Use of Industry 4.

0 in Manufacturing for
Improving Resource Utilization and Reducing Conversion Cost
 Godrej & Boyce Mfg. Co. Ltd.
Established in 1897

Mohali, Punjab Mohali, Punjab Products

1996

Shirwal, Maharashtra Land Area : (75.01Acres) Capacity: 1.6 million 2.7 million 0.4 million

Employee-1700 Green Co Platinum TPM

 Organization Vision Manufacturing Vision
Top 3 by 2020 in Indian Lowest cost appliances
Appliances industry producer in India
Future ready manufacturing Initiatives
Lean tools Automation Flexible manufacturing
POKA
YOKE

JIT
SMED

LEAN
KAN
VSM
TOOLS BAN

LINE
QC BALANCING
CIRCLE 5S

Additive manufacturing Advance materials & NANO technology Simulation software

 Evolution of manufacturing systems – The journey so far …
Organization Vision Manufacturing Vision
Top 3 by 2020 in Indian Lowest cost appliances
Appliances industry producer in India
Digitalization
3500 Automation 120
Turnover Mfg cost

Indexed Manufacturing cost

3000
Flexible Manufacturing
100
100 3019
96 2809
Turnover In Crs

2500 77
89 85 2506 80
83
2000
2243 69 60
1500 1725 61
1560 53
1350 1456 40
1000 TPM
1120
Total Green–GREEN COMPANY RATING
Total lean –CII cluster program 20
500
Green–MSG
Basic Lean tools
0 0
2010 2011 2012 2013 2014 2015 2016 2017 2018
 Reason for Choosing Digitalization…….

Delay in Root Cause Analysis Inconsistency of data due to

conventional recoding methods

High Inventory because of lack of

visibility Incorrect/Inaccurate data
capturing

Improper resource utilization High response time to attend

Breakdown leading to production loss

High Rejections & Quality defects

due to no real time monitoring Conventional Methods of
monitoring productivity/Quality

High Lead Time Non accountability for losses

How to Implement Digitalization ?
 Process for Implementing Digitalization………

STEP 1- DEFINE OBJECTIVE AND SCOPE FOR DIGITIZATION

STEP 2- DEFINE RELATIONSHIP WITH ORGANIZATION AND MANUFACTURING VISION

STEP 3- DEFINE APPROACH AND ROADMAP FOR IMPLEMENTATION

STEP 4- TARGET SETTING

STEP 5- INTEGRATION WITH TPM PILLARTS FOR PROJECTS IDENTIFICATION

STEP 6- DEFINING METHODOLOGY FOR IMPLEMENTING PROJECTS

 STEP 1- OBJECTIVE AND SCOPE FOR DIGITIZATION
Objective:- To make cost efficient factory by effective use of resources with the help of digitization, real time
visibility, connected, smart and flexible manufacturing.

SCOPE:-

i-FACTORY

Production Systems & Intelligent Energy & Utility Condition Digital Supply chain
Maintenance System Monitoring System
 STEP 2- RELATIONSHIP WITH ORGANIZATION VISION

Division Vision, Division Key Business Manufacturing Key Performance Index by Use of
Mission, Values Index Business Index Digitalization
•To be TOP3 in 1. Asset Productivity 1.1 To increase asset 1.1.1 S class machines OEE
Indian Appliance turnover ratio of Mohali improvement by 10 % with the
industry plant by 30% help of Real time monitoring.
2.Cost Productivity 2.1 To improve 2.1.1 Machine spares, tools &
•Offering innovative Manufacturing cost Coolant cost reduction by 10% by
& quality products Index life optimization .
2.1.2 Inventory reduction by 10%
•Financial by improving visibility.
sustainability 3. People 3.1 Improve VAPCO by 3.1.1 10% Productivity
Productivity 5% improvement for man power used
for data collection & surveillance
•3P(People, Planet, by using digital system.
Profit)
4.Integrated Quality 4.1To Reduce rejection 4.1.1 Rejection cost reduction by
Management cost as % of BOM by 10% through real time
•Stress free, worry
20% for all categories measurement of quality
free, fear free, work
parameters.
environment
 STEP 3- APPROACH AND ROAD MAP FOR DIGITIZATION
2017- 2019
2016-2018 2019- 2021

