Engagement One –
Here, our aim was to reduce breakdown of critical machines from level of 24 failures a month to as low as possible. Further, we also aimed towards identifying weak areas that would not sustain stress of running the facility to around 120% of its capacity.
- Failures reduced from 24 failures a month to 1 failure a year for 36 identified critical machines
- The plant runs at 129% of its designed capacity
Engagement Two –
Here, the need was to redesign existing machine so as to obtain productivity gain of around 50% as well as reduce maintenance time and effort. Further, we also aimed at building the machine locally at less than 10% of price which would otherwise have to be paid if machine was imported.
- All objectives of engagement were achieved within 6 months of start of the project