Virutal stonesetting

8/8/2019 Virutal stonesetting

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VIRTUAL STONESETTING

TITAN INDUSTRIES LTD - JEWELLERY DIVISION


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Introduction

Jewellery Division of Titan Industries Limited and have 2 Brands

Tanishq & Gold plus

Mfg & Retailing of Gold & Diamond Jewellery.

Expected turn over of 4000+ Cr. for the year 2010-11

Major strengths include Design leadership and state-of-art integrated

manufacturing facility at Hosur & DDN.

Won 1st Tata Innovation award in 2006

Won MMA award in 2009 for Supply chain practices

Won IIMM award in 2009 for Best Supply chain management

European Business School awardBest talent in supply chain

Innovation School of Management - creating Innovation culture across

organization


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V-M-V


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Innovation at Titan Jewellery

SLT

Training & Development

Sharing Platform

Ideas What is

Visit to national/international Fairs

Training through TMTC / IIM

Sharin ofee c

Unlimited

new ?e e

Organizational Learning

Prioritization through

SLT / Technology Cell

Innovation & Improvement

Implementation

Hall of Fame

Outstanding Titanian COOs Great Show certification

MOF

visit learning

Recognition through

un


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Traditional jewellery making

Master makingMould making Waxing

Casting

Stone settingLinkingPolishingFinished product


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Traditional jewellery making


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Limitations

Process

High Labour and Skill intensive.

Master making and Stone setting, most complex operations.

Longest lead time 4 weeks

People

High fatigue and stress

Variation in skill levels among people

Customer Restricted introduction of new designs

Non-availability of new designs at frequent intervals.

(* 60 70 % of the Tanishq Customers are repeat buyers )


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Need of the Innovation

Market Demand :

Bring newness in designs frequently to meet high expectations of customers.

Speed to Market for the new designs to beat the competition.

Downstream operations are manual and require high skill levels

Stone setting is the most complex operation 65% of complexity

Capacity of the proto product is determined by the capacity of stone setting


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Voice of Customer

23%

24%

25%

26%

*Availability of Range of Jewellery

Good

20%

21%

22%

2005 2006

Voice-T for Range

*Data source: Voice-T


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How to Overcome ?

FORMING A cross functional

team was formed to

identify the alternate

STORMING

Brainstorming sessions

Conducted

Ideas collated and taken

up for further evaluation

Team Members

B.Manimaran - Production

K.Karthikeyan - Mould setting

M.Saravanan - CAD / CAM

R.Jayamadhu - Mould Cutting

M.Nanda Kumar - Waxing

CFT


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How to Overcome ?

NORMING Filtering of the ideas in a

structured manner

Derived Many alternates

Job work / Outsourcing

Mechanized stone setting

Virtual stone setting in CAD


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Options worked out

Job-Working / Outsourcing

Quality of Output

Enormous time spent in developing

Cash outflow

Lead-time

Mechanized Stone setting

Found best suitable only for single design with more volumes

Virtual stone setting

Innovative Idea


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Challenges faced by the team

No technical expertise within the country on mould setting

Across the globe, no data available for this process

No inputs available on the process parameters as well as

the master dimensions

For the skilled manpower, threat of loosing the job

Inconsistent Behavior of diamonds at high temperatures

resulting in huge loss


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Virtual stone setting processCAD with VIRTUAL

STONE

Master

making

Mould

cutting WaxingCAM output

CastingLinkingPolishingFinished product


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Virtual stone setting process


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What makes this innovation so unique/different

Deskilling of the most complex / highly skilled operation

Developed with internal knowledge without any external consultancy

Can not be copied by any one without the complete process details /

parameters

,

enhancement as well as reduction in cash outflow

Also, resulting in enhanced customer satisfaction through elimination of

a major defect in customer returns.

Patent application has been accepted by the Government of India

Patent application number : 2371 \ CHE \ 2007


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Benefits

Customer

Availability of more choice of new designs very often at stores.

Speedy supply of single piece customer orders.

Enhanced Setting quality and Diamond Glittering.

Employee

Less Fatigue and High morale

Joyful working atmosphere

Enhanced creativity level


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Benefits...

Company

Availability of enhanced capacity for New designs

3000 No's / Annum to 12000 No's / Annum).

e uce roto ro uct on ea -t me 6 wee s to 2 wee s

Resources are deployed @ other Value added activities.

More Importantly,

Innovation at Zero Cost !!!!


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This development has resulted in

Increase in productivity from 70% to 163%

Reduction of

Impact of the innovation

. .

Gold loss from 2.15% to 1.75%

Stone loss from 1.25% to 0.20%

Tools and consumables cost from Rs.21 to Rs.12 per product

Mfg cost per NP from Rs.325 to Rs.212.


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6.91

10.37

8

10

12

Cost savings trend value in Cr.

Impact of the innovation

0.962.13

3.134.0

5.07

0

2

4

6

Till Now, net saving : Rs 10.22 Cr


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THANK U

Documents

Virutal stonesetting