100% Digitalization
1. Machines 1. Application 1. Machine Data 1. Digital alerts
2. Processes 2. Software 2. Process Data 2. Dash boards
3. Data points 3. ERP 3. Quality Data 3. Push SMS
4. User points 4. Servers 4. Productivity data 4. Updates
 STEP 4- TARGET SETTING
Base year Phase 1 Phase 2 Target Phase 3 Target
Focus area Parameter
2016-17 Target(2017-18) (2018-19) (2019-20)
OEE 78% 81 86 90
FPY 89% 96% 98.5 99.5
Tooling Cost (Rs) 32 30 24 20
Process capability 1.2 1.33 1.67 -
Production Systems &
Spare cost (Rs) 6.4 6.0 4.5 2.5
Intelligent Maintenance
System TBM To CBM 20% 40% 60% 100%
Power consumption
31 28 25 22
(Rs)

Water consumption
35 30 27.41 25
Energy & Utility System (Lts /appl.)

Inventory reduction
15 12 10 7
(DOH)

Hard copy formats

0 1200 1800 2400
Digital Supply chain reduced
 STEP 5- INTEGRATION WITH TPM PILLARS FOR PROJECT SELECTION
Provide details of OLE / OEE / Technical support for real time OEE
System transactions KK KK Calculations

Provide details for any A system for Tool Management &

Support From Other pillars

JH

Support To Other pillars

automation of JH systems. JH electronic cock pit

Details of the machine Auto condition based

parameters to monitor PM PM maintenance with alerts

Identifying areas for inspection Inspection automation and

automation and provide details. QM QM digitisation of data.
DIGITAL
Training to develop new skills in
Paperless transactions
the areas of new technologies E&T E&T

Identify opportunities for office Office process lead time reduction

process lead time reduction OTPM OTPM through IT enabled working.

IT supported BE safe portal

Support during building IT infra
SHE SHE management and other automations

Develop a system for project

Building IT Infra
DM DM milestone monitoring
 STEP 6- METHODOLOGY FOR IMPLEMENTING PROJECTS
Seven Step Methodology :

Need Identification a. Interaction with other pillars b. Understanding

purpose & necessity c. Efforts mapping.

Exploring Ideas a. Brainstorming for various ideas. b. Technology &

investment. c. Optimal solution

a. Decision for Inhouse make or Buy. b. Return on

Feasibility study investments.

Designing a. Study in totality. b. Easy to operate. c .Catering

future needs
Converting Data
Analogue to Prototyping & Testing a. Pilot run b .Observe the
digital Capturing performance.

Transfer to Display to Installation & Commissioning a. Installation

Cloud HMI etc. b. Trials.

Monitoring & Review

 CASE STUDY

DIGITALIZATION IN PRODUCTION SYSTEM

 Need Identification
SCOPE

Production Systems & Intelligent Energy & Utility Condition Digital Supply chain
Maintenance System Monitoring System

PRODUCTION REQUIREMENT CONVERSION COST

GAP- 2.5 Lakh

Conversion Cost
28 130 128
Comp. In lacs

26.5 Lacs
126
24 Lacs
24 122 120
118
20 114
2016-17 2018-19 2016-17 2018-19
 Need Identification
GAP- 2.5 Lakh Compressors
28

Comp. In lacs
26.5 Lacs
PRODUCTION CAPACITY ENHANCEMENT
24 Lacs
24

20
2016-17 2017-18

CAPITAL INVESTMENT EFFICIENCY IMPROVEMENT OF EXISTING MACHINES

BY USING INDUSTRY 4.0
ADDING UP NEW MACHINES
88 86
INVESTMENT REQUIRED
84

OEE
80 78
76
20 Crores
72
2016-17 2018-19
 GANTT CHART
Activity Sub activity 2017-18
Q1 Q2 Q3 Q4
Need Identification Identifying and prioritization of needs
Exploring possible ideas (Brainstorming,
Exploring ideas technology & investment, Optimal Solution)
Feasibly study Idea Feasibility study

Designing Designing of concept

Procurement of material
Hardware upgradation and Introduction of
Dashboard
Prototyping and Testing
Prototyping on one machine

Modifications & Validation of results

Hardware and software modification on all
machines
LAN & Cloud based connectivity
Installation &
Commissioning Installation

