Use of Industry 4.0 in Manufacturing for Improving Resource Utilization … · 2019-08-26 ·...

Use of Industry 4.0 in Manufacturing forImproving Resource Utilization and Reducing Conversion Cost

Mohali, Punjab

1996

Shirwal, Maharashtra

Mohali, Punjab

Godrej & Boyce Mfg. Co. Ltd.

Established in 1897

Land Area : (75.01Acres)

Products

Capacity: 1.6 million 2.7 million 0.4 million

Employee-1700 Green Co Platinum TPM

Future ready manufacturing Initiatives

Additive manufacturing

Automation

Advance materials & NANO technology Simulation software

LEAN

TOOLS

POKA

YOKE

SMED

QC

CIRCLE

VSM

5S

JIT

LINE

BALANCING

KAN

BAN

Organization Vision

Top 3 by 2020 in Indian Appliances industry

Manufacturing VisionLowest cost appliances

producer in India

Flexible manufacturingLean tools

11201350 1456 1560

1725

2243

25062809

301910096

89 85 83

77

6961

53

0

20

40

60

80

100

120

0

500

1000

1500

2000

2500

3000

3500

2010 2011 2012 2013 2014 2015 2016 2017 2018

Turnover Mfg costAutomation

Turn

ove

r In

Crs

Ind

exe

d M

anu

fact

uri

ng

cost

Digitalization

Organization Vision

Top 3 by 2020 in Indian Appliances industry

Manufacturing Vision

Lowest cost appliances producer in India

Flexible Manufacturing

Evolution of manufacturing systems – The journey so far …

Basic Lean tools

Total lean –CII cluster program

TPM

Green–MSG

Total Green–GREEN COMPANY RATING

Reason for Choosing Digitalization…….

High Inventory because of lack of

visibility

Delay in Root Cause Analysis

Improper resource utilization

High Rejections & Quality defects

due to no real time monitoring

High Lead Time

Incorrect/Inaccurate data

capturing

Inconsistency of data due to

conventional recoding methods

Conventional Methods of

monitoring productivity/Quality

High response time to attend

Breakdown leading to production loss

Non accountability for losses

How to Implement Digitalization ?

Process for Implementing Digitalization………

STEP 1- DEFINE OBJECTIVE AND SCOPE FOR DIGITIZATION

STEP 2- DEFINE RELATIONSHIP WITH ORGANIZATION AND MANUFACTURING VISION

STEP 3- DEFINE APPROACH AND ROADMAP FOR IMPLEMENTATION

STEP 4- TARGET SETTING

STEP 5- INTEGRATION WITH TPM PILLARTS FOR PROJECTS IDENTIFICATION

STEP 6- DEFINING METHODOLOGY FOR IMPLEMENTING PROJECTS

STEP 1- OBJECTIVE AND SCOPE FOR DIGITIZATION

Objective:- To make cost efficient factory by effective use of resources with the help of digitization, real time

visibility, connected, smart and flexible manufacturing.

SCOPE:-

Production Systems & Intelligent

Maintenance System Digital Supply chainEnergy & Utility Condition

Monitoring System

i-FACTORY

Division Vision,

Mission, Values

Division Key Business

Index

Manufacturing Key

Business Index

Performance Index by Use of

Digitalization

•To be TOP3 in

Indian Appliance

industry

•Offering innovative

& quality products

•Financial

sustainability

•3P(People, Planet,

Profit)

•Stress free, worry

free, fear free, work

environment

1. Asset Productivity 1.1 To increase asset

turnover ratio of Mohali

plant by 30%

1.1.1 S class machines OEE

improvement by 10 % with the

help of Real time monitoring.

2.Cost Productivity 2.1 To improve

Manufacturing cost

Index

2.1.1 Machine spares, tools &

Coolant cost reduction by 10% by

life optimization .

2.1.2 Inventory reduction by 10%

by improving visibility.

3. People

Productivity

3.1 Improve VAPCO by

5%

3.1.1 10% Productivity

improvement for man power used

for data collection & surveillance

by using digital system.

4.Integrated Quality

Management

4.1To Reduce rejection

cost as % of BOM by

20% for all categories

4.1.1 Rejection cost reduction by

10% through real time

measurement of quality

parameters.

