The document outlines various maintenance improvement and cost saving best practices implemented at the Amber Pune plant. These include installing water cooling for bending machines to reduce machine tripping, reconditioning the RO plant and fire hydrant, improving safety of the press brake and installing a new compressed with increased capacity. Other initiatives involved standardizing pipe color coding, improving shop floor fans and ductwork, installing LED lights to reduce electricity costs and reconditioning the maintenance office. The best practices improved safety, productivity, quality and reduced costs.

1. Maintenance : Improvements list for 15-16
Amber Pune Unit
Process owner : Amrit Raj Jaiswal & Team

2. Best Practice : Water cooling arrangement for Bending & TPP
 Result Details Issue Details
 Process
 Provision for heat exchangers with
cooling tower arrangement for
Armstrong bending m/c & TPP m/c.
 M/c tripping problem due to
heating reduced to zero.
 Oil cooling proper now
 M/c tripping due to heat up
 O-ring damage problem.
 Bending & TPP
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
NOT EXIST
EARLIER

3. Best Practice : R.O plant re-conditioning
 Result Details Issue Details
 Process
 Cover boxes provided for all motors
 Painting activity done
 Safety Improvement & 2’s
Improvement
 Poor 5 ‘S’ & no equipment safety
during rainy & dust
 R.O Plant
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation

4. Best Practice : Re-conditioning of main fire hydrant
 Result Details Issue Details
 Process
 Cover boxes provided for all motors
 Painting activity done
 Safety Improvement & 2’s
Improvement
 Poor 5 ‘S’ & no equipment safety
during rainy & dust
 Main fire hydrant
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation

5. Best Practice : Press brake Safety improvement
 Result Details Issue Details
 Process
 Hand operated switch with
protected cover
 Safety Improvement Unsafe working condition due to
Foot operated switch , major cause
of accident
 Press brake operating
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation

6. Best Practice : Cost saving by In-house installation of new ITW Gama gun
 Result Details Issue Details
 Process
 Proposed cost - Rs. 74000 (quote)
 Actual In-house cost - Rs. 24000
 CI - Rs. 50000 New gun Installation cost higher
 Auto Gun booth
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
Before After
74 K
24 K
Installation cost In Rs.
 CI Benefit: Rs. 50 k
 CI Approved By :
Accounts GM (O) Plant Head

7. Best Practice : Installation of New compressor with capacity enhancement
 Result Details Issue Details
 Process
 New compressor installation In-
house with added capacity
 Capacity enhancement Lesser capacity of compressor with
added business volumes
 Compressor
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
NOT EXIST
EARLIER

8. Best Practice : Rack provision for PU sheet storage ( Trolley cover)
 Result Details Issue Details
 Process
 Rack designed & mfg. , stored near
trolley rectification area
 5 ‘S’ improvement Plastic corrugated sheets keeping
on floor, poor 5 ‘S’
 PU Sheet Storege
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation

9. Best Practice : VM on Motor for lubrication & rotation point.
 Result Details Issue Details
 Process
 VM done by using vinyl sticker on
motors & m/c
 VM improvement No identification mark for motor
rotation & lubrication point
 Motor preventive measures
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation

10. Best Practice : Cutter m/c mobile trolley with safety
 Result Details Issue Details
 Process
 Mobile trolley in-house made for
operator’s safety & mobility
 Safety improvement Unsafe working condition for
operator’ during pipe cutting
 Fabrication work
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation

11. Best Practice : Re-conditioning of dispatch ramp hyd. powerpack
 Result Details Issue Details
 Process
 Dispatch Ramp motor cover to
avoid water entry during rainy
season & dust prevention & 2’s
 Safety improvement & 2’s No motor safety provision for hyd.
Motor power pack , also poor 2 ‘S’
 Dispatch Ramp
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation

12. Best Practice : Material rack provision & VM For fabrication material
 Result Details Issue Details
 Process
 New material rack made
in-house with VM sticker on
the rack
 VM & 2’s improvement No proper identification & space for
fabrication material , poor 5 ‘S’
 Fabrication area
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
NOT EXIST
EARLIER

13. Best Practice : Transformer area re-conditioning
 Result Details Issue Details
 Process
 Cleanliness & painting activity with
VM display
 Utility
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
NOT EXIST
EARLIER
 Safety & 5 ‘S’ improvement Unsafe working condition & poor 5
‘S’ at transformer area