Commissioning and Validation of results

Monitoring and Review Implementation and Monitoring

Planned Start Planned End Activity Continued

Actual Start Actual End Activity Completed

 Need Identification
Requirement from various Pillars

KK PM JH SHE
1. Real time loss capturing. 1. Autonomous spare planning. 1. Low number of manual check points. 1. Real time humidity level monitoring in
2. Monitoring of micro Stoppages. 2. All Servo motor current monitoring. 2. Real time monitoring of critical check points. machining section.
3. Real Time OEE Monitoring. 3. Spare life monitoring in hours/days 3. Digital size adjustment of boring tools. 2. Bacteria level and PH level monitoring in
4. Real time cycle time monitoring. recommended by supplier. 4. Autonomous CLITA. machine coolant.
5. Stop time Recording. 4. Condition based Maintenance Spindle. 5. Digital checkpoints for easy monitoring of 3. Intimation of safety alarms on machine to
6. Changeover time Monitoring. 5. Spindle temperature monitoring. critical points. safety department and concern department.
7. Defects and rework monitoring. 6. Servo encode temperature monitoring. 6. Auto lubrication of parts. 4. Real time condition monitoring of safety
8. Loss wise bifurcation. 7. All servomotor temp Monitoring. 7. Autonomous cleaning of machines. sensors installed in machine.
9. Alarms/ time taken per alarm monitoring. 8. Real time monitoring of ball screw life. 8. Real time monitoring of lubrication pressure. 5. Coolant temperature monitoring.
10. Tool life monitoring. 9. Spindle motor load monitoring.
11. Coolant life monitoring. 10. Lubrication Oil/ Hydraulic oil level 9. Real time monitoring of clamping pressure.
12.
13.
Tool holder life monitoring.
Condition based monitoring of tool life. 11.
monitoring.
Real time PMI check point monitoring.
10.
11.
Automatic tool length measurement.
Program modification and micro adjustment
QM
14. Production monitoring. 12. Intimation to maintenance department for from PC. 1. Elimination of rejection due to tool
15. Autonomous production report generation. abnormal condition of machine. 12. Breakdown call from machine itself. breakage.
16. Line efficiency monitoring. 13. Condition monitoring of drive fan’s. 13. Component position sensing on fixture after 2. Elimination of rejection due to component
17. Intimation of loss/ micro stoppages to 14. Condition monitoring of panel cooling fan’s. clamping. wrong clamping.
department. 15. Machine battery health monitoring. 14. Tool break/ damage sensing and feedback to 3. Elimination of rejection due to material
18. Inventory monitoring and inventory cost 16. Automatic lubrication and lubrication operator. defect.
reduction. frequency monitoring. 15. Auto loading and Un-loading of component 4. Elimination of component rejection due to
19. Monitoring of hidden losses. 17. Root cause analysis for machine breakdowns from fixture. tapping defects.
20. Running program sequence number and alarms. 16. Coolant life monitoring/ cleaning frequency 5. Elimination of rejection due to component
monitoring. 18. Ball screw temperature monitoring. monitoring. rusty issue.
21. Tool wise load monitoring of spindle motor. 19. LM rail condition based life monitoring. 17. Autonomous Coolant concentration/PH 6. Metallic chips elimination in final
22. Machine running parameter (Feed/ RPM/ 20. All Proximity sensor life monitoring. monitoring. component.
Cutting speed) monitoring. 21. All motor alarm monitoring. 18. Coolant temperature monitoring. 7. Elimination of operation shifting due to
23. Machine current state & selected mode 22. Breakdown history monitoring. 19. Auto cleaning of coolant tank and chip component position shifting on fixture.
monitoring. 23. Hydraulic pressure and air pressure evacuation.
monitoring.
24. Machine should be stopped if abnormal
condition are there for critical parts.
 PRIORITIZATION OF REQUIREMENTS
Cost OEE Working Environment
Machine Running Cost
93 95 97 99 100 Contributors In Productivity Loss HIRA ON REQUIREMENT FROM SHE PILLAR
100 88 91
96 97 99 100 100
84 94
78 100 89 92
70 85 Activity Hazard Severity Prob. S*P
75 73
58 Loss Time in %
Cost in % Cumulative % 75 High Humidity Biological Effect on
Cumulative % 2 3 6
50 40 Level Due to mist respiratory system
45
50
18 Bacterial & PH
25 12 28 Skin Irritation 2 1 2
8 6 level Monitoring
4 3 2 2 2 2 1 25
12
0 4 3 Chance of
2 2 2 1 1 0 Safety sensors
0
inappropriate 2 1 2
working condition
functioning

No intimation of
Chance of alarm
safety alarm to 2 1 2
being ignored
dept.

