Hll lifecare ltd.


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    1. 1. HLL Lifecare Limited Innovating for Healthy Generations Time for Profit
    2. 2. HLL Lifecare Limited, Akkulam Factory, Thiruvananthapuram Time for Profit
    3. 3. Time for Profit
    4. 4. Agenda for next 15 minutes Time for Profit
    5. 5. Time for Profit
    6. 6. HLL business segments Contraceptive Products Condoms Cu -T OCP ECP Hospital Products Blood bags Hydrocephalus Shunt Sutures Rapid test kit Pharmaceutical Products Gynecological medicines Services Infrastructure Consultancy Iron Supplements Diagnostics Antibiotics PCD Oral Re-hydration Salts Life Spring Hospitals Time for Profit
    7. 7. Time for Profit
    8. 8. Time for Profit
    9. 9. Needle assembly  Most important part of the blood bag system; the only one part which comes in direct contact with the donor.  It has 3 parts:  Needle holder  Stainless steel 16 / 17 G needle  Protective cover Time for Profit
    10. 10. How to use? Time for Profit
    11. 11. Current scenario  Annual requirement: 9 million pieces  Assembly process: Manual  Output: 1000 pcs / person / shift  Quality level: Satisfactory  Overall process rejection: 3.2%  Total manpower cost: Rs. 66.6 lacs / annum Time for Profit
    12. 12. Existing production process Time for Profit
    13. 13. Time for Profit
    14. 14. WORK IMPROVEMENT TEAM Time for Profit
    15. 15. ISHIKAWA FISH BONE DIAGRAM CAUSE Non concentricity of fixtures Old technology machine Low speed operations Poor reliability Operator dependant Dimensional defects of incoming materials Flash on moulded components EFFECT Manual bevel orientation No provision for pull test No provision for marking NEEDLE ASSEMBLY – LESS OUTPUT, HIGH COST, HIGH REJECTION Increased product handling time Higher process rejection Improper handling of materials Higher manpower requirement Excess gate projection on moulded components Lack of training Carelessness Human fatigue Time for Profit
    16. 16. Time for Profit
    17. 17.  New system with higher productivity required, to meet growing production demand  Operating cost per piece to be reduced  Process rejections, due to human errors to be eliminated  In process inspection systems to be strengthened to ensure the consistency in product quality  Fatigue of operators to be minimized  SOLUTION: Automation of the needle assembly operations Time for Profit
    18. 18. Machine overview Time for Profit
    20. 20. PRODUCTIVITY TECHNIQUE Time for Profit
    21. 21. Benefits / advantages on implementation of new system 66.06 70 60 50 40 30 Man power required 30 20 10 4 9.44 0 Old system New system Manpower cost/ annum (in lakh rupees) Time for Profit
    22. 22. PAYBACK PERIOD Time for Profit
    23. 23. Benefits of new system for production of 9 million pieces SL NO. ASPECT EARLIER SYSTEM NEW SYSTEM 1 Output 1000 per person 7000 per person 2 Manpower (2 shift operation) 30 per day 4 per day 3 Manpower cost per annum Rs. 66.06 lakhs Rs. 9.44 lakhs 4 Rejection percentage 3.2% 1% to 1.5% 5 Mode of operation Manual Fully Automatic 6 Check for strength bonding Not present Present 7 Online marking to indicate bevel Not present position Present 8 Check for bevel marking presence. Present 9 Leak check Present (not much Present & effective effective) 10 Fatigue of operator Yes needle orientation, Not present No Time for Profit
    24. 24. Challenges faced while implementing the new system Time for Profit
    25. 25. Needle bevel orientation The needle bevel is to be oriented along the flat side of the needle holder. Initially, the job was performed using a vision system and servomechanism to do the orientation. This system lacked consistency. Later on, the system was replaced with a mechanical, much simpler and reliable system. Time for Profit
    26. 26. UV curing As per manual trial performance, 1.5 sec was sufficient to cure the adhesive (which bonds the needle with the holder). But, in real situation, it was not achievable with the original design concept. It was overcome by the introduction of additional UV curing system and changed four-probe system to two-probe system. The optical fiber probe angle and proximity to the curing part were optimized and thus achieved the required level of curing within 2.5 seconds. Time for Profit
    27. 27. Siliconisation According to the original design, the siliconisation operation was to be done using a wiping mechanism, but it lacked consistency and uniformity and also, the maintenance of the system was difficult. It was overcome by introducing a dipping mechanism, where the part is picked up, tilted to 180o, dipped into the silicon tank and placed back to the fixture. Time for Profit
    28. 28. Vision system Providing of proper backgrounds, back lights / front lights in order to get clear and consistent image acquisition. Defining of the pixel limits within which the product is to be accepted / rejected. Elimination of chances for distortion of captured images due to machine movements. Time for Profit
    29. 29. Gluing on holder According to initial design, adhesive was to be dispensed onto the component in a vertical position. But, the glue distribution was not uniform and it affected the cover bonding. Finally, the design was changed to apply the adhesive on the needle holder in a horizontal position (after tilting to 900 by a tilting mechanism). After this, the component had to be placed back properly onto the fixture. The complete operation has to be performed within the time frame of 3.5 sec, so as to match the cycle time. Time for Profit
    30. 30. Cap loading and wrong orientation challenges These problems were overcome with the introduction of suitable detection and aligning mechanisms. Time for Profit
    31. 31. Curing of cover bonding operation It was originally designed to employ UV curing system having 4- probe system. Due to the transparency issues of the outer PP cover, the UV penetration consistency was not obtained and cover bonding was not adequate. Then, the whole system was changed to a UV curing chamber system. The design of the chamber was a challenge to suit with the rotary table and minimize the UV light exposure. Time for Profit
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    33. 33. CONCLUSION Time for Profit
    34. 34. “Productivity is never an accident. It is always the result of a commitment to excellence, intelligent planning, and focused effort.” - Paul J. Meyer Paul J. Meyer, Founder of ‘Success Motivation Institute’, 1960 Thank You Do visit : www.lifecarehll.com Time for Profit
    35. 35. Time for Profit