A Project on Ekc Innovations

7/29/2019 A Project on Ekc Innovations

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A project on

INNOVATIONSEKC Ltd.

By,

Nishad Khamkar

Sonia Mirajkar

Shashank Palande

Shailaja Patil

Ashwini Pokharkar

Aseem Halani



About EKC

• Established in 1978

• 8 Manufacturing units around the globe.

• Restructured to public limited in 2001.

• Capacity to produce 500000 cylinders around the

globe.

• All major markets covered.



Major competitors

• Rama cylinders

•

Bharat forge

• CPI industries USA

• Hi Tech industries Japan



Photos of some plants



Products



Products



Products



Products



Kaizen – idea generation.



Kaizen Idea Sheet

Shop: Spinning Section M/C: Pipe Cutting I / II /III m/cs Reg. No: 004 / 2010

Kaizen Theme :- Elimination of

Unwanted Running of Hyd. Power pack.

Kaizen Idea : Providing Automatic Timer to cut off powerwhile M/c. is running for Idle .

Problem/Present Status: Countermeasure:

Kaizen Finish

15/6/10Kaizen Start

10% SavingTarget

To be calculateBench Mark

Team Members :-

Mr. Amol Pawar , Mr. Jadhav ,

Mr. V Sharma, Mr. Umesh Meher

Team Leader : M H Thakur Benefits:-

1) Mistake proofing foravoiding loss due toOperators oversight.2) Energy saving in safe

practices

Analysis: Unnecessary Running of elect.

Motor of Hyd. Power packResult:-

1 )Reduction in Energy consumptions2 )Safe running of machine .3) Optimum use of machine elements .4 ) Oil temp. will be in controlled zone ,

less oil leakages

* E xact calculations are to be done forsaving

Activity KK JH QM PM SH OTPM DM ET

Result Area P Q C D S M

Defect Type

C

No

M/C T/date Res. Status

1 PC1 15/7/10

Mr.Amol

2 PC2 15/7/10

Mr.Amol

3 PC3 15/7/10

Mr.Amol

This is applicable for All

Conventional Machines

Providing Automatic timer /

Relay to cut / switch off

electrical motor ( 2 HP),

while Machine is not in Use

And Hyd. Power pack is on

Machine is running and

there is not having

mistake proofing for

switching off the power

when running in idlecondition . Unnecessary

Running of elect. Motor of

Hyd. Power pack.

Why –Why Analysis

Continuous Running Elect. Motor .

M/cs. Running continuouslywithout stopping Hyd. Motor.

Forget / Fail to switchOff in idle /no load condition.



Why – why analysis.

My car will not start.

1. Why? - The battery is dead

2. Why? - The alternator is not functioning.

3. Why? - The alternator belt has broken.

4. Why? - The alternator belt was well beyond its useful service life

and has never been replaced.

5. Why? - I have not been maintaining my car according to the

recommended service schedule.



OLD LAYOUT



Benefits of proper layout

• Plays a major role in cost reduction

• Time reduction

• Continuous flow

• Maximum utilization of available space

• Flexibility as per predicted future demand



New Layout



Achievements through layout changes

• Smooth uninterrupted flow of cylinders

• Increase in productivity

• Maximum utilization of machinery

• Cost reduction from 360 to 210 per cylinder

• Flexibility in producing any size of cylinders



Spinning and furnace



Before change

PRODUCTION Capacity Achieved Variance

Causes of negative variances Previous Month

Major loss of hours Total

Set-

up

B/d Any

other N/L

No plan,

N/M

Lost

Hours

Productio

n

Qty

Lost

Hours

Spinning

m/c 1 11000 4280 6720 72.2 224.5 81.25 378 9690 181.25

m/c 2 12000 6700 5300 81 80.5 129.25 290.75 8549 239.75

m/c 3 8000 5404 2596 85.2 44.5 201 330.75 5156 259.5

m/c 4 12000 7083 4917 91 85.2 89.2 265.5 7051 281.75

23467 19533 30446



After change

PRODUCTION Capacity Achieved Variance

Causes of negative variances Previous Month

Major loss of hours Total

Set-

up

B/d Any

other N/L

No plan,

N/M

Lost

Hours

Prodn

Qty

Lost

Hours

Spinning

m/c 1 15000 9015 5985 62.2 174.5 11.25 248 8546 235.75

m/c 2 15000 9874 5126 62.7 125.2 20.25 208.2 8916 222.25

m/c 3 8000 328 7672 55.5 69.25 320.5 445.2 240 473.75

m/c 4 15000 6237 8763 124 139.2 61 324.2 6507 249.5

m/c 5 15000 8394 6606 95.2 54.25 73.25 222.7 9809 181.75

33848 34018



Process Flow

• Tube cutting

• Bottom forming

• Neck forming operation

• Heat treatment

• Neck machining

• Internal cleaning

• Hydraulic test

• Tightness test





Innovations in processes

• Capable to develop pull type of production

• Line balancing

• Transportation

– Lead time reduction

– Automation

• Elimination of unwanted processes

• Continues flow (no WIP)

• Ergonomics achieved

Documents

A Project on Ekc Innovations