STEP 2- RELATIONSHIP WITH ORGANIZATION VISION

10

0%

Dig

ital

izat

ion

1. Machines

2. Processes

3. Data points

4. User points

1. Application

2. Software

3. ERP

4. Servers

1. Machine Data

2. Process Data

3. Quality Data

4. Productivity data

1. Digital alerts

2. Dash boards

3. Push SMS

4. Updates

2019- 2021

2017- 2019

2016-2018

STEP 3- APPROACH AND ROAD MAP FOR DIGITIZATION

Focus area ParameterBase year

2016-17

Phase 1

Target(2017-18)

Phase 2 Target

(2018-19)

Phase 3 Target

(2019-20)

OEE 78% 81 86 90

FPY 89% 96% 98.5 99.5

Tooling Cost (Rs) 32 30 24 20

Process capability 1.2 1.33 1.67 -

Spare cost (Rs) 6.4 6.0 4.5 2.5

TBM To CBM 20% 40% 60% 100%

Power consumption

(Rs)31 28 25 22

Water consumption

(Lts /appl.)35 30 27.41 25

Inventory reduction

(DOH)15 12 10 7

Hard copy formats

reduced0 1200 1800 2400

STEP 4- TARGET SETTING

Energy & Utility System

Digital Supply chain

Production Systems &

Intelligent Maintenance

System

Su

pp

ort

Fro

m O

ther

pil

lars

Su

pp

ort

To O

ther

pil

lars

KK

JH

PM

QM

E&T

OTPM

SHE

DM

KK

JH

PM

QM

E&T

OTPM

SHE

DM

DIGITAL

Identify opportunities for office

process lead time reduction

Details of the machine

parameters to monitor

Provide details for any

automation of JH systems.

Provide details of OLE / OEE /

System transactions

Building IT Infra

Support during building IT infra

Training to develop new skills in

the areas of new technologies

Identifying areas for inspection

automation and provide details.

Office process lead time reduction

through IT enabled working.

Auto condition based

maintenance with alerts

A system for Tool Management &

electronic cock pit

Technical support for real time OEE

Calculations

Develop a system for project

milestone monitoring

IT supported BE safe portal

management and other automations

Paperless transactions

Inspection automation and

digitisation of data.

STEP 5- INTEGRATION WITH TPM PILLARS FOR PROJECT SELECTION

STEP 6- METHODOLOGY FOR IMPLEMENTING PROJECTS

Seven Step Methodology :

Need Identification

Exploring Ideas

Feasibility study

Display to HMI etc.

Prototyping & Testing

Installation & Commissioning

Monitoring & Review

a. Interaction with other pillars b. Understanding purpose & necessity c. Efforts mapping.

a. Brainstorming for various ideas. b. Technology & investment. c. Optimal solution

a. Decision for Inhouse make or Buy. b. Return on investments.

a. Study in totality. b. Easy to operate. c .Catering future needs

Data

Capturing

Converting Analogue to

digital

Transfer to Cloud

Designing

a. Pilot run b .Observe the performance.

a. Installationb. Trials.

CASE STUDY

DIGITALIZATION IN PRODUCTION SYSTEM

20

24

28

2016-17 2018-19

Co

mp

. In

lacs

24 Lacs

26.5 Lacs


Maintenance System

SCOPE

Digital Supply chainEnergy & Utility Condition

Monitoring System

PRODUCTION REQUIREMENT

Need Identification

GAP- 2.5 Lakh128

120

114

118

122

126

130

2016-17 2018-19

Co

nve

rsio

n C

ost

CONVERSION COST

20

24

28

2016-17 2017-18

Co

mp

. In

lacs

24 Lacs

26.5 Lacs

Need IdentificationGAP- 2.5 Lakh Compressors

CAPITAL INVESTMENT

PRODUCTION CAPACITY ENHANCEMENT

78

86

72

76

80

84

88

2016-17 2018-19

OEE

EFFICIENCY IMPROVEMENT OF EXISTING MACHINES BY USING INDUSTRY 4.0

INVESTMENT REQUIRED

20 Crores

ADDING UP NEW MACHINES

Activity Sub activity 2017-18

Q1 Q2 Q3 Q4

Need Identification Identifying and prioritization of needs

Exploring ideasExploring possible ideas (Brainstorming,

technology & investment, Optimal Solution)