14. Best Practice : CI in localization in purchase of Vibration motor
 Result Details Issue Details
 Process
 More efficient vibration motor
purchasing
 Local vendor developed for
vibration motor
 CI – By Rs. 92 K
 Supplier localization leads to
easy for spare mgt.
 Powder Choking Problem due to
vibration motor life ends
 Imported motor ( ITW Gama) cost
too high
Powder recovery unit
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
Before After
Purchase cost In Rs.
1.04 L
0.12 L
 CI Benefit: Rs. 92 k
 CI Approved By :
Accounts GM (O) Plant Head

15. Best Practice : Installation of a new Desiccant dryer for capacity enhancement
 Result Details Issue Details
 Process
 New desiccant dryer installation
with double capacity
 Dew point with in (-40 )
 Dry Air capacity increase
 Quality improvement
 Lesser capacity of dry air in paint
shop dept.
 Continuous quality issues related
to higher dew point ,reqd. (-40)
actual (-30)
Powder coating utility
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
Before After
Dry Air capacity
90 cfm
200cfm

16. Best Practice : Air set up time reduction during power cut
 Result Details Issue Details
 Process
 Installed an accumulator in series
with input of a desiccant dryer for air
storage
 During power cut air change
over time reduced
 During power cut , air pressure
lower due to no air accumulation ,
loss of air
 Powder coating utility
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
Before After
Air change over time
10 min
Zero
NOT
EXIST
EARLIER

17. Best Practice : Welding line re-layout with Jogging track creation
 Result Details Issue Details
 Process
 All water , Air & Electrical lines
installed from roof side , line re-layout
done
 Safety & VM improvement
Jogging track creation from
wall side
 Welding area water line /air line &
cabling not as per industrial norms ,
All line are on floor , unsafe
 Weld shop layout
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation

18. Best Practice : Fabrication Shed re-conditioning
 Result Details Issue Details
 Process
 Re-conditioning done by wall
painting, providing display board &
switch covers
 5’S & VM improvement Poor 5’S in fabrication shed
 Fabrication shed
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation

19. Best Practice : Dispatch ramp Elect panel safety improvement
 Result Details Issue Details
 Process
 Emergency s/w provided
 Switch board re-conditioning
 Safety improvement Elect switches in broken condition ,
unsafe
 Dispatch ramp working panel
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation

20. Best Practice : Re-conditioning of shop floor fans
 Result Details Issue Details
 Process
 Fan guards cleanliness and
powder coating
 Equipment efficiency improved Shop floor wall-mounted fans
condition poor , dust , color fade
 Shop floor Infra
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation

21. Best Practice : Transfer Pipes standardization – Color coding
 Result Details Issue Details
 Process
 Pipe line color coding as per
Industry standardization
 VM & safety improvement
 As per Std. coding :
Air – Blue
Water – Green
Gas – Yellow
Fire – Red
 All transfer pipelines no
standardization / identification for
water, air & gas pipes
 Shop floor Infra
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation

22. Best Practice : LT cable duct Fabricated covers provision
 Result Details Issue Details
 Process
Duct covering with fabricated
structure
 Safety & VM improvement LT cable duct in open condition ,
unsafe
 LT cable routing at outside area
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation

23. Best Practice : PCO & WDO ducts Re-conditioning
 Result Details Issue Details
 Process
 Internal duct and Damper broken
and worn out need to be repaired
 Productivity & Quality
improvement
 Improper temperature variation
observed at PCO & WDO due to duct
open & damper broken
 Paint shop Area
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation

24. Best Practice : Paint shop motors autonomous maintenance
 Result Details Issue Details
 Process
Complete overhauling with varnish
,bearing check ,fan check & coloring
 Autonomous Maintenance Motor Preventive Maint. Not as
per TPM std.
 Motor PM
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation

25. Best Practice : Elect wiring /cables dressing in tray
 Result Details Issue Details
 Process
 All open cable routed by providing
cable tray
 Elect cables in paint shop are in
open condition , Unsafe working
 Paint shop Infra
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
 Safety/ VM improvement

26. Best Practice : Removal of excess cables & proper dressing
 Result Details Issue Details
 Process
 All excess cable removed and
proper dressing done
Unwanted open cables in paint
shop area causes unsafe working
 Paint shop Infra
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
 VM Improvement

27. Best Practice : Safety guard on blower shaft
 Result Details Issue Details
 Process
 Safety cover provided for safe
operation
 Unsafe working condition at PT
line blower
 Paint shop Infra
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
 Safety improvement