Condition Base Tool life Real time capturing of minor and Real Time Monitoring of Mist
Monitoring micro stoppages. Collector Efficiency.
Auto Monitoring of manual check
Real time health Monitoring of
points.
critical machine elements
5 needs shortlisted
by prioritization
 FEASIBILITY STUDY
Options available in machine ? How to get Data?
Available/ Logical/Analytical
S No. Data to be monitored Hardware Required
Not Available Solution
Condition base Tool Life Can be derived by
1 Not Available __________
Monitoring monitoring spindle motor
load at time of cutting
Servo / Ball screw condition __________
2 Available __________
based life monitoring
Can be captured by logic __________
3 Capturing micro Stoppages Not Available
modification
Spindle Temperature __________ __________
4 Available
Monitoring
Mist Collector efficiency
5 Not Available F-Monitor Required
Monitoring
Auto Monitoring of Pressure Switches ,Float Switch,
6 Not Available
checkpoints Reed switches, Proximity sensors

Real Time data can be

Pressure Switches Pressure gauges F- Monitor
captured in PLC for all 6
Hydraulic Clamping Air Pressure To monitor
parameters Pressure feedback Monitoring Mist collector
Hydraulic pressure Efficiency
Pneumatic Clamping
Pressure feedback monitoring
 PROTOTYPING AND INSTALLATION HARDWARE
Requirements UPGRADATIONS
Spindle Temperature Capturing micro Real time Servo Load Mist Collector Auto Monitoring of
Tool Life Monitoring
Monitoring Stoppages Monitoring efficiency Monitoring checkpoints

MACHINES
Real time Servo load Data to PLC
data in servo drive INTERFACE
Analog Signal Ethernet connection

Digital Signal
INTERFACE
Intimation of Abnormal load to Maintenance Team Time Load Time Load
Interface
11:10:12:50 124 11:10:19:50 169
11:10:13:00 127 11:10:20:00 158
Dear All 11:10:13:50
11:10:14:00
129
135
11:10:20:50
11:10:21:00
155
175
11:10:14:50 158 11:10:21:50 238
11:10:15:00 211 11:10:22:00 175
Servo Motor – 11:10:15:50 257 11:10:22:50 162
11:10:16:00 137 11:10:23:00 75
Spindle load has 11:10:16:50 182 11:10:23:50 88

gone above warning

11:10:17:00
11:10:17:50
75
68
11:10:24:00
11:10:24:50
175
312
REAL TIME DATA
zone.
11:10:18:00
11:10:18:50
175
168
11:10:25:00
11:10:25:50
276
241
Real Time
Email Received 11:10:19:00 196 11:10:26:00

Real time Servo Motor Load

176
Monitoring
 MONITORING & RESULTS
Requirements

Spindle Temperature Mist Collector efficiency Auto Monitoring of Capturing micro

Tool Life Monitoring Servo Load Monitoring
Monitoring Monitoring checkpoints Stoppages

Autonomous Inspection
INSPECTION INSPECTION
Spindle Gear / Turret Gear Mist Collector
183/2000 (Hour)
Turret CAM/UC Cam
Clamping Pressure
362/2000 (Hour)
OK NOT OK
Flexible Hose Condition
74/2000 (Hour) Chip Conveyor

Fan Motor OK NOT OK

160/1500 (Hour)
Spindle Coolant Pressure
Air Filter Regulator
OK NOT OK
74/1000 (Hour)

Real Time Spindle Temperature Real Time Servo load Capturing Auto Monitoring of Checkpoints
Time Machine Alarm Alarm Message
Error
0VMC-09 OPR AIR PRESSURE LOW
Zone (RED)
THE DOOR OF THE SPLASH GUARD IS
0.08VMC-09 OPR
OPEN
Warning 1.6VMC-09 OPR AIR PRESSURE LOW
Zone (YELLOW) 0.21VMC-09 OPR
THE DOOR OF THE SPLASH GUARD IS
OPEN
Optimum 1.23VMC-09 OPR
THE DOOR OF THE SPLASH GUARD IS
OPEN
Zone (GREEN)
0.05VMC-09 OT (Y)+ OVERTRAVEL ( SOFT 1 )
0.95VMC-09 EX CTC PRESSURE LOW
Real Time mist collector
Real Time Servo load Capturing Real Time loss capturing
Efficiency Monitoring
How to Utilize Real time
the captured data?
 1.REDUCTION IN INSPECTION TIME
Manual Check Points (CLITA Sheet) Manual Check Points
S. No. Check Point Time Machine Layout/ Check Points
1.
Component Clamping
Pressure 20 sec 12
Chip Conveyor
6 Machines
2.
Hydraulic Main Line
30 Sec
7
Coolant tank X
pressure 4 3 10 13

