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Welcome to the “CII – AP TQM FORUM MEMBERS”

Welcome to the “CII – AP TQM FORUM MEMBERS”. Agenda: Our Company – 5 Minutes Thoughts Sharing on Low Cost Automation – 10 Minutes LCA Projects in Amara Raja Batteries – 15 Minutes Question & Answer Session – 5 Minutes. Core Purpose.

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Welcome to the “CII – AP TQM FORUM MEMBERS”

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  1. Welcome to the “CII – AP TQM FORUM MEMBERS”

  2. Agenda: • Our Company – 5 Minutes • Thoughts Sharing on Low Cost Automation – 10 Minutes • LCA Projects in Amara Raja Batteries – 15 Minutes • Question & Answer Session – 5 Minutes

  3. Core Purpose To transform our spheres of influence and to improve the quality Of life by building institutions that provide better access to better opportunities, goods and services to more people….all the time.

  4. Amara Raja Innovation Excellence Entrepreneurship Experiences Responsibility

  5. Vision 2025 Through the Amara Raja way, and through enduring progressive partnerships, we will be a global leader in batteries and battery technologies and dominant player Indian Ocean Rim

  6. The Journey…. • Quality systems certifications • ISO-9001 in Feb 1997 • QS 9000 in May 1999 • TS 16949 in Jan 2004 • Re certifications – Jan 2007, Jan 2010 • Environment management systems • ISO 14001- certification in May 2002 • Re certifications - May 2005, May 2008 & May 2011 • Occupational Health & Safety Management system • OHSAS 18001:2007  - Certified in Aug 2010 • Six Sigma initiation in the year 2002 • 5 S Practices from the year 2004 • Total Productive Maintenance initiation in the year 2007 • Quality Control Circles initiated from 2007

  7. The Amara Raja Group

  8. The Amara Raja Group

  9. Amara Raja Batteries Ltd. • Ownership: • Public Limited Company • Joint venture with JCI, USA • Share holding of 26% each - JCI & Gallas • Size and scope of business: • Total Land area : 195 acres • Built up area : 50,000 sq mts • Direct Employment. : 3000 + people • Total investment --Mar08 : Rs. 3000mn ( USD 60 Mn) • Sales 2005-06 : Rs. 4458 Mn (USD 100 Mn) • Sales 2006-07 : Rs. 7451 Mn (USD 166 Mn) • Sales 2007-08 : Rs. 13500 Mn (USD 300 Mn) • Sales 2008-09 : Rs. 15840 Mn (USD 352 Mn) • Sales 2009-10 : Rs. 16904 Mn (USD 382 Mn) • Sales 2010-11 : Rs. 20765 Mn (USD 464 Mn) AMARA RAJA JCI

  10. LOW COST AUTOMATION

  11. INDIAN SENARIO Under the present regime of globalization and liberalization - Quality enhancement and Cost reduction are two major steps to enhance productivity when many factors (economic recession , slump in demand , risk , lack of funds with long gestation period) make heavy investment not possible. One of the very practical, safe, economical and rewarding strategies is the application of Low Cost Automation.

  12. LOW COST AUTOMATION WHAT ? Introduction of simple machinery like pneumatic , hydraulic ,mechanical and electrical devices into existing production… To Improve - Productivity ,Quality ,Safety ,Delivery , Ergonomics and reducing cost WHY ?

  13. Automation VsLow cost automation Automation Low Cost automation • High initial cost • Computerization is required • Skilled labor is required • Low Investment • Simple Machines can be used • Operation is possible with Semi-Skilled and unskilled labor

  14. LOW COST AUTOMATION Applications LCA Methods • Pneumatic • Hydraulic • Mechanical • Electrical Loading Feeding Clamping Cutting Cleaning Insertion Crimpling

  15. Benefits • Increases productivity • Highly skilled labour is not required • Production time is reduced • Increases the quality of products • Computerization is not required • Cost of production is reduced • Better Utilization of material • Less rejections • Manufacturing Lead-time can be reduced

  16. LCA in AMARA RAJA

  17. LOADING

  18. Conveyor system for Bottom paste addition OLD METHOD: • 1 Manpower per shift 3 manpower per day • High operator fatigue leads to attrition • 5% Paste loss while manual loading CONSTRAINT: Operator has to collect fallen paste from floor and add into hopper in Pasting Developed U type inclined conveyor for loading paste into the hopper PRESENT METHOD :

  19. Conveyor system for Bottom paste addition BEFORE AFTER Manual addition of bottom paste • Operator fatigue elimination • 3 Manpower saved • Paste loss elimination • Consistant plate thickness Benefit

  20. Label dispensing system OLD METHOD: CONSTRAINT: • 12 seconds per battery • Loss of adhesiveness due improper peel off • Label damages while handling Operator manually peel off the label and paste on the battery in batch flow of batteries at Finishing PRESENT METHOD : Developed label dispenser for auto peel off label

  21. LABEL DISPENSING SYSTEM BEFORE AFTER • Retention of adhesiveness • Auto peel off sticker • 9 seconds per label Benefit Improvement

  22. FEEDING

  23. CHARGE EYE FEEDING OLD METHOD: Indicates the charging status of battery • Uneven orientation of Charge eye • Improper fitment of charge eye CONSTRAINT: Operator manually fixing the charge eye with mallet to the battery at assembly PRESENT METHOD : Auto Charge eye fixing to the battery

