a project on ekc innovations
TRANSCRIPT
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 1/21
A project on
INNOVATIONSEKC Ltd.
By,
Nishad Khamkar
Sonia Mirajkar
Shashank Palande
Shailaja Patil
Ashwini Pokharkar
Aseem Halani
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 2/21
About EKC
• Established in 1978
• 8 Manufacturing units around the globe.
• Restructured to public limited in 2001.
• Capacity to produce 500000 cylinders around the
globe.
• All major markets covered.
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 3/21
Major competitors
• Rama cylinders
•
Bharat forge
• CPI industries USA
• Hi Tech industries Japan
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 4/21
Photos of some plants
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 5/21
Products
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 6/21
Products
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 7/21
Products
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 8/21
Products
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 9/21
Kaizen – idea generation.
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 10/21
Kaizen Idea Sheet
Shop: Spinning Section M/C: Pipe Cutting I / II /III m/cs Reg. No: 004 / 2010
Kaizen Theme :- Elimination of
Unwanted Running of Hyd. Power pack.
Kaizen Idea : Providing Automatic Timer to cut off powerwhile M/c. is running for Idle .
Problem/Present Status: Countermeasure:
Kaizen Finish
15/6/10Kaizen Start
10% SavingTarget
To be calculateBench Mark
Team Members :-
Mr. Amol Pawar , Mr. Jadhav ,
Mr. V Sharma, Mr. Umesh Meher
Team Leader : M H Thakur Benefits:-
1) Mistake proofing foravoiding loss due toOperators oversight.2) Energy saving in safe
practices
Analysis: Unnecessary Running of elect.
Motor of Hyd. Power packResult:-
1 )Reduction in Energy consumptions2 )Safe running of machine .3) Optimum use of machine elements .4 ) Oil temp. will be in controlled zone ,
less oil leakages
* E xact calculations are to be done forsaving
Activity KK JH QM PM SH OTPM DM ET
Result Area P Q C D S M
Defect Type
C
No
M/C T/date Res. Status
1 PC1 15/7/10
Mr.Amol
2 PC2 15/7/10
Mr.Amol
3 PC3 15/7/10
Mr.Amol
This is applicable for All
Conventional Machines
Providing Automatic timer /
Relay to cut / switch off
electrical motor ( 2 HP),
while Machine is not in Use
And Hyd. Power pack is on
Machine is running and
there is not having
mistake proofing for
switching off the power
when running in idlecondition . Unnecessary
Running of elect. Motor of
Hyd. Power pack.
Why –Why Analysis
Continuous Running Elect. Motor .
M/cs. Running continuouslywithout stopping Hyd. Motor.
Forget / Fail to switchOff in idle /no load condition.
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 11/21
Why – why analysis.
My car will not start.
1. Why? - The battery is dead
2. Why? - The alternator is not functioning.
3. Why? - The alternator belt has broken.
4. Why? - The alternator belt was well beyond its useful service life
and has never been replaced.
5. Why? - I have not been maintaining my car according to the
recommended service schedule.
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 12/21
OLD LAYOUT
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 13/21
Benefits of proper layout
• Plays a major role in cost reduction
• Time reduction
• Continuous flow
• Maximum utilization of available space
• Flexibility as per predicted future demand
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 14/21
New Layout
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 15/21
Achievements through layout changes
• Smooth uninterrupted flow of cylinders
• Increase in productivity
• Maximum utilization of machinery
• Cost reduction from 360 to 210 per cylinder
• Flexibility in producing any size of cylinders
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 16/21
Spinning and furnace
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 17/21
Before change
PRODUCTION Capacity Achieved Variance
Causes of negative variances Previous Month
Major loss of hours Total
Set-
up
B/d Any
other N/L
No plan,
N/M
Lost
Hours
Productio
n
Qty
Lost
Hours
Spinning
m/c 1 11000 4280 6720 72.2 224.5 81.25 378 9690 181.25
m/c 2 12000 6700 5300 81 80.5 129.25 290.75 8549 239.75
m/c 3 8000 5404 2596 85.2 44.5 201 330.75 5156 259.5
m/c 4 12000 7083 4917 91 85.2 89.2 265.5 7051 281.75
23467 19533 30446
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 18/21
After change
PRODUCTION Capacity Achieved Variance
Causes of negative variances Previous Month
Major loss of hours Total
Set-
up
B/d Any
other N/L
No plan,
N/M
Lost
Hours
Prodn
Qty
Lost
Hours
Spinning
m/c 1 15000 9015 5985 62.2 174.5 11.25 248 8546 235.75
m/c 2 15000 9874 5126 62.7 125.2 20.25 208.2 8916 222.25
m/c 3 8000 328 7672 55.5 69.25 320.5 445.2 240 473.75
m/c 4 15000 6237 8763 124 139.2 61 324.2 6507 249.5
m/c 5 15000 8394 6606 95.2 54.25 73.25 222.7 9809 181.75
33848 34018
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 19/21
Process Flow
• Tube cutting
• Bottom forming
• Neck forming operation
• Heat treatment
• Neck machining
• Internal cleaning
• Hydraulic test
• Tightness test
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 20/21
7/29/2019 A Project on Ekc Innovations
http://slidepdf.com/reader/full/a-project-on-ekc-innovations 21/21
Innovations in processes
• Capable to develop pull type of production
• Line balancing
• Transportation
– Lead time reduction
– Automation
• Elimination of unwanted processes
• Continues flow (no WIP)
• Ergonomics achieved