28. Best Practice : Water level indication for low/high level
 Result Details Issue Details
 Process
 Installation of Level indicator panel
to sense water level & avoid water
wastage
 No level indicator t for identification
of low/high level of water in the tank
 Paint shop Infra
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
 VM improvement

29. Best Practice : Cable dressing at Conference hall
 Result Details Issue Details
 Process
 All excess cable removed properly
dressed & covered
 Unwanted open cables in
Conference room
 Conference room
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
 Safety & Equipment Efficiency

30. TPM
PT line – Cleaning with meaning
v v vv
v v

31. Best Practice : Repairing of Solar street light
 Result Details Issue Details
 Process
 Repairing activity carried out & 6
nos. of lights repaired
 Solar street light not in working
condition
 Plant
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
Energy efficiency
Before After
Power cost redn.
 CI Benefit: Rs. 09 k
 CI Approved By :
Accounts GM (O) Plant Head

32. Best Practice : Closed area for DM & ETP line
 Result Details Issue Details
 Process
 Fabricated shed installation , which
protect instruments
 ETP line is open condition , no
infra safety
 Paint shop Infra
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
 Basic infrastructure safety

33. Best Practice : Re-conditioning of STP
 Result Details Issue Details
 Process
 Re-conditioning with added
capacity of STP plant
 Capacity less as per current
requirement , STP water not 100 %
usages
 General Infra
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
 Basic infrastructure improvement
Capacity added by 30 %

34. Best Practice : Elect power conservation activity
 Result Details Issue Details
 Process
 Removal of all CFL cubes by LED
cubes of 30 W /Pc.
 High power consumption of typical
CFL cubes (72W/Pc.)
 Office Area
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
Energy efficiency – Total 15 no. of
cubes changed.
Before After
Power cost reduction
 CI Benefit: Avg. Rs. 34 k /Year
 CI Approved By :
Accounts GM (O) Plant Head

35. Best Practice : Elect power conservation activity
 Result Details Issue Details
 Process
 Removal of all CFL cubes by LED
cubes of 30 W /Pc.
 Total 15 no. of cubes changed.
 High power consumption of typical
CFL cubes (72W/Pc.)
 Office Area
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
Energy efficiency
Before After
Cost Saving
Before After
LUX level
600
1000
 CI Benefit: Avg. Rs. 32 k /Year
 CI Approved By :
Accounts GM (O) Plant Head

36. Best Practice : Elect power conservation activity
 Result Details Issue Details
 Process
 Removal of all CFL cubes by LED
cubes of 30 W /Pc.
– Total 15 no. of cubes changed.
 High power consumption of typical
CFL cubes (72W/Pc.)
 Office Area
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
Energy efficiency
Before After
Cost Saving
LUX level
 CI Benefit: Avg. Rs. 32 k /Year
 CI Approved By :
Accounts GM (O) Plant Head
Before After
600
1000

37. Best Practice : Maint office renovation
 Result Details Issue Details
 Process
 Removal of Red Tag components
Re-conditioning
 Maint dept poor 5 ‘S’
 Office Area
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
Basic infrastructure improvement

38. Best Practice : TPM activity board
 Result Details Issue Details
 Process
 Design & display board on shop
floor
 No TPM monitoring board display
at shop floor
 Shop floor
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
TPM activity
NOT EXIST
EARLIER

39. Best Practice : Greece & Oil storage room provision
 Result Details Issue Details
 Process
 New location at Compressor room, No storage area for Grease & Oil
storage
 Maint stores
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
Basic infrastructure.
NOT EXIST
EARLIER

40. Best Practice : All utility equipment board display board
 Result Details Issue Details
 Process
 Design of board & implementation Utility board display not available
 Office Area
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
 FI 05 activity
 VM improvement
NOT EXIST
EARLIER

41. Best Practice : Facility provision for Nano coating booth
 Result Details Issue Details
Design & in-house fabrication
activity
 No provision for fumes extraction in
Nano coating area
Operator unsafe activity
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
 Cost saving by In-house red tag
material using
Operator safety ensured
NOT EXIST
EARLIER

42. Best Practice : Design of Enclosure in PC panel
 Result Details Issue Details
 Design of enclosure &
implementation with Air conditioner
working
Reduction in maint time
 All wiring & panels are in open
condition, unsafe activity
 Dust & temp. affects on panel
working, higher down time
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
 Equipment safety
 Lower maint B/down time

