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MFSI Recommendation

Chairman Award 2008

Plant - Pune

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MR. Rajesh KakkarDirector Plant Operation Project Guide

MR. Kishore PatilManager Mfg. Engineering

MR. Uday DeshmukhAsst. Manager Mfg. Engineering

MR. Suryakant PalandeTechnical Head

Chairman Award Nomination

Project Team

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Nominee Name : Team : Suryakant Palande / Kishore Patil / Uday Deshmukh

Under Guidence of : Rajesh Kakkar

Age : 44 / 35 / 32

Designation : Technical Head / Manager ME / Asst. Manager ME

Deptt : Manufacturing Engineering

Experience : 24 / 15 / 11 Years

Project Undertaken : Inhouse Refurbishment of discarded / written off machine

( Hot Melt Extruder )

Project Started : October – 2007

Project Ended : February – 2008

Cost Recovery : Rs 7.0 M would have cost for a new equipment.

Spent Rs 1.5 M on refurbishment.

Nomination

Chairman Award Nomination

Executed new Business worth 60 M and Saved Rs 5.5 M

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Issue

Hot Melt glue dispensing machine required for new “Panel Type” PU Air filterswith cured media and co-polyester hot melt. Most crucial factor was MELTINGTEMP of 225°C as against normal temperature of 180°C.

Customers

TATA Motors (2.2 CRDI and ACE) / MARUTI SUZUKI (Swift diesel)

Impact

• Able to acquire and execute new business worth Rs. 60M

• Capex Saving Rs. 5.5 M

• Maintained competitive advantage in Air filter segment

Year 2008

Trigger

a. New business opportunity

b. Capex limitation. Poor Pay back with initial volumes

c. Availability of written off asset and in-house skill set

Project Details

Chairman Award Nomination

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Process Adopted

In view of the CAPEX constraints and not to loose potential business with prime OEs like TMLand MUL an old non-moving (written off) extruder (MELTEX German make) was identified forrefurbishment under guidance of Mr Rajesh Kakkar.

German counterpart strongly recommended to scrap the extruder and go for new Investment.

Extruder manufacturer refused to provide any type of technical help / support.

There was a potential risk of loosing investment of 1.5 M in case of failure however the teamtook the challenge.

Chairman Award Nomination

Project Details contd....

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Chairman Award Nomination

Project Details contd....

Before

Refurbishment

Extrusion screw found damaged

Gear box of Main Motor was found to be worn out

Conventional 8 segment temperature controller for hoses,

application heads and screw zones were non functioning

Screw and Pump motor drive found to be non functioning

Electrical panel was beyond repair due to unavailability

of spares as the model was out dated

Electrical and mechanical parts were checked

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Chairman Award Nomination

Project Details contd....

After

Refurbishment

Electrical hard wiring was minimised by using Siemens S7 300 PLC

with solid state relays for heaters

Control panel was made user friendly by using Siemens OP207 touch screen panel.

This helps in problem diagnosis and controlling of various parameters.

PID control loop was used for min-max glue pressure setting.

This dispenses constant and equal glue quantity.

Pleating machine and extruder pump were synchronised (Tacho-generator

feedback) to achieve metered glue dispensing quantity w.r.t. paper pleating speed.

Man and machine safety inter locks were added

which were not there on the original equipment.

New Lenz drives were installed for screw and pump motor

Extrusion screw and gear box repaired. Parts were manufactured

locally by taking reference from damaged sample parts.

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Chairman Award Nomination

Project Details contd....

Project Status

Equipment is in use for production on 2 shift basis since March 2008

Production Capacity

3800 filters / shift

Output

Machine has produced more than 480,000 PU elements since March 2008 till date

Delivery

100 % delivery against customer requirement in 2008

Quality

Metered glue dispensing resulted in consistent quality and reduction in Internal scrap

(COPQ)

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Special Thanks to; - Lenze Mechatronics India - Kletti Germany- Siemens India- Swaraj Automation

Project Details contd.... After

Chairman Award Nomination

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Recommendation

The Nominee team :

� Took challenge to refurbish old extruder in-house because Meltex, Germany / Nordson, Indiarefused for reconditioning of Extruder and strongly recommended to go for a new one.

� Noteworthy efforts were taken for restructuring of Electrical & Electronic Hardware as everycomponents had special purpose application.

� Hybridization of Critical Imported components with Indian branded product for costoptimization.

� Mechanical parts for Extrusion screw / Gear box were manufactured locally.

� Several experiments / trials were conducted for synchronization of Signal converters for Hotmelt Pressure & temperatures.

� Efforts were taken to achieve precise control for process parameters like uniform hot meltdispensing quantity at constant pressure.

� All experiments / trials / fine tuning were possible only in hot condition of machine.

� Latest technological hardware's – Like Siemens PLC / Siemens Touch screen / Lenze driveensured safety / user friendly operation / cycle time reduction & quality improvement.

� Achieved ease of operating and PM of equipment. Also resulted in increased productivitywith minimum internal scrap.

Chairman Award Nomination

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Thank You

Chairman Award Nomination