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Problem statement :
- Accountable Preventive & predictive Maintenance
- 24X7 reliable Service Support for Shock Absorber
- Equipment & process
- Valve Cap Co2 Dual gun 16 Qty
- Projection welding Machine 30 nos
- Piston rod welding machine 20 Nos
- Inner tube leak Testing Machine 4 Nos
- Piston rod Robot welding machine Machine 12 Nos
Approach :
- Study of Plant within 1 week
- Summarize KPI resources management within 3 months
- Setting KPI prepare action plan and execute within 2 months
- Measure performance and plans review
- Gap analysis with action plan
- Improvement & execution of action plan & report
Activity:
- Planning of Manpower required. Reduced 20% Manpower
- Implementation of Six Sigma
- Implementing & day on day improvement of KPI consisting up time from 95% to 98%
- MTTR 15hrs to 9 hrs, MTBF 72hrs to 100hrs
- Providing Vendor development / spare part management saving of Rs. 29 lac
Approach :
- 100% manpower available in plant with cost optimization
- Reduction in response time in return reduction Breakdown 23%
- Saving of 6 % of consumable cost
- Saving of excessive amount on maintenance
- Reduction of maintenance cost by 6.8%