  24. CHARGE EYE FEEDING BEFORE AFTER 1. Consistency in orientation 2. Zero chance of improper fitting ( Automatic Operation ) • Consistency in orientation • Zero chance of improper fitting • ( Automatic Operation ) Benefit

  25. CLAMPING

  26. ONLINE ENGRAVING Engraving battery type on cover by manually holding cover in offline PHASE :1 OLD METHOD: Engraving battery type on cover by clamping cover in offline PHASE : 2 Battery type is hot punched on cover in Assembly PHASE : 3 Engraving battery type on cover by clamping cover in online

  27. ENGRAVING AUTOMATION BEFORE AFTER 1. Holding the cover ,Movement of operator eliminated 2.No additional manpower is required add this activity to line operator Benefit

  28. CUTTING

  29. SHIM CUTTING OLD METHOD: • Operator cut the shim 1 piece per cycle • Unable to meet the requirement • 3 manpower per day is required CONSTRAINT: Shims are manually cutting using cutter in Plastics PRESENT METHOD : Automatic shim cutting will cut 4 pieces per cycle

  30. SHIMCUTTING SETUP BEFORE AFTER • 1 In single cutting we can produce 4 shims at a time. • 2.Operator fatigue reduced. • 3.Productivity raised by 134% • 4.Manpower saved-3 No’s Benefit

  31. FOAM CUTTING OLD METHOD: • 6 manpower per day • Unable to meet the requirement • Operator safety CONSTRAINT: Manual foam cutting using knife at Packing PRESENT METHOD : Semiautomatic setup will cut the foam

  32. FOAM CUTTING SETUP BEFORE AFTER Scale to measure length Auto Cutting with hand valve Easy to pull • Minimize operator fatigue • Optimum work content • Good workplace management Benefit

  33. CRIMPLING

  34. RE USAGE OF CABLES OLD METHOD: PURPOSE: Cables are used to interconnect cells at charging process CONSTRAINT: • 30000 cables are ready to scrap Cables are scrapped due to lug damages in Formation process PRESENT METHOD : Developed semi automatic set up for cut the lug of cable and crimple the new lug. Cable cost Rs 30 Lug cost Rs 1.25 Each cable has 2 lugs

  35. Directly scrapping the cables in ABD,IBD & SBD formation after usage. CRIMPLING SETUP BEFORE AFTER Cable cutting Cable crimpling Lug(sleeve is open) damaged Cable after usage Cable ready for reuse • Cable cost Rs 30 • Lug cost Rs 1.25 • Each cable has 2 lugs • Cost saving by each cable Rs27.50, Savings/Annum Rs 825000 Benefit

  36. NUMBER PUNCHING OLD METHOD: PHASE 1: Semi automatic setup for Number punching CONSTRAINT: • 3manpower per day • Uneven location of the punch • Operator fatigue & punch visibility was not good ( Manual Operation) Hot number punching on Battery with Punching gun PRESENT METHOD : Automatic setup for Number Punching

  37. AUTO HOTNUMBER PUNCH BEFORE AFTER • 1. Consistency in location of the punching • 2. Visibility of the serial number is good ( Automatic operation ) • 3. No operator fatigue • 4.Work content reduced by 42% Benefit

  38. AUTO AIR PULSING OLD METHOD: CONSTRAINT: • Water getting stayed on post threads • Sulphation formed in threads • More thread damages • Manual cleaning of water in post threads • More water spills on floor due to manual cleaning • Additional man power to clean the post water • Air loss one manpower per shift is assigned to fix and release bolts in post of the cell to check is it freely moving or sulphation form in the cells at Finishing Sulphation is formed due to cell is not cleaned after leak testing Auto air pulsing is provided to eliminate sulphation PRESENT METHOD :

  39. AUTO AIR PULSING BEFORE AFTER • No sulphation observed(QA Approved). • Elimination of thread damages due to sulphation. • Elimination of manual cleaning of water droplets on posts. • No additional man power required to clean water on posts. • Elimination of repetitive thread inspection in finishing. Benefit

  40. AUTO ALIGNER OLD METHOD: CONSTRAINT: Manual alignment leads to operator Fatigue Operator has to manually align the group in COS Operation in Assembly Auto aligner will align the groups in COS Operation PRESENT METHOD :

  41. AUTO ALIGNER BEFORE AFTER No operator fatigue Benefit

  42. CARTON INSERTION Manual inserting the batteries in carton box in Finishing OLD METHOD: CONSTRAINT: Manual lifting of around 60 kgs batteries is difficult High operator Fatigue 2000 times bend and raise for 1000 batteries Difficult to handle on conveyor 2 manpower/shift totally 6 manpower day is required PRESENT METHOD : Semi automatic setup for carton insertion .

  43. CARTON INSERTION BEFORE AFTER • No bend and raise • Fatigue Reduction • Easy to operate • 3 Manpower per day is enough Benefit

  44. NP OIL FILLING Manually filling of NP Oil on vent cap for lubrication purpose in Formation process OLD METHOD: CONSTRAINT: Spillage/Wastage of oil PRESENT METHOD : NP Oil filling on vent cap through saline bottle

  45. NP OIL FILLING BEFORE AFTER Saline bottle • No Spillage of NP Oil Benefit

  46. GROUP INSERTION Groups inserted in to the container manually at Assembly OLD METHOD: CONSTRAINT: Difficult to insert Operator fatigue PRESENT METHOD : Pneumatic setup developed to insert the groups in container

  47. GROUP INSERTION BEFORE AFTER • Easy to insert • Operator fatigue reduction Benefit

  48. Open to Questions, Suggestions, ……

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