30% Increase in Productivity for a Seal Manufacturing Plant

Consulting Process:

1. Data Collection Phase:

• • ✔ The study of 5M’s
  • ⮚ Man – Skill Matrix preparation based on the Process criticality.
  • ⮚ Machine – Machine Capability Study and suitability for the process (Existing & Proposed) and their maintenance team’s records.
  • ⮚ Method – Study the Process Parameters based on the Drawing and Tools selected.
  • ⮚ Measurement – Study the Gauge R&R after confirming Suitability.
  • ⮚ Materials – Measure the desired VS actual input material condition.

• ✔ Status of PFMEA Vs Actuals (Rejection/Scrap levels).

2. Gap Analysis:
Identified the gaps and prioritized them based on their importance and urgency. The most critical gap that requires immediate attention to enhance productivity is the need to upgrade the machining process and tools to the latest technology. This was confirmed during a meeting with top and middle management, ensuring alignment on the priority for immediate action.

Any other targets related to project level costing and efficiency.

3. Solution
Delivered a comprehensive solution by leveraging expertise in Mastercam, best manufacturing practices, tool management, training, and fixture, tool, and gauge design. Key activities included the following:

• ✔ Programmed CNC machines using Mastercam to optimize manufacturing processes.
• ✔ Translated and created new programs to enhance flexibility and production efficiency.
• ✔ Upgraded tooling to next-generation technology, achieving cost savings and better utilization.
• ✔ Trained operators on the use of advanced cutting tools for improved productivity.
• ✔ Programmed all the CNC machines in compliance with the documented requirements.
• ✔ Implemented cutting-edge tools to boost productivity and tool life.
• ✔ Rewrote and exported existing programs for advanced machines, particularly milling, with enhanced capabilities.
• ✔ Developed methodologies to address programming changes in response to Engineering Change Notices (ECNs).
• ✔ Assessed CNC operators’ skill levels and provided targeted training on system variables in programming.
• ✔ Calibrated tool probes for lathes and mills, and trained machinists on proper calibration techniques.
• ✔ Developed generic, feature-based machining programs to ensure efficiency across various software platforms.
• ✔ Delivered the updated PFMEA post implementation of improvement and trained the process team.

Challenges involved:

• ✔ Assessing the team’s current capabilities by evaluating their existing processes and their readiness to adapt to changes.
• ✔ Analysing the costing methodology employed by the team to determine the selection of process flows and machine tools.

Value delivered:

• ✔ Delivered a 15% improvement in process efficiency over previous benchmarks.
• ✔ Achieved a 30% increase in productivity and exceeding the target of 25%, resulting in substantial operational gains.