Feasibly study Idea Feasibility study

Designing Designing of concept

Prototyping and Testing

Procurement of material

Hardware upgradation and Introduction of

Dashboard

Prototyping on one machine

Modifications & Validation of results

Installation &

Commissioning

Hardware and software modification on all

machines

LAN & Cloud based connectivity

Installation

Commissioning and Validation of results

Monitoring and Review Implementation and Monitoring

Planned Start Planned End Activity Continued

Actual Start Actual End Activity Completed

GANTT CHART

Need Identification

1. Real time loss capturing.2. Monitoring of micro Stoppages.3. Real Time OEE Monitoring. 4. Real time cycle time monitoring.5. Stop time Recording.6. Changeover time Monitoring.7. Defects and rework monitoring.8. Loss wise bifurcation.9. Alarms/ time taken per alarm monitoring.10. Tool life monitoring.11. Coolant life monitoring.12. Tool holder life monitoring.13. Condition based monitoring of tool life.14. Production monitoring.15. Autonomous production report generation.16. Line efficiency monitoring.17. Intimation of loss/ micro stoppages to

department.18. Inventory monitoring and inventory cost

reduction.19. Monitoring of hidden losses.20. Running program sequence number

monitoring.21. Tool wise load monitoring of spindle motor.22. Machine running parameter (Feed/ RPM/

Cutting speed) monitoring.23. Machine current state & selected mode

monitoring.

1. Autonomous spare planning.2. All Servo motor current monitoring.3. Spare life monitoring in hours/days

recommended by supplier.4. Condition based Maintenance Spindle.5. Spindle temperature monitoring.6. Servo encode temperature monitoring.7. All servomotor temp Monitoring.8. Real time monitoring of ball screw life.9. Spindle motor load monitoring.10. Lubrication Oil/ Hydraulic oil level

monitoring.11. Real time PMI check point monitoring.12. Intimation to maintenance department for

abnormal condition of machine.13. Condition monitoring of drive fan’s.14. Condition monitoring of panel cooling fan’s.15. Machine battery health monitoring.16. Automatic lubrication and lubrication

frequency monitoring.17. Root cause analysis for machine breakdowns

and alarms.18. Ball screw temperature monitoring.19. LM rail condition based life monitoring.20. All Proximity sensor life monitoring.21. All motor alarm monitoring.22. Breakdown history monitoring.23. Hydraulic pressure and air pressure

monitoring.24. Machine should be stopped if abnormal

condition are there for critical parts.

1. Low number of manual check points.2. Real time monitoring of critical check points.3. Digital size adjustment of boring tools.4. Autonomous CLITA. 5. Digital checkpoints for easy monitoring of

critical points.6. Auto lubrication of parts.7. Autonomous cleaning of machines.8. Real time monitoring of lubrication pressure.

9. Real time monitoring of clamping pressure.10. Automatic tool length measurement.11. Program modification and micro adjustment

from PC.12. Breakdown call from machine itself.13. Component position sensing on fixture after

clamping.14. Tool break/ damage sensing and feedback to

operator.15. Auto loading and Un-loading of component

from fixture.16. Coolant life monitoring/ cleaning frequency

monitoring.17. Autonomous Coolant concentration/PH

monitoring.18. Coolant temperature monitoring.19. Auto cleaning of coolant tank and chip

evacuation.

1. Real time humidity level monitoring in machining section.

2. Bacteria level and PH level monitoring in machine coolant.

3. Intimation of safety alarms on machine to safety department and concern department.

4. Real time condition monitoring of safety sensors installed in machine.

5. Coolant temperature monitoring.

QM1. Elimination of rejection due to tool

breakage.2. Elimination of rejection due to component

wrong clamping.3. Elimination of rejection due to material

defect.4. Elimination of component rejection due to

tapping defects.5. Elimination of rejection due to component

rusty issue.6. Metallic chips elimination in final

component.7. Elimination of operation shifting due to

component position shifting on fixture.

Requirement from various Pillars

KK PM JH SHE

Cost OEE Working Environment

Activity Hazard Severity Prob. S*P

High Humidity Level Due to mist

Biological Effect on respiratory system

2 3 6

Bacterial & PH level Monitoring

Skin Irritation 2 1 2

Safety sensors working condition

Chance of inappropriate

functioning2 1 2

No intimation of safety alarm to dept.

