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Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
Jk files (india) limited
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Jk files (india) limited

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Jk files (india) limited

Jk files (india) limited

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  • 1. Redesign & Technology Infusion in “Engineering File” Manufacturing Process.
  • 2. About Us. JK Files (India) Limited, a subsidiary of Raymond Ltd is today the largest producer of files in the world. It has an impressive 32% global market share. With expertise of over 60 years in the business, JK Files (India) Limited has established over 1300 Distributors and dealers networks across globe. We export 50% of our products to over 100 countries including the technologically sophisticated markets of U.S., Canada and Europe. The plants located in India are Ratnagiri and Chiplun (all in Maharashtra), Pithampur (in Madhya Pradesh), Kolkata, Vapi (Gujarat) and Surabaya in Indonesia are all ISO 9001: 2008 certified. 2 Confidential
  • 3. Context & Background.  At JK Files, we aim at becoming the Largest and the Best manufacturer of Files in the world. And to achieve this we need to Build - World Class plants & best manufacturing practices to retain the Competitive edge & sustainable growth. To Build De-skilled & Robust Processes with High Capability & Reliability. Offer wider range of products with consistent Quality and on time Availability.  This can only be achieved by dedicatedly working on each fronts of the existing process & eliminating the wastes by using breakthrough technologies.  So we have targeted a massive redesign of our operations & the machineries. Since we are the leaders in manufacturing the files in the world, the technology is not easily available outside & we need to focus on each and every minute integrity of the process & design it such away that 3 Confidential we are miles away from our competitors.
  • 4. Drivers of the Project OPERATIONS RE-DESIGN • VALUE STREAM BASED LAYOUTS. • TO REDUCE THROUGHPUT TIME & WORKING CAPITAL TECHNOLOGY INFUSION • INTRODUCE NEW TECHNOLOGY • FOR BETTER PRODUCTIVITY, QUALITY CONSISTENCY , BETTER ENVIRONMENT & SAFETY PROCESS RE-ENGINEERING • ALTERNATE PROCESS /ELIMINATION/COMBINATION OF PROCESS. • TO REDUCE WASTAGE & CONVERSION COSTS 4 Confidential
  • 5. Value Stream Layouts 5 Confidential
  • 6. Value Stream Layouts Objectives: • To reduce material movement • The machines to rearrange in an organised manner (nearer to the next work station) enabling single piece flow • Indirect workmen engaged in material handling to reduce through reducing the TOUCHES • Reduce the working WIP Results/Benefits Achieved: • This Re-layouting activity was done across all the plants of JK Files leading to a Monthly cost saving of Rs. 26 Lac and the micro indicators are summarized as follows: • Productivity per Man-day was improved by 18 %. • WIP was reduced from 13.5 days to 7 days • Material Movement was reduced from 460m to 240m. • 31% Saving in Floor Space • Throughput reduced from 7 days to 2 days. 6 Confidential
  • 7. Value Stream layouts. Before After Chiplun . 7 Ratnagiri. Confidential
  • 8. Value Stream layouts. Before After Kolkata. 8 Pithampur. Confidential
  • 9. Results / Benefits Achieved. Indicators Ratnagiri Chiplun Kolkata Pithampur 9,782 m² 5,986 m² 7,800 m² 5,850 m² 8,645 m² 6,484 m² 4,048 m² 2,530 m² 750 m 245 m 450 m 365 m 410 m 205 m 224 m 130 m 16 Days 7 Days 14 Days 7 Days 14 Days 8 Days 10 Days 5 Days 8.4 Dz/Manday 11 Dz/Manday 7.5 Dz/Manday 8.5 Dz/Manday Saving in Floor Space Before Value Stream After Value Stream Distance Traveled by Material Before Value Stream After Value Stream WIP Before Value Stream After Value Stream Producivity per Manday Before Value Stream After Value Stream 6.2 Dz/Manday 6.8 Dz/Manday 6.8 Dz/Manday 7.8 Dz/Manday Quality Consistency Before Value Stream After Value Stream 4.5% 4.0% 4.5% 3.0% 4.0% 3.0% 3.6% 3.0% 7 Days 2 Days 7 Days 2 Days 7 Days 2 Days 7 Days 2 Days Throughput time Before Value Stream After Value Stream 9 Confidential
  • 10. Technology Infusion – Steel Hot Rolling Mill Upgradation 10 Confidential
  • 11. Steel Hot Rolling Mill (HRM) Upgradation. Objectives: • Steel Hot Rolling mill being the starting point of our internal supply chain, consistency in steel (output and quality) obtained from hot rolling determines the operational efficiency in file manufacturing . • In our previous process of hot rolling, we were losing substantial quantity of steel as scrap. • The capacity of our HRM is 600 MT per month. • So as to minimize the wastages we have adopted the latest techologies like Induction heating in Neutral atmosphere, Peeling etc. Results/Benefits Achieved: • An Annual Saving in Raw material of 384 MT (Rs. 173 Lac) is being achieved by minimizing the process scrap by Infusion of New Technology in the Manufacturing. The micro details of savings in discussed in the following slides. 11 Confidential
  • 12. Present Hot Steel Rolling Process. Semis Heating in oil fired furnace Manual Gas Cutting Stock / Dispatch to plants 12 Shearing in multiple mood lengths Section Rolling Confidential
  • 13. Technology Infusion in Hot Rolling Process. Semis Heating in Heating in oil Induction fired furnace furnace Circular Saw Manual Cutting Gas Cutting Stock / Dispatch to plants 13 Shearing in multiple mood lengths Section Rolling Confidential
  • 14. Benefits BILLET CUTTING –CIRCULAR SAW     Consistency in the size of billets for input to Induction heating Consistency in the length of rolled sections Faster throughput Perpendicular cutting of billets reducing material loss INDUCTION BILLET HEATING      Consistency of Heating temperature resulting in Dimensional consistency No over-heating of billets. Uniform temperature at the surface and the core Reduction in the De-carb levels Reduction in Scale and Burning losses Automatic Accept-Reject mechanism 14 Confidential
