1. SPECIMEN ENTRY FORM
Company Name: ABC Ltd.
Address of Unit / Plant:
Annual turnover of Unit/Plant (FY 2012-2013)
Rs.………………..Crore(s)/ annum
Name of principal author / project leader: XYZ
Designation : AAA
Phone/ Mobile :
Email *: xyz@abc.com
ABSTRACT OF CASE STUDY
(Before filling the form please read the guidelines for participation and rules governing the competition)
1.Title : Improving On Time Delivery (OTD) on FGOI & FG 03 by Productivity & Quality Improvement
2. a) Industry Sector: (please select from the below)
☐ Aerospace, ☐ Automotive & Auto components, ☐ Consumer Durables, ☐ Defence & Railway Units, ☐General Engineering,
☐ Machine Tools, ☐ R&D Organisations, ☐ Tool-rooms, ☐ Job Shops
Others (Please specify)…………………
b) Indicative Streams: (Please select from the below)
☐ Manufacturing System Re-design, ☐ Optimizing metal working process, ☐ Better asset utilization,
☐ Productivity through Quality improvement, Others (Please specify)…………………
3. a) Project implementation start and end date : 15.08.2013 to 11.11.2013
b) Is it in continued operation now (Yes/No) : Yes
4. Abstract (Not exceeding 200 words) :
 FG01 & FGO3 is our High Value & runner Valves items in our Elements Segment. The market & customer demand of these 2 products
has grown considerably and we were unable to cater to the customer in full on Daily basis, as productivity was low due to high Cycle
time and life of tool / insert is less. Our target was 100% OTD for this product but we were at 50% only.
 Our Core Machining Operations includes : Milling / Turning / VMC / Spot Facing / Drilling / DCB / CSK Tapping/ Brushing / Cleaning /
Inspection and send to Assembly
 We took this project for improving the OTD (Delivery) from 50% to 100% through Productivity enhancement in-turn improving our sales /
Meeting Demand & OEE of the machine from 55% to 85%
 A 6 member team was formed which includes persons from Production / Maintenance / Engineering / Quality and the task was taken on
the 4 key areas: Machine Cycle time Improvement (Target - FGO3: 82 mins to 41 Mins & FG01: 20 Mins to 10 Mins)/ Improving OEE (From
55% to 85% I Changeover Time improvement (240 Mins to 30 Mins) & Tool life improvement Reamer (From 50 pieces to 150 Pieces).
Major Improvement activities carried out :
1. Non Cutting time reduction during Machine Cycle ON (Reduction 4 Minutes)
2. Feed rate Improvement by 30% without affecting the quality
3. Introduction of Combination tools (reduction by 10 Minutes)
4. Component Loading & Unloading time reduced to Zero (by effectively utilizing second Pallet instead of one pallet (No loading &
unlading now when machine stops it’s Cycle)
5. Multi tip T Slot Cutter introduced (Imported). Cost impact overcome by reduction in Cycle time & Output increase.
5. What makes your project unique? Describe the innovation if any, in maximum 2 sentences.
We were very badly hit in supply due to very low On time delivery which was at 50% and we had a potential threat of our customers
switching to our competitors. Sales growth in this two products were almost stagnant for couple of years and also our Equipment
utilization was low when we run this product in line taking a hit at OEE also. During this project we have used our inputs & innovative
design while making the combination tools to suit our Model. This was validated and Pilot lots was taken and introduced and we are
now in the process of horizontally deploying to our other Products.
6. Give up to 4 important benefits from the project, in quantified terms.
i) On time Delivery improved from 50% to 100% (Maintained for 5 months and sustained)
ii) OEE improvement from 55% to 77%
iii) Cycle time reduction FGO3 — From 82 Mins to 55 Mins & FG01 — From 20 Mins to 13 Mins
iv) Tool life improvement from 50 nos to 140 nos & change overtime from 240 mins to 90 mins
v) Financial benefits: Manufacturing Cost per component improved from Rs 588 to Rs 390 (Reduction by Rs 198 per component for
FG03) & FG01 From Rs 142 to Rs 92.3 — Reduction by Rs 49.7)
1. Per year 2500 Nos — Total Cost avoidance is Rs 495000 for FG03
2. Per Year 6000 Nos - Total Cost avoidance is Rs 298200 for FG01
Company Authorization
We certify that the contents of the abstract are factually correct and we agree to depute our team to make a final presentation at the National
Productivity Summit (scheduled in August 2014) in case this entry is short listed for final evaluation of the award. Further we also certify that
this case study was not submitted for previous IMTMA-Siemens Productivity Championship Awards.
Name : Designation : Signature :
Date :
*All future communication will be sent to the principal author/project leader through email.