Chance of alarm being ignored

2 1 2

HIRA ON REQUIREMENT FROM SHE PILLAR

1812 8 6 4 3 2 2 2 2 1

40

58

7078

8488 91 93 95 97 99 100

0

25

50

75

100

Machine Running Cost

Cost in % Cumulative %

28

124 3 2 2 2 1 1 0

45

73

85 89 92 94 96 97 99 100 100

0

25

50

75

100

Contributors In Productivity Loss

Loss Time in %

Cumulative %

Condition Base Tool life

Monitoring

Real time health Monitoring of

critical machine elements

Real time capturing of minor and

micro stoppages.Real Time Monitoring of Mist

Collector Efficiency.

Auto Monitoring of manual check

points.

PRIORITIZATION OF REQUIREMENTS

5 needs shortlisted

by prioritization

S No. Data to be monitored Available/

Not Available

1Condition base Tool Life

MonitoringNot Available

2Servo / Ball screw condition

based life monitoringAvailable

3 Capturing micro Stoppages Not Available

4Spindle Temperature

MonitoringAvailable

5Mist Collector efficiency

MonitoringNot Available

6Auto Monitoring of

checkpointsNot Available

FEASIBILITY STUDYOptions available in machine ?

Logical/Analytical

SolutionHardware Required

Can be derived by

monitoring spindle motor

load at time of cutting

__________

____________________

Can be captured by logic

modification

__________

__________ __________

F-Monitor Required

Pressure Switches ,Float Switch,

Reed switches, Proximity sensors

How to get Data?

Real Time data can be

captured in PLC for all 6

parameters

Pressure Switches

Hydraulic Clamping

Pressure feedback

Pneumatic Clamping

Pressure feedback

Pressure gauges

Air Pressure

Monitoring

Hydraulic pressure

monitoring

F- Monitor

To monitor

Mist collector

Efficiency

Requirements

Spindle Temperature Monitoring

Tool Life MonitoringMist Collector

efficiency MonitoringAuto Monitoring of

checkpointsReal time Servo Load

MonitoringCapturing micro

Stoppages

PROTOTYPING AND INSTALLATION

Real time Servo load data in servo drive

Ethernet connection

Real time Servo Motor Load

Data to PLC INTERFACE

Dear All

Servo Motor –Spindle load has gone above warning zone.

Email Received

Analog Signal

Digital SignalIntimation of Abnormal load to Maintenance Team Time Load Time Load

11:10:12:50 124 11:10:19:50 16911:10:13:00 127 11:10:20:00 15811:10:13:50 129 11:10:20:50 15511:10:14:00 135 11:10:21:00 17511:10:14:50 158 11:10:21:50 23811:10:15:00 211 11:10:22:00 17511:10:15:50 257 11:10:22:50 16211:10:16:00 137 11:10:23:00 7511:10:16:50 182 11:10:23:50 8811:10:17:00 75 11:10:24:00 17511:10:17:50 68 11:10:24:50 31211:10:18:00 175 11:10:25:00 27611:10:18:50 168 11:10:25:50 24111:10:19:00 196 11:10:26:00 176

Interface

Real Time Monitoring

REAL TIME DATA

INTERFACE

MACHINES

HARDWARE UPGRADATIONS

Requirements

Spindle Temperature Monitoring

Tool Life MonitoringMist Collector efficiency

MonitoringAuto Monitoring of

checkpointsServo Load Monitoring

Error Zone (RED)

Warning Zone (YELLOW)

Optimum Zone (GREEN)

Real Time Spindle Temperature

Real Time Servo load Capturing

Real Time Servo load Capturing

Real Time mist collector Efficiency Monitoring

Auto Monitoring of Checkpoints

INSPECTION INSPECTION

Spindle Gear / Turret Gear

Turret CAM/UC Cam

Flexible Hose Condition

Fan Motor

Air Filter Regulator

Mist Collector

183/2000 (Hour)

362/2000 (Hour)

74/2000 (Hour)

160/1500 (Hour)

74/1000 (Hour)

Clamping Pressure

OK NOT OK

Chip Conveyor

OK NOT OK

Spindle Coolant Pressure

OK NOT OK

Autonomous Inspection

Capturing micro Stoppages

Time Machine Alarm Alarm Message

0VMC-09 OPR AIR PRESSURE LOW

0.08VMC-09 OPRTHE DOOR OF THE SPLASH GUARD IS OPEN

1.6VMC-09 OPR AIR PRESSURE LOW



0.05VMC-09 OT (Y)+ OVERTRAVEL ( SOFT 1 )

0.95VMC-09 EX CTC PRESSURE LOW

Real Time loss capturing

MONITORING & RESULTS

How to Utilize Real timethe captured data?