  • 15. Technology Infusion – Yield Improvement by Hot Point Rolling for Taper files. 15 Confidential
  • 16. Hot Point Rolling for Taper Files Objectives:  For Triangular files we need to have 1/3rd of its length in a taper form. Taper length W Body length  Previously this was achieved by Grinding process.  Avg. 237 MT of material is lost in Grinding during point preparation process. (which is not recoverable)  Poor Dimensional consistency of files.  Low productivity. Results/Benefits Achieved: • An Annual Saving of Raw material by 237 MT is being achieved by elimination of the Grinding process. The micro details of savings in discussed in the following slides. 16 Confidential
  • 17. Hot Point Rolling for Taper Files 17 Confidential
  • 18. Hot Point Rolling for Taper Files Stage I Stage II 18 Confidential
  • 19. Technology Infusion – New Generation File Grinding machine. 19 Confidential
  • 20. New Generation Files Grinding Machine Objectives: • Grinding being the operation for Surface preparation for Teeth Cutting, which requires good surface finish & accuracy to control the quality of cut being produced. • In the present Grinding machine the material removal rate cannot be controlled in Microns, it is only designed for heavy material removal. • Today we are using a Magnesite bonded grinding wheel which is going obsolete day by day. To upgrade the present technology we need to switch over to vitrified bonded grinding wheel. Results/Benefits Achieved: • An Annual Saving of Rs. 32 Lac is achieved with the new design of the machine & use of Vitried bond grinding wheel. The micro details of savings in discussed in the following slides. 20 Confidential
  • 21. Conventional Grinding Machine. New Generation Grinding Machine. Drawback in Current Benefits:  Process: 3 times Productivity. High Energy Consumption. Power requirement reduced by 50 % Low Productivity & Machine  Use of Low Power High Utilization. Electrical Motor. Efficiency Low Safety. Use of Vitrified Bond Grinding Wheel. Constrain in Grinding wheel  Multi Station Grinding with avalibility. PLC control Feed to improve the productivity. No precise control.  Deskilled Process with Auto Dressing & Compensation.  Higher Productivity with Auto Indexing. 21 Confidential
  • 22. New Generation Files Grinding Machine 22 Confidential
  • 23. Technology Infusion – New Generation Teeth Cutting Machine. 23 Confidential
  • 24. New Generation File Teeth Cutting Transfer Line. Objectives: • We were using conventional individual cutting machine for cutting operation on different sides of the file, after each operation the files are manually transferred to the next operation resulting in higher foot print & WIP. Following were the major concerns in the earlier process : • Low Productivity & Low Machine Utilization. • Skill is required to set the machine properly. • Age old design. • High consumption of lubricating oil & spare parts. Results/Benefits Achieved: • Productivity improvement by 6 times leading to an annual Saving of Rs. 39 Lac with the new design of the machine. The micro details of savings in discussed in the following slides. 24 Confidential
  • 25. Conventional NewTeeth Cutting File Teeth Cutting . Prototype of File Concept for Machine. Drawbacks in Current Process:   Monotonous work cycle.  High Skill Requirement for Quality output.  Complicated Setting parameters.  25 Low Productivity. High Maintenance required. Confidential
  • 26. New Generation File Teeth Cutting Transfer Line. Benefits:     Multi-Machine operation, Productivity Improvement by 6 times De-skilling of operation Consistency in Quality 26 Confidential
  • 27. New Generation File Teeth Cutting Transfer Line. 27 Confidential
  • 28. Technology Infusion – Robotic Hardening. 28 Confidential
  • 29. Robotic Hardening. Objectives: • Previously we were using conventional MANUAL hardening process of the files, where each & every file is hardened manually one by which requires a lot of skill for achieving the hardness & straightness of the files. Due to this below were major concerns in the manual process: • Low Productivity & Low furnace Utilization. • Hazardous work Environment. (continuous exposure to temp. of appx. 600 to 700° C) • Poor Quality consistency. • Monotonous work cycle. Results/Benefits Achieved: • Productivity improvement by 5 times. • An Annual Saving of Rs. 125 Lac is being achieved with the introduction of Robots in Hardening. 29 Confidential
  • 30. Manual Hardening. Robotic Hardening. Drawbacks in Current Benefits: Process:  Manpower productivity  Improvement by 5 times. Low Productivity.  Monotonous work cycle.  Low manual interface.  Poor consistency &  AccuracyConsistency. Quality  Hazard free process.  Hazardous work environment. 30 Confidential
  • 31. Redesign of Packaging. – Single Piece Packing. 31 Confidential
  • 32. Single Piece Laminate Packing. Benefits:  Brand take away by the end user.  Difficult to counterfeit & Temper proof.  Longer shelf life. New Packaging inline with new merchandise for modern trade Before After  Eye-catching display 32 Confidential
  • 33. Alternate Power Source – Solar Rooftop PV cells. 33 Confidential
  • 34. Solar power by Roof top PV cells of 60 kW. Solar Power: JK Files (india) Ltd, Thane Office  Generation of 69,000 units annually.  Savings of Rs. 8.8 Lac per annum  48 MT of CO2 is avoided.  Life of the system – 25 Years. 34 Confidential
  • 35. 35 Confidential

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