3. Incoming Air Pressure 15 sec

8 6
12 5 Min/ Machine
Hydraulic
Spindle through Power Pack
4.
Coolant Pressure 30 sec Machine 9

Air seat sensor 2

5.
pressure 20 sec 1 30 Minutes
5
11 Check Points
6. Lubrication Pressure 30 sec
7. Coolant Level 20 sec DIGITAL COCKPIT POINT Inspection Time
40 30
Mist Collector Air seat Pressure
8. Lubrication Oil Level 25 sec OK NOT OK 30

Minutes
Hydraulic Pressure 20
9. Hydraulic Oil Level 20 sec Clamping Pressure OK NOT OK 10 6
OK NOT OK Lubrication Pressure 0
10. Panel Fan Motor 20 sec Chip Conveyor OK NOT OK
Before After
OK NOT OK Coolant Level
Productivity Improvement
11. Emergency Switch 15 sec Spindle Coolant Pressure OK NOT OK
OK NOT OK Lubrication oil level 250 240

Components
12. Chip Conveyor 35 sec OK NOT OK

Number of
Incoming Air Pressure
Emergency Switch 225
OK NOT OK
13. Air Filter 20 sec Hydraulic oil level
OK NOT OK
Chip Conveyor
TOTAL 300 sec OK NOT OK
OK NOT OK 200
Before After
 2. OEE IMPROVEMENT BY
ELIMINATING HIDDEN LOSSES & MICRO STOPPAGES
Comparison of Cycle No1 & Cycle No 4
Target vs Actual Production Std. Cycle Actual
Cycle No Difference
15 Output Plans Time Cycle time Cycle 1
Tool Cycle 4 Difference
No alarm and 1 378 378 0 (sec)
10 minor stoppages 2 378 382 4 1 6 6 0
5
3 378 378 0 2 11 11 0
4 378 386 8
3 14 14 0
0 5 378 379 1
9:00 9:30 10:00 4 8 8 0
6 378 385 7
5 22 22 0
ANALYSIS Variation in cycle time of Block No. 9,10,13,14 Corrective Action 6 18 18 0
7 12 12 0
Laser Beam Height 8 7 7 0
Water Droplet Shifted up by 0.2 mm 9 20 23 3
Laser Transmitter Laser Transmitter
10 18 20 2
11 13 13 0
12 28 28 0
13 36 37 1
Beam Refracted Receiver Receiver 14 24 26 2
15 37 37 0
Cycle Time Hidden Losses 16 23 23 0
405
390 383 400 17 22 22 0
Time (seconds)

378 18 12 12 0
seconds

300
370 200 19 23 23 0
100 20 24 24 0
0
350 0 Total 378 386 8
Before After Before After
 3. Condition base Health Monitoring of critical machine
elements
Machine Spindle

Forced Deterioration Natural Deterioration

(Due to High Cutting forces) (Due to more Friction)

Error Zone (RED)

Warning Zone (YELLOW)
Optimum Zone (GREEN)

Spare Cost/ Component Avg. Perventive Maint time

1
Rs/Component

40
0.7 30

Time (Minutes)
0.75
Cost in

30
0.5 20
10
0.25 0.15 10
Time Based Condition Based 0 0
Maintenance Maintenance Before After Before After
 4. TOOL LIFE OPTIMIZATION
30 Meters 400 Components
Life Recommended by supplier
4mm Drill (Combination tool) Tool life Improvement for 4mm Drill
1200
1200

Tool life in Numbers

900
600 400
300
Tool Wise spindle 0
Motor load Before After

Annual 4mm drill cost After life optimization

3 2.5

Cost in lakh
Spindle Motor load 2 1.5

Real time spindle motor load monitoring 0

300 Error Limit (RED) Before After
250
Spindle Motor Load

200
150 Warning Limit (YELLOW)
100 Tool life extended by
50 Life Recommended by
Tool manufacturer
monitoring Spindle load Optimum Zone (GREEN)
0