1.REDUCTION IN INSPECTION TIME

S. No. Check Point Time

1. Component Clamping

Pressure 20 sec

2. Hydraulic Main Line

pressure 30 Sec

3. Incoming Air Pressure 15 sec

4.Spindle through Coolant Pressure 30 sec

5.Air seat sensor

pressure 20 sec

6. Lubrication Pressure 30 sec

7. Coolant Level 20 sec

8. Lubrication Oil Level 25 sec

9. Hydraulic Oil Level 20 sec

10. Panel Fan Motor 20 sec

11. Emergency Switch 15 sec

12. Chip Conveyor 35 sec

13. Air Filter 20 sec

TOTAL 300 sec

6 Machines X

5 Min/ Machine

30 Minutes

30

6

0

10

20

30

40

Before After

Min

ute

s

Inspection Time

Machine

Coolant tank

Hydraulic Power Pack

1

2

34

5

6

7

8

9

10

11

12Chip Conveyor

Check Points

12

Machine Layout/ Check Points

13

225

240

200

250

Before After

Nu

mb

er

of

Co

mp

on

en

ts

Productivity Improvement

Mist Collector

Clamping Pressure

OK NOT OK

Chip Conveyor

OK NOT OK

Spindle Coolant Pressure

DIGITAL COCKPIT POINT

OK NOT OK

Incoming Air Pressure

OK NOT OK

Air seat PressureOK NOT OK

Hydraulic PressureOK NOT OK

Lubrication PressureOK NOT OK

Coolant LevelOK NOT OK

Hydraulic oil level

OK NOT OK

Lubrication oil levelOK NOT OK

Emergency Switch

OK NOT OK

Chip Conveyor

OK NOT OK

Manual Check Points (CLITA Sheet) Manual Check Points

Comparison of Cycle No1 & Cycle No 4

2. OEE IMPROVEMENT BY

ELIMINATING HIDDEN LOSSES & MICRO STOPPAGES

Cycle NoStd. Cycle

TimeActual

Cycle timeDifference

1 378 378 0

2 378 382 4

3 378 378 0

4 378 386 8

5 378 379 1

6 378 385 7

Tool Cycle 1

(sec)Cycle 4 Difference

1 6 6 0

2 11 11 0

3 14 14 0

4 8 8 0

5 22 22 0

6 18 18 0

7 12 12 0

8 7 7 0

9 20 23 3

10 18 20 2

11 13 13 0

12 28 28 0

13 36 37 1

14 24 26 2

15 37 37 0

16 23 23 0

17 22 22 0

18 12 12 0

19 23 23 0

20 24 24 0

Total 378 386 8

0

5

10

15

9:00 9:30 10:00

Target vs Actual ProductionOutput Plans

No alarm and minor stoppages

Variation in cycle time of Block No. 9,10,13,14 Corrective ActionANALYSIS

383

378

350

370

390

Before After

Tim

e (

seco

nd

s)

Cycle Time405

00

100

200

300

400

Before After

seco

nd

s

Hidden Losses

Laser Transmitter

ReceiverBeam Refracted

Laser Transmitter

Receiver

Laser Beam Height Shifted up by 0.2 mmWater Droplet

3. Condition base Health Monitoring of critical machine

elements

Machine Spindle

Forced Deterioration (Due to more Friction)

Natural Deterioration (Due to High Cutting forces)

Error Zone (RED)

Warning Zone (YELLOW)

Optimum Zone (GREEN)

0.7

0.15

0

0.25

0.5

0.75

1

Before After

Co

st in

R

s/C

om

po

nen

t

Spare Cost/ Component

30

10

0

10

20

30

40

Before After

Tim

e (M

inu

tes)

Avg. Perventive Maint time

Time Based Maintenance

Condition Based Maintenance

0

50

100

150

200

250

300Real time spindle motor load monitoring

Spindle motor load monitoring at time of cutting Operation

Error Limit (RED)

Warning Limit (YELLOW)

