Strategic Cost Reduction Initiative

( Pilot engagement)

Manufacturing Excellence

“Welding consumable cost reduction”

Methodology : SIX SIGMA (D.M.A.I.C)

Gap Analysis - Welding Consumable reduction

399

120

67

84

112

16

0

100

200

300

400

500

600

SavingTargetedper M/C

Equivalent

Reducedsaving in

Wire

Reducedsaving in

Gas

Reducedsaving in

Disc

Pendingsaving in

Spare

Saving inGas

Va

lue

pe

r M

ac

hin

e

In Analysis phase no improvement action plans are generated. In

Analysis phase no improvement action plans are generated.

In measure phase data shows there is no scope in project

Potential Saving to be confirmedAction Plan to be Given

Potential Saving - Confirmed

Target Annual Savings @ 19000 53LSaving for year 2008 @ 11457 26.8 L

Target Achieved @ 19000 7.3 LTarget Achieved in 2008 @9607 3.6 L

* Assuming 30% supply from JCBM

Welding consumable cost reductionWelding consumable cost reductionProject Theme: Reduce the consumption of welding consumables by reducing the wastage in usage.

Summary :

Consumables Project ThemeInitial Saving

(Rs) / Machine Equ

Target Saving (Rs) / Machine Equ

Achieved Saving (Rs) / Machine Equ

Points out Way Forward

Eliminate the breakage of spool, minimizing the left over of wire in spool

120 0In Analysis phase no improvement action plans (Vital Few X's) are generated.

Involve all possible people who have any relevant knowledge.

Reduce wire deposition amount.

* *Separate project is to done to understand the source of variation in wire deposition.

Six sigma project is under taken to reduce the variation in wire deposition

Implement SOP for filling gas to storage tank .

67 0In Measure phase data shown that there is no scope in the project.

Install auto controller of gas flow

Reduce the outlet pressure of gas flow

Repair the source of leakage of gas

Torch sparesImplement the system in store to issue the spares.

84 0 System is partially implemented. The project is in progress.

Buffer DiscOptimize the usage of buffer disc

16 0In Analysis phase no improvement action plans (Vital Few X's) are generated.

Involve all possible people who have any relevant knowledge.

399 55

55

Following activites are conducted >Brazing of leakage points in main gas line.>Tightening/ Replacing of all loses/damaged valves. >Replacing M.S Tee Joint with Brass Tee Joint.>Replacing damaged hoses with new one.>Replacing joint hoses with

The project is in progress.

83

Total saving / Machine Eqv ( Rs)

112

Wire

Argon Gas

316

110

Reduction In wastage of torch Reduction In wastage of torch spares spares and buffer discand buffer disc

Welding consumable issue slipDate………..

Name…………………………………………………………………

Area………………………………………………………………….

Item…………………………………………………………………

Quantity……………………………………

Signature………………………

Spares of torches, buffer disc and liner were wasted in shop floor due to underutilization and spillage. Usage of consumables were not monitored and controlled.

Issuing of consumables through “Welding consumable issue slip” is implemented in the shop floor to bring the accountability of supervisor and operator in over usage of consumables. Through this system it is easy to monitor and take corrective action to reduce the wastage of consumables.

Reduction In wastage of wireReduction In wastage of wire

Weight Weight Weight Weight Weight Weight

7.7 8.6 7 10.9 3.9 1.88.8 8.6 6.4 10.7 3.85 1.86.9 8.9 6.1 10.6 4.05 2.16.6 9.3 7.1 10.8 3.9 2.1

10.3 9.9 6.7 10 4 2.39.9 9.5 5.8 10.1 2.48.8

8.4 9.1 6.5 10.5 3.9 2.1

Analysis of weight consumed per component

Dip

per

Boo

m

Load

er T

ower

Mai

n Fr

ame

Leg

Rea

r Fr

ame

Wastage due to variation in the wire deposition from components to components

Wastage due to poor house keeping of store

Wastage due to breakage of wire spool. Wastage due to leftover of wire in the spool

Reduction In wastage of Argon GasReduction In wastage of Argon Gas

Gas Leakages arrested byGas Leakages arrested by

• Brazing of leakage points in main gas line.

• Tightening/ Replacing of all loses/damaged valves.

• Replacing M.S Tee Joint with Brass Tee Joint.

• Replacing damaged hoses with new one.

• Replacing joint hoses with single one.

• Installing separate main gas line for Loader Tower Robotic Welding.

Sources of gas leakageSources of gas leakage

Leakage from main line

Leakage from hoses

Reduction In wastage of Argon GasReduction In wastage of Argon Gas

To Reduce Surges LossesTo Reduce Surges Losses

• Reduces the Surging losses during Welding and Tacking

To identify Leakage in hoses

Eliminate manual Interference in increasing

Auto Flow Controller