43. Best Practice : Facility provision at ETP plant
 Result Details Issue Details
 In-house fabricated ladder
installation with safe working in
inspection at ETP plant
 No ladder in ETP plant, unsafe to
operator while working
Initial Status Breakthrough Idea Initial Status
Leadership Through Innovation
 Equipment Efficiency
 Safety Improvement
NOT EXIST
EARLIER

44. Best Practice : Re-design in sheet feeding process
Extra roller provided to hold the sheet
Issue Improvement Result
 Extra Roller provided which hold the
sheet during feeding
 In perforation Mc higher rejection due
to folding of sheet in working
Leadership Through Innovation
Mc down time reduction due to
wrong sheet feeding
Before After
90
Avg. Mc BD time in min/day
Zero

45. Best Practice : Safety activity at HT area
Entrance gate reconditioning
Issue Improvement Result
 Repairing of gate with in-house facility HT area unsafe due to entrance gate
not working
 Safety Improvement
Leadership Through Innovation

46. Best Practice : 110 T hydra. press BD time reduction
Issue Improvement Result
 Re-design entire system with new
hardware locally available
 Continuous BD of mc due to relay
design not suites in mass production ,
also spares not locally available
Old system replaced with New hardware system
Leadership Through Innovation
 BD time reduction
Before After
18
Avg. Mc BD hrs/month
Zero

47. Best Practice : Energy conservation in press shop
Replacement of MHSV lamp by LED for power cost saving
Issue Improvement Result
Power cost per Year
[Unit : INR ]
 Installation of LED lights to replace the
conventional 250W MHSV lamp , replacing
08 nos. MHSV lamp to 4 nos. of LED lamps
with LUX level as per std.
Before After
49920
8986
LUX Level
[Unit : Lumen ]
Before After
210
300
 Higher power cost with low LUX level
Leadership Through Innovation

48. Best Practices : Exhaust system design at Nano coating line
Issue Improvement Result
 Design of exhaust system as per process
std. & safety measures
 No provision of exhaust Chimney in
Nano coating line , unsafe to operator
Leadership Through Innovation
 Safety improvement
NOT EXIST
EARLIER
Design of Exhaust system with safety measures

49. Best Practices : Energy conservation at Street light working
Issue Improvement Result
 Timer fitted which automatically OFF the
street light s & avoid power misusages
 Street light getting ON during day if
person forgotten to OFF
Leadership Through Innovation
 Power saving
Design of Exhaust system with safety measures

50. Best Practices : Water wastages reduction
Issue Improvement Result
 Hand spray pump installation to avoid
water spillage
 During water dispensing , spillage &
wastages
Leadership Through Innovation
 Water wastage reduction
Hand spray pump for drinking water dispensing

51. Best Practices : Dummy designing with cost reduction
Issue Improvement Result
 In-house Fabrication ,Designing & hardware
implementation of dummy
 Designing & Preparation of in-house dummy
Leadership Through Innovation
 Cost Saving – INR 200000
In-house modification of Dummy for ODU checking
NOT EXIST
EARLIER
Section : Maint.
Month : Apr ’16
Before After
Rs 250000
Rs 50000

52. Best Practices : Quality Enhancement Activity
Issue Improvement Result
 Condenser checking station with automatic
buzzer system
 Designing of N2 purging station 28 Bar
pressure
Leadership Through Innovation
 Quality improvement
Implementation of N2 purging station
NOT EXIST
EARLIER
Section : Maint.
Month : Apr ’16

53. Best Practices : Safety Activity in Scrap yard
Issue Improvement Result
 Extra fire point tap provided in scrap area for
safety purpose as it has EPS material
 Installation of fire point tap in scrap yard
Leadership Through Innovation
 Safety Improvement
New tap point installed for fire hydrant system
NOT EXIST
EARLIER
Section : Maint.
Month : Apr ’16

54. Best Practices : Testing facility installed at Assy. line
Issue Improvement Result
 FG line insulation, leakage ,earth & high voltage
test setup implemented
 Basic testing infrastructure not available
Leadership Through Innovation
 Quality Improvement
Testing machine implementation
NOT EXIST
EARLIER
Section : Maint.
Month : Apr ’16

55. Best Practices : Productivity Improvement at FG line
Issue Improvement Result
 Operation Sequence changed in PLC
programming
1 ODU unit stoppage issue hampering productivity
so logic changed
2 Rectification - New logic implemented with
push button to provide stoppage.
 Ideal time more at LQC stage
1. Machine not stopping at dummy transfer
area.
2. To stop kit operator has to press
emergency
Leadership Through Innovation
 Productivity Improvement
Operation sequence Changed in PLC programming at LQC stage
NOT EXIST
EARLIER
Section : Maint.
Month : May ’16

