COMPANY INFORMATION Established : 1991 No. of employees : 300+ Total number of Machines: 200+ Number of Cells: 25 Certification : ISO/TS 16949 Turnover : 255 Cr
Our Customers
Top management drive ■ In 2016, Top management drive to implement TPM- Trak OEE monitoring solution, now being called as Industry 4.0 and digitization initiatives in our newly built state of the art factory at Pune to improve the efficiency of equipments
1 st Month of Installation -22 Machines
For the Time period 1st-Jan-2016 to 31 st – Jan-2016 For the Time period 1st-Mar-2016 to 31 st – Mar-2016
Top 5 Reasons identified ■ Break down: it is observed that most of the break downs occurred due to poor autonomous maintenance, improper training to operators ■ New settings : Setting time was taking more due to improper planning ■ Tool/Wheel change: Tool and wheel changing was taking more time ■ No operator: working on other machines/absent ■ Machining Time increase: causing less productivity
Countermeasures ■ Break down: Developed strong autonomous maintenance schedules and trained operators and maintenance departments and keeping critical spare part in stock ■ New settings : Setting time is reduced with SMED concept. Reduced by ■ Tool/Wheel change: Provided proper training to operators, implementing tool life monitoring methods and proper planning of tools ■ No operator: By making them understanding the importance of delivery schedules and by developing customer centric culture ■ Machining Time increase: identified and avoided minor stoppages occurring in between cycles, by locking original part program and speed, feeds and by educating the operators
Data Analysis Rij Engineering deployed TPM-Trak OEE monitoring on 21 machines – Phase 1 ■ ■ Rij Engineering decided to work on improving efficiency of the equipments Machine hour rate ■ For CNC INR 255 ■ For Shaping Machines INR 1,000 ■ For Leibherr Gear cutting machines INR 3,000 Observations from 1 st month out come Identified top 10 low performing machines – 3,291 hr ■ ■ Which means 137 days Down time loss – INR 29,08,528 ■ After optimizing the down time over Three months period ■ Down time reduced to 1,784 hrs (74 days) Down time loss – INR 15,97,601 ■ Losses avoided : INR 13,10,927
Asset utilization increase over Three Months Period on 10 machines Increase Asset Utilization Increase Asset Utilization Machines (in Hrs) (in INR) CNC Machines 1039 2,64,957 CNC Shaping Machines 182 1,82,930 Leibherr Gear Cutting Machines 287 8,63,040 1508 13,10,927 Total Hours saved & Profit 1 st Year increased profit on 22 machines – INR 158 Lakh ROI > 200%
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