Optimum Zone (GREEN)Life Recommended by Tool manufacturer

Tool life extended by monitoring Spindle load

Number of Parts

Spin

dle

Mo

tor

Load

4. TOOL LIFE OPTIMIZATION

4mm Drill (Combination tool)

30 Meters 400 ComponentsLife Recommended by supplier

400

1200

0

300

600

900

1200

Before After

Too

l lif

e in

Nu

mb

ers

Tool life Improvement for 4mm Drill

2.5

1.5

0

1

2

3

Before After

Co

st in

lakh

Annual 4mm drill cost After life optimization

Spindle Motor load

Tool Wise spindle

Motor load

5. MIST COLLECTOR EFFICIENCY IMPROVEMENT

Before 2016 2016-17 2017-18

MIST COOLECTORS ADDED ON MACHINES REAL TIME EFFICIENCY MONITORING OF MIST COLLECTORS

Mist Collector

Flowsensor

Mist Collector

Servicing Required

Warning Zone

High Efficiency

NO MIST COLLECOTRS ON MACHINE

73 78 77 79 76 7481

50 56 5160 58 52

59 6249 48 49 5030

60

90

Hu

mid

ity

Coolant Mist & Humidity

Target - 55

Before 2016Mist collector added

Activity Hazard Severity Prob. S*P

High Humidity Level Due to mist

Biological Effect on

respiratory system

2 1 2

HIRA After Digitization

Addition of monitoring device

78

8386

70

75

80

85

90

2016-17 2017-18 2018-19

3.5

2.8

1.2

0

1

2

3

4

2016-17 2017-18 2018-19

15.512.48

10.2

0

5

10

15

20

2016-17 2017-18 2018-19

40

30

6

0

10

20

30

40

50

2016-17 2017-18 2018-19

300

150

200

100

200

300

400

2016-17 2017-18 2018-19

10

140

260

0

100

200

300

2016-17 2017-18 2018-19

OEE IMPROVEMENT TOOLING COST

REDUCTION

SPARE COST

REDUCTION

SPARE REPLACEMENT

FROM TBM TO CBM

INSPECTION TIME

REDUCTION

REDUCTION IN MANUAL

FORMATS

VALUE CREATION AND BUSINESS RESULTS

LIFE CYCLE COST ANALYSIS

S. No. Items Quantity Unit Price

Total

(One time

cost)

Estimated

Life

Recurring

Cost

1. Pressure

Switch120 3500 4,20,000 5 years 42000

2. Float switch 80 2800 2,24,000 5 years 22400

3.Proximity

sensors60 400 24000 2 years 6000

4.IOT

software2 6,00,000 1200000 -

5. PC 2 74000 148000 5 years 14800

6. LED screen 2 32000 64000 5 years 6400

7. Hardware &

integration - 400000

Total 132 22.28 Lakh 0.91Lakh

S.

No.Category

Saving

Comp (Rs)

Annual

Production

Annual

Savings in

Lakhs

1. Tooling Cost 5.3 2000000 106

2.Spare & Maint.

cost2.3 2000000 46

3. Manpower cost 0.20 2000000 4

4.Miscellaneous

cost 0.10 2000000 2

Total 2950000/- 158 Lakh

HORIZONTAL DEPLOYMENT


INVERTER

SOLAR PANELS

ENERGY METERS

COMMON POTENTIAL BUS BAR

Bi-Directional meter

REFRIGERATORPLANT

COMPRESSOR PLANT

REFRIGERATORLINE 4

LOGISTICPLANT

STORE

WASHER PLANT

CANTEEN

LIQUID NITROGEN AREA

GODREJ & BOYCE MFG. CO. LTD, MOHALI

DATA ON CLOUD

GRID

0.890.97

0

0.2

0.4

0.6

0.8

1

BEFORE AFTER

Solar cell efficiency improvement

EFFICIENCY IMPROVEMENT

880

0

200

400

600

800

BEFORE AFTER

Tim

e [

Min

ute

s]

ZERO

MANHOUR SAVING


Maintenance System

SCOPE

Digital Supply chainEnergy & Utility Condition Monitoring

System


ENERGY METERS

(Connected to all machines)

