The document discusses HLL Lifecare Limited's efforts to automate the manual needle assembly process to increase productivity and reduce costs. It describes the existing manual process, issues with quality and output. An analysis identified opportunities to automate the process through a new machine. The proposed automated system is expected to increase output from 1000 to 7000 pieces per operator per shift, reduce manpower costs from Rs. 66 lakhs to Rs. 9 lakhs annually, and lower rejection rates. Challenges in implementing the new system around needle orientation, curing, siliconisation, vision systems and bonding are also summarized.

1. HLL Lifecare Limited
Innovating for Healthy Generations
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2. HLL Lifecare Limited, Akkulam Factory, Thiruvananthapuram
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4. Agenda for next 15 minutes
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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
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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
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10. How to use?
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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
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12. Existing production process
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14. WORK IMPROVEMENT TEAM
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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
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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
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18. Machine overview
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19. PROPOSED SYSTEM FOR PRODUCTIVITY
INCREASE
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20. PRODUCTIVITY TECHNIQUE
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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)
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22. PAYBACK PERIOD
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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
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24. Challenges faced while
implementing the new system
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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.
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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.
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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.
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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.
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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.
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30. Cap loading and wrong
orientation challenges
These problems were
overcome
with
the
introduction of suitable
detection and aligning
mechanisms.
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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.
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33. CONCLUSION
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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
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