Number of Parts
Spindle motor load monitoring at time of cutting Operation
 5. MIST COLLECTOR EFFICIENCY IMPROVEMENT

Before 2016 2016-17 2017-18

Flow
sensor

Mist Collector Mist Collector

Servicing Required

Warning Zone

High Efficiency

NO MIST COLLECOTRS ON MACHINE MIST COOLECTORS ADDED ON MACHINES REAL TIME EFFICIENCY MONITORING OF MIST COLLECTORS

Coolant Mist & Humidity HIRA After Digitization

90 Before 2016 Addition of monitoring
Mist collector added
device
Humidity

Activity Hazard Severity Prob. S*P

81
60 73 78 77 79 76 74 Target - 55

56 60 58 59 62 High Biological
30 50 51 52 49 48 49 50 Humidity Effect on
2 1 2
Level Due to respiratory
mist system
 VALUE CREATION AND BUSINESS RESULTS
TOOLING COST SPARE COST
OEE IMPROVEMENT
REDUCTION REDUCTION

90 20 4 3.5
86 15.5 2.8
85 83 15 12.48 3
10.2
80 78 10 2
1.2
75 5 1
70 0 0
2016-17 2017-18 2018-19 2016-17 2017-18 2018-19 2016-17 2017-18 2018-19

SPARE REPLACEMENT INSPECTION TIME REDUCTION IN MANUAL

FROM TBM TO CBM REDUCTION FORMATS
300 260 50 400
40 300
40 300
200 30
140 30
200 150
100 20
6 100
10 10 20
0 0 0
2016-17 2017-18 2018-19 2016-17 2017-18 2018-19 2016-17 2017-18 2018-19
 LIFE CYCLE COST ANALYSIS
Total
Estimated Recurring Annual
S. No. Items Quantity Unit Price (One time S. Saving Annual
Life Cost Category Savings in
cost) No. Comp (Rs) Production
Lakhs
Pressure
1. 120 3500 4,20,000 5 years 42000
Switch
2. Float switch 80 2800 2,24,000 5 years 22400 1. Tooling Cost 5.3 2000000 106
Proximity
3. 60 400 24000 2 years 6000 Spare & Maint.
sensors 2. 2.3 2000000 46
cost
IOT
4. 2 6,00,000 1200000 -
software 0.20
3. Manpower cost 2000000 4
5. PC 2 74000 148000 5 years 14800
6. LED screen 2 32000 64000 5 years 6400 Miscellaneous
4. 0.10 2000000 2
Hardware & cost
7. - 400000
integration
Total 132 22.28 Lakh 0.91Lakh Total 2950000/- 158 Lakh
HORIZONTAL DEPLOYMENT
 HORIZONTAL DEPLOYMENT
SCOPE

Production Systems & Intelligent Energy & Utility Condition Monitoring Digital Supply chain
Maintenance System System

Solar cell efficiency improvement

EFFICIENCY IMPROVEMENT
STORE
LOGISTIC 0.97
REFRIGERATOR PLANT
WASHER
1 0.89
LINE 4
LIQUID NITROGEN AREA PLANT
REFRIGERATOR COMPRESSOR 0.8
PLANT PLANT
CANTEEN 0.6
GODREJ & BOYCE MFG. CO. LTD, MOHALI
0.4

0.2

SOLAR PANELS COMMON 0

POTENTIAL BEFORE AFTER
BUS BAR
DATA ON CLOUD

MANHOUR SAVING
Bi-Directional
meter 880
800

Time [Minutes]
600
INVERTER 400
200
0 ZERO
ENERGY METERS GRID BEFORE AFTER
 HORIZONTAL DEPLOYMENT
SCOPE

Production Systems & Intelligent Energy & Utility Condition Monitoring Digital Supply chain
Maintenance System System

Optimization of electric power consumption

MACHINES ENERGY METERS COMMUNICATION SYSTEM
(Connected to all machines)

DATA

REAL TIME DATA ON SYSTEM

Electric Power Consumption

40 31 28

Rs/Comp
30 25
20
10
0
2016-17 2017-18 2018-19
 HORIZONTAL DEPLOYMENT
SCOPE

Production Systems & Intelligent Energy & Utility Condition Monitoring Digital Supply chain
Maintenance System System