DATA

COMMUNICATION SYSTEMMACHINES

Optimization of electric power consumption


Maintenance System

SCOPE


System

31 28 25

0

10

20

30

40

2016-17 2017-18 2018-19

Rs/

Co

mp

Electric Power Consumption

REAL TIME DATA ON SYSTEM



Maintenance System

SCOPE


System

LIQUID NITROGEN

LIQUID NITROGEN REFILLING

SUPPLIER

LIQUID NITROGEN AREA

SUPPLY CHAINTEAM

Material Lead time Reduction

15

2

0

5

10

15

20

BEFORE AFTER

No

of

day

s

LEAD TIME TO PROCURE

750 780720

0

500

1000

Jul-18 Aug-18 Sep-18 After

Tim

e in

Min

ute

s

MANHOURS FOR LEVEL MONITORING

ZERO


Cooling tower 3

Cooling tower 2

Cooling tower 1

Grinding Section

Compressor Assembly Line

Chiller 1

Chiller 2

COMPRESSOR PLANT

AHU-1

AHU-2ST Dept.

Real Time Data

Data on Server

Data Monitoring of all critical parts

Monitoring Screen -1

Monitoring Screen -2

55005000

62007000

3800

300

0

2000

4000

6000

8000

2013-14 2014-15 2015-16 2016-17 2017-18 2018-19

Production Loss Eliminated by improving response time

2.84 2.962.76 2.57 2.59

2.14

0

1

2

3

2013-14 2014-15 2015-16 2016-17 2017-18 2018-19

Power cost reduction by optimum Usage

Intelligent Maintenance system for- AHU


Maintenance System

SCOPE


System

UNIQUENESS IN OUR APPROACH

DIGITIZATION

5-S

KK

JH

PM

QM

SH&

E

E &

T

OTP

M

DM

DIGITIZATION

PROCESS EQUIPMENTS

OLD EQUIPMENTS NEW EQUIPMENTS

IoT ENABLEDNOT IoT ENABLED

UPGRADED 40 YEARS OLD EQUIPMENTS TO MAKE IT IoT ENABLED WITH THE HELP OF LEAN MACHINE APPROACH

Speed & Scalability

Org

aniz

atio

nal

leve

l

DIGITIZATION

Wit

h In

Pla

nt

Trad

e P

artn

ers

Moving Parallel

= =

OP

ER

AT

ION

AL


32 3024

0

10

20

30

40

2016-17 2017-18 2018-19

Tooling Cost

1.201.33

1.67

0.00

0.40

0.80

1.20

1.60

2.00

2016-17 2017-18 2018-19

Process capability

89%

96%

98.5%

84%

88%

92%

96%

100%

2016-17 2017-18 2018-19

FPY

78%

81%

86%

72%

76%

80%

84%

88%

2016-17 2017-18 2018-19

OEE

25% ImprovementFINANCIAL YEAR

Rs/

Ap

pl.


Cp

k


PER

CEN

TAG

E


PER

CEN

TAG

E

FIN

AN

CIA

L

10095

86

60

80

100

2016-17 2017-18 2018-19

CONVERSION COST (INDEXED)

0.320.29

0.20

0.00

0.10

0.20

0.30

0.40

0.50

2016-17 2017-18 2018-19

REJECTION COST(AS % OF BOM)

14.25 15.3016.60

0.00

5.00

10.00

15.00

20.00

2016-17 2017-18 2018-19

VAPCO

15

1210

0

10

20

2016-17 2017-18 2018-19

Inventory

14% Improvement

FINANCIAL YEAR

IND

EXED

BA

SE 1

00

16% Improvement

FINANCIAL YEAR

RAT

IO33% Improvement

FINANCIAL YEAR

DA

YS


PER

CEN

TAG

E


Future PlanDigitalization Roadmap

1. Machines

2. Processes

3. Data points

4. User points

1. Application

2. Software

3. ERP

4. Servers

1. Machine Data

2. Process Data

3. Quality Data

4. Productivity data

1. Digital alerts

2. Dash boards

3. Push SMS

4. Updates

2020- 20212019- 2020

2018-2019

10

0%

Dig

ital

izat

ion

PLAN

ACTUALProduction

system

Energy &

Utility

Monitoring

Intelligent

Maint.

Digital

Supply

Chain

PLAN

ACTUAL

PLAN

ACTUAL

PLAN

ACTUAL

THANK YOU

Use of Industry 4.0 in Manufacturing for Improving Resource Utilization … · 2019-08-26 ·...

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