The Customer

Enhancing Automation Through Comprehensive Process and Tool Validation

This leading Indian automotive manufacturer, with a prestigious client roster including TATA, SKODA/VW, and MAHINDRA, exemplifies their slogan, “Our touchstones are our milestones.” Renowned for their innovation and extensive production network across India, they are a major force in the automotive industry. Partnering with them allowed Team Torque to contribute to their remarkable achievements and support their continued success in delivering excellence to their high-profile customers.

The Challenge

Our customer faced a significant challenge due to the recent increase in automobile sales. This surge in demand led to a pressing need for more child parts, requiring the customer to ramp up their production capacity. Despite having already engaged with other vendors, the customer found their solutions lacking and turned to Team Torque for assistance.

The Customer’s Needs
The sharp rise in automobile sales created an urgent need for increased production of child parts. The customer needed to enhance their Job Per Day (JPD) output to meet the new demands from their automotive clients. Given the critical nature of this requirement, the customer sought a solution that would not disrupt their ongoing production processes.

Our Response
Team Torque’s expert engineers quickly assessed the situation and developed innovative solutions to increase productivity without the need for additional robots or jigs. We worked within the existing production constraints, ensuring
that daily operations continued smoothly. Our team’s approach allowed the customer to meet the heightened demand for child parts without any disruptions.

Approach Taken
To shorten the production line’s cycle time, we adopted a systematic and collaborative approach. Our strategy involved several key steps:

1. On-Site Study:

We sent our team to the site to observe and study the running conditions of the production line first-hand. This allowed us to gain a comprehensive understanding of the current operations and identify potential areas for improvement.

2. Data Collection:

Our team diligently collected all the necessary data required for a thorough analysis. They immediately began working on interpreting this data to uncover inefficiencies and opportunities for optimization.

3. Comprehensive Report:

After gathering the data, we compiled a detailed report outlining what could be improved on the specific production line. This report served as the foundation for our subsequent actions.

4. Collaboration with the Customer:

Our team of experts analysed the data and collaborated closely with the customer to ensure that the proposed improvements would align with their -production needs. Together, we developed a plan that would not disrupt ongoing production.

5. Optimization of Paths, Movements, and Wait Times:

Our team identified unwanted paths, movements, and wait times in the robotic operations. These inefficiencies were optimized, significantly contributing to reducing the overall cycle time.

6. Advancing Clamp Signals:

We found instances of late or delayed clamp signals during the process. By advancing these signals, we improved the timing and efficiency of the clamping sequence.

7. Correction of Fouling Issues:

We discovered some fouling of the gun with the fixtures, which was causing wear and tear. Our team made corrections to these fouling issues to enhance the quality of the work and reduce unnecessary damage to the equipment.

8. Optimization of Gun Operations:

There were unwanted gun openings in continuous spot points, leading to longer cycle times. By minimizing these openings, we achieved a shorter cycle time, particularly in continuous spot operations.

9. Trial Runs:

To ensure the effectiveness of our improvements, our team conducted trial runs after completing their daily activities. These trials were crucial in validating the success of the optimizations without disrupting the customer’s production schedule.

10. Teamwork and Collaboration:

The success of this project was due to the tireless efforts of our team and the strong cooperation from the customer. Their combined dedication and collaboration were key to achieving the target cycle time and improving overall production efficiency.

Outcome

The customer was extremely satisfied with the results delivered by Team Torque. Our solutions enabled them to meet the increased demand from TATA, SKODA/VW, and MAHINDRA, ensuring that they could maintain their commitments to these major automotive clients. The customer praised our ability to solve the problem efficiently and effectively, where others had failed.

Results Achieved

The project was successfully executed, meeting the targeted cycle time and delivering significant operational improvements. The key results include:

Cycle Time Reduction:
Shed 2: Achieved time savings of 17.65 minutes.
Shed 3: Achieved time savings of 13.65 minutes.

Improved Spot Timing:
Before Improvements:
      Average time per spot in Shed 2: 3.4 seconds.
      Average time per spot in Shed 3: 3.2 seconds.
After Improvements:
      Successfully reduced the average time per spot to 2.8 seconds in both sheds.

Increased Production Volume:

The reduction in cycle time and the improvement in spot timing have led to a notable increase in overall production volume, enhancing the efficiency and throughput of the entire production line.

These achievements underscore the effectiveness of the strategies implemented and the collaborative effort between our team and the customer. The production line now operates more smoothly and efficiently, contributing to the customer’s ability to meet increasing demand with greater agility.