Material Lead time Reduction

LEAD TIME TO PROCURE
20
15

No of days
15

SUPPLIER 10
5 2
0
BEFORE AFTER

MANHOURS FOR LEVEL

MONITORING

Time in Minutes
LIQUID 1000
NITROGEN REFILLING LIQUID 750 780
720
SUPPLYNITROGEN
CHAIN
TEAM
500

ZERO
0
LIQUID NITROGEN AREA Jul-18 Aug-18 Sep-18 After
 HORIZONTAL DEPLOYMENT
SCOPE

Production Systems & Intelligent Energy & Utility Condition Monitoring Digital Supply chain
Maintenance System System

Intelligent Maintenance system for- AHU

Production Loss Eliminated by improving response time
Real Time Data
Data Monitoring of all
critical parts
8000 7000
6200
6000 5500
Data on Server 5000
3800
Grinding Section 4000
Chiller 1
AHU-1
2000
Chiller 2
300
0
Compressor
Assembly Line
2013-14 2014-15 2015-16 2016-17 2017-18 2018-19
Cooling tower 1
Power cost reduction by optimum Usage
AHU-2
ST Dept. Cooling tower 2 Monitoring Screen -1
2.84 2.96
3 2.76 2.57 2.59
Cooling tower 3 2.14
2

1
COMPRESSOR PLANT
0
Monitoring Screen -2 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19
 UNIQUENESS IN OUR APPROACH

DIGITIZATION

PROCESS EQUIPMENTS
Speed & Scalability

DIGITIZATION NOT IoT ENABLED IoT ENABLED

With In Plant

Trade Partners
Organizational level
OLD EQUIPMENTS NEW EQUIPMENTS

=
=
UPGRADED 40 YEARS OLD
EQUIPMENTS TO MAKE IT IoT
OTPM
KK

JH

QM
DM
PM

E&T
SH&E

ENABLED WITH THE HELP OF

LEAN
MACHINE APPROACH

5-S Moving Parallel

DIGITIZATION
 VALUE CREATION AND BUSINESS RESULTS
Tooling Cost FPY
40 100% 98.5%
32 30 96%
30 24 96%

PERCENTAGE
Rs/Appl.

20 92%
89%
10 88%
OPERATIONAL

0 84%
2016-17 2017-18 2018-19 2016-17 2017-18 2018-19
FINANCIAL YEAR FINANCIAL YEAR

25% Improvement 9% Improvement

OEE Process capability

88% 86% 2.00
1.67
84% 1.60 1.33
81% 1.20
PERCENTAGE

1.20

Cpk
80% 78%
0.80
76%
0.40
72% 0.00
2016-17 2017-18 2018-19 2016-17 2017-18 2018-19
FINANCIAL YEAR FINANCIAL YEAR
10% Improvement 39% Improvement
 VALUE CREATION AND BUSINESS RESULTS
VAPCO
CONVERSION COST (INDEXED)
20.00 16.60
100 15.30
INDEXED BASE 100
100 95
15.00
14.25
86
10.00
80

RATIO
5.00

60 0.00
FINANCIAL

2016-17 2017-18 2018-19 2016-17 2017-18 2018-19

FINANCIAL YEAR FINANCIAL YEAR

14% Improvement 16% Improvement

20 Inventory REJECTION COST

15 0.50 (AS % OF BOM)
12 0.40 0.32

PERCENTAGE
10 0.29
10 0.30
0.20
DAYS

0.20
0.10
0 0.00
2016-17 2017-18 2018-19 2016-17 2017-18 2018-19
FINANCIAL YEAR FINANCIAL YEAR

33% Improvement 40% Improvement

 Digitalization Roadmap Future Plan
2019- 2020
2018-2019 2020- 2021

100% Digitalization
1. Machines 1. Machine Data 1. Digital alerts
1. Application
2. Processes 2. Process Data 2. Dash boards
2. Software
3. Data points 3. Quality Data 3. Push SMS
3. ERP
4. User points 4. Productivity data 4. Updates
4. Servers

Production PLAN
system ACTUAL
Energy & PLAN
Utility
Monitoring ACTUAL
PLAN
Intelligent
Maint. ACTUAL
Digital PLAN
Supply
Chain
ACTUAL
THANK YOU