliable and profitable future.