56. Best Practices : Efficiency Improvement at Press shop
Issue Improvement Result
 Grading implementation to improve machine
health
1. All tools designed and arranged to carry out
grading of m/c
 M/C grading system not available
Leadership Through Innovation
 Efficiency Improvement
M/c grading system implementation
NOT EXIST
EARLIER
Section : Maint.
Month : May ’16

57. Best Practices : Cost/machine eff. improvement
Issue Improvement Result
 Designed spare seal through local vendor Continuous oil leakages at Armstrong
bending m/c
1. valve leakage seal not available - china
make
Leadership Through Innovation
 Cost/Machine Eff. Improvement
Oil leakages removal
NOT EXIST
EARLIER Before After
Rs 10000
Rs 200
Section : Maint.
Month : June ’16

58. Best Practices : Machine eff. Improvement at Press shop
Issue Improvement Result
 All Press m/c main motor housing & play check
carried out
 Motor in contenious run since 5 years
Leadership Through Innovation
Machine Eff. Improved
1. No. of motor checked – 22 Nos.
2. Major Problem observed – 5 M/c
All main Motor internal housing check
NOT EXIST
EARLIER
Section : Maint.
Month : Apr ’16
Before After
Rs 100000
Rs 20000
CI achieved

59. Best Practices : Safety improvement at LPG Gas Yard
Issue Improvement Result
 Sensor &alarm based system implemented to
detect leakages in gas yard
 No facility to detect LPG leakages
Leadership Through Innovation
Safety improvement
Sensor & alarm system to detect LPG leakages
NOT EXIST
EARLIER
Section : Maint.
Month : June ’16

60. Best Practices : Safety improvement at shop floor
Issue Improvement Result
 Sensor based fire line system done in whole
plant to deal with fire situations
 No facility to detect and to rectify fire
situation
Leadership Through Innovation
Safety improvement
Automatic fire detection and prevention system
NOT EXIST
EARLIER
Section : Maint.
Month : June ’16

61. Best Practices : Infrastructure improvement at Weighing Scale
Issue Improvement Result
 Reconditioning of weighing done
1. Height increased with slope arrangement
both side
2. Calibration done with installation of
transparent window
 Weighing scale issues
1. Contentious water penetration
2. Scale calibration & height expansion
Leadership Through Innovation
Safety improvement
Weighing Scale reconditioning
NOT EXIST
EARLIER
Section : Maint.
Month : June ’16

62. Best Practices : TPM activity in press shop
Issue Improvement Result
 TPM implementation
1. All press m/c main motor overhauling carried
out to make it production ready for new season
 All press main motor Pro-active
maintenance carried out
Leadership Through Innovation
TPM activity
Press motor overhauling
NOT EXIST
EARLIER
Section : Maint.
Month : June ’16

63. TPM Activity – Press Shop
v v
v v

64. Best Practices : M/c Equipment improvement at dispatch
Issue Improvement Result
 Oil leakage elimination, m/c overhauling
1. Dock leveler bush & pin worn out , designed
new one with manual greasing option
2. New seal developed for hydraulic cylinder to
eliminate leakages
3. Overall overhauling done
 Hydraulic dock leveler Safety issue and
continuous leakages
Leadership Through Innovation
 Equipment improvement & cost saving
M/c overhauling & Safety improvement
NOT EXIST
EARLIER
Section : Maint.
Month : July ’16

65. TPM Activity – Dock leveler
v v
v v

66. Best Practices : M/c Equipment improvement at Armstrong
Issue Improvement Result
 Gear movement not precise
1. New angular gear designed in place of
conventional straight gear ie Feeder roller
mechanism changed to angular type gear
profile
 Length variation issue
Leadership Through Innovation
 Equipment improvement
M/c Efficiency improved by change in design
Section : Maint.
Month : July ’16

67. Best Practices : Basic safety & infra improvement
Issue Improvement Result
 In-house ladder designed & installed
1. Proper ladder designed to carry out man &
material
 No provision to work on shed safely
1. Ladder not available to reach on
shed
2. No proper arrangement to transport
material upside
Leadership Through Innovation
Safety improvement
Overhead ladder to shed provided
NOT EXIST
EARLIER
Section : Maint.
Month : Aug ’16