OD INTERVENTION

Manu M Nair
Oswal Electricals Pvt. Ltd
 Incorporated on 01 October 2003.
 Subsidiary of the “Oswal Group of Industries”.
 Headquartered at Faridabad, Haryana.
 Manufacturer of High Pressure Aluminum Die Cast Components in India.
 Annual turnover of approx. 70 Million US Dollars.
 Production capacity of about 24000 tons of casting annually.
Products/Services
Robots are Successfully Used in a Wide Range
of Casting Processes.

 Die casting
 Sand casting
 Chill casting
 Lost foam process
 Investment casting
 Background of the problem
 Transformation from the manual production to automation in 2015.
 Focused on increasing productivity, reduce time and reduce wastage
 Earlier used manual technique for Casting metal.
 In 2015 they introduced Robots Technology
 Resulted in reduction of employee productivity and engagement due to lack of awareness
 Why?
 Automation is becoming increasingly important in many different industries around the globe. The sharp
increase can be explained by the high potential of robots and continuous optimization processes in the
manufacturing industry.
 Robot-based automation increases efficiency and productivity and guarantees maximum precision.
 One aspect is particularly important when safety-relevant parts are manufactured.
 They ensures a safe and healthy work environment.
 Robots in foundries can also save floor space because they can work in confined areas.
 Generate a great deal of added value for workers as they are exposed to work under high temperatures, noise
and chemicals in this industry.
Before Implementing the Technology
 Observe the current job routine. System designers visited the factory floor several times
and each time interviewed eight to ten operators about their work procedures.
 Pay special attention to those parts of the work that required users to make decisions or
seek information about which tools or materials to use, which sequence of steps to follow
in machining, and which jobs operators ought to run first.
 Discuss with workers what they found especially frustrating or rewarding about their work.
In this case, it turned out that they liked some flexibility in the sequencing of jobs, felt that
the choice of materials should be theirs, and were often frustrated by the difficulty of
finding tools.
 Examine how this manufacturing process related to others. The machine operators were
extremely dependent on materials personnel,maintenance, the tool room, and order
expediters.
Steps to be taken

1. Organization assessment

 Studying the production line of the product

 One to one interaction with the production engineers involved
 Surveys to analyse the employee understanding and satisfaction regarding the top
management decision
 Get company-wide support
STEPS TO BE TAKEN

2. Goals and objectives

 To provide training to the employees in different levels about the usage of machineries
 To provide training to employees on safety precautions
 To make them understand the need for automation
 Reduced risk of personal injury
 Development of team spirit as a culture and behavioral change
 To bring in involvement ,commitment and training in employees
STEPS TO BE TAKEN

3. Action Plan

 Providing training to all employees.

 Deploy the pilot phase
 Managing product work flow.
 Employee Skillset and Training
 Circulate feedback forms to understand their level of satisfaction
STEPS TO BE TAKEN
4. Implementation

 Review by Board and Senior Management

 Approval by Board of Directors

5. Evaluation

 Compare the level of productivity of plant before and after automation

 To circulate feedback forms to understand level of effectiveness of training
 End of every month, productivity report is prepared. The actual productivity of each
department is compared with the benchmarks and root-cause analysis is done for any gaps.
WHY OD
 Top management involved
 Whole system involved
 Change was planned, Sequential process followed
 Collaborative effort
 Aimed at organizational effectiveness and change
THANK YOU