REVIEW

PRESENTATION

G.Pranay Teja
Engineer
R&D
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 CATIA EXPOSURE


SOLID MODELLING

DRAFTING

EXPOSURE OF PLM

DEALING WITH DUMB SOLID (while working on safari merline
roof unit ac)

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 VAVE PROJECTS


Packing Linearization

Packing material change from EPT to PVC

Brazing to Caulking

O-Ring Optimization

TXV Packing Optimization

Bracket Optimization

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 Team Formation: Mr.G.Pranay Teja
Mr.Subhash More
Mr.Sudhanshu Nayak
Mr. Ashraf Mirza
Mr.Somnath Sen (Facilitator)

Target: Cost Saving up to Rs. 1 crore.

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 Packing Linearization

Reason: Cost saving upto 23 lacs and also feasible to handle packing.

Before VAVE After VAVE

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 Project status:

Model
Drawing
Project Savings Existing New Drawing Submission CQF Drawing
in lacs Part No. Part No. Readiness to CQF Comments release
Status status

Packing X1 646689- 646689- Drawing Given to Approved Released

Linearization HVAC 1540-1-L 1540-2-L Ready CQF for
23 checking on
21-06-14

X1 646689- 646689- Drawing Given to the previous Released

HVAC 1490-0-L 1490-1-L Ready CQF for revision is
checking on not released.
20-06-14

Model-U 646689- 646689- Drawing Given to the previous Released

HVAC 2300-0-L 2300-1-L Ready CQF for revision is
checking on not released.
20-06-14

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 Result:

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 Packing material change from EPT to PVC

Reason:

Cost saving upto Rs.7432800

No risk for insulation application.

Desired properties in PVC foam sheet.

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 Material Test Certificate ( MTC)
Current RM (EPT) Proposed RM (PVC)

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 Project status:

Drawing
Project Savings Model Existing New Part Drawing Submission CQF Drawing
in lacs Part No. No. Readiness to CQF Comments release
Status status

SPRINT 646689-4990- 646648- Drawing

ALL 0-H 2380-0-L Ready
VARIANTS
646689-5000- 646648- Drawing
0-H 2390-0-L Ready

Packing SAFARI 646689-0811- 646648- Drawing

material 84 ALL 0-H 2470-0-L Ready
change EPT VARIANTS
to PVC
646648- Drawing
2490-0-H Ready

646679-0470- 646648- Drawing

0-H 2480-0-L Ready

TCIC 646679-0430- 646648- Drawing

1-H 2500-0-L Ready

TMCC 646649-0010- 646648- Drawing

ALL 0020- 2510-2520- Ready
VARIANTS 0030-0040-0- 2530-2540-
H 0-L
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 Drawing
Project Savings Model Existing New Part Drawing Submission to CQF Drawing
in lacs Part No. No. Readiness CQF Comments release
Status status

INDICA , 645422- 646648- Drawing

XENON 0180-1-H 2550-0-L Ready
ALL
VARIANTS

645422- 646648- Drawing

0020-0-H 2360-0-L Ready
Packing TMCC
material
change EPT
to PVC 646649- 646648- Drawing
TRAX 0640-0-H 2330-0-L Ready
GURKHA
ALL
VARIANTS 646649- Drawing
646648-
0630-0-H 2370-0-L Ready

Model-U 146649- 646648- Drawing

HVAC 4030-0-H 2560-0-L Ready
ALL
VARIANTS
646689- 646648- Drawing
9420-0-H 2350-0-L Ready

646689- 646648- Drawing

9310-0-H 2340-0-L Ready
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 Savings Calculation:

SL.NO EPT FOAM PVC FOAM Avg. Monthly Annual

. SHEET SHEET Require cost cost
ment saving saving
per in Rs. in Rs.
month
Part Cost Part Cost
Description Description

1 Foam 2450 Foam

Packing 520 180 347400 4168800
Packing
(900x2000 (900x2000x
x4mm) 4mm)

2 Foam 2150 Foam 450 160 272000 3264000

Packing Packing
(900x2000x (900x2000x
3mm) 4mm)

Total 7432800
savings
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 Result:

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 O-Ring Optimization
Reason:Cost saving

Before VAVE After VAVE

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 Project status:

Drawing
Project Savings Model Existing New Drawing Submission CQF Drawing
in lacs Part No. Part No. Readiness to CQF Comments release
Status status

O Ring 27 Model U 646689-2460- 649142- Drawing ReadyGiven to CQF

optimization Rear AC 1-L 1290-0-L for checking on
26-06-14

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 TXV PACKING OPTIMIZATION

Reason: cost saving

Before VAVE After VAVE

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 Project status:

Drawing
Project Savings Model Existing New Drawing Submission CQF Drawing
in lacs Part No. Part No. Readiness to CQF Comments release
Status status

TXV Packing 6 Model U 646679-4780- 646679- Given to CQF

optimization Front AC 0-L 4780-1-L Drawing Ready for Checking on
01-07-14

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 BRACKET OPTIMIZATION

Reason: cost saving

Before VAVE After VAVE

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 Project status:

Drawing
Project Savings Model Existing New Drawing Submission CQF Drawing
in lacs Part No. Part No. Readiness to CQF Comments release
Status status

Bracket 3.7 Model-U 647700-4070- 647700-

Optimization MDI cond 2-H 4070-3-H Drawing Ready

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 BRAZING TO CAULKING

Reason: cost saving

S.no. Before VAVE

After VAVE

Manufacturing Manufacturing
process includes process is optimized
the Brazing by elimination of
process. brazing process which
results in reduction of
manufacturing cost.

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 Cost Comparison between brazing and caulking:
S.NO. RESOURCES BRAZING CAULKING COST COST EXTRA COST PAID
SAVING SAVING/ FOR UNION
RS./PCS YEAR CHANGE /YEAR

1 Man Power 3 1 - 288000 96000

2 Material (union Rs.5/pcs Rs.6/pcs - - 270000
half)
3 Oxygen cyl 0.32 0 86400
4 Acetylene cyl 0.65 0 175500
5 Filler wire 0.24gm/joint Not required 0.316 85304
6 Flux 0.45gm/joint Not required 3.356 906138
7 2-chamber Elyklin 0.004 Not required 0.82 177120
ultrasonic M/C ltr/pcs

Water
Not
required
Negligibl
e
Nitrogen
Not Limited. All rights reserved
© Subros
 Net cost saving: Rs.1738334

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 Drawing
Project Savings Model Existing New Drawing Submission CQF Drawing
in lacs Part No. Part No. Readiness to CQF Comments release
Status status

O Ring 27 Model U 646689-2460- 649142- Drawing ReadyGiven to CQF

optimization Rear AC 1-L 1290-0-L for checking on
26-06-14

TXV Packing 6 Model U 646679-4780- 646679- Given to CQF

optimization Front AC 0-L 4780-1-L Drawing Ready for Checking on
01-07-14

Bracket 3.7 Model-U 647700-4070- 647700-

Optimization MDI cond 2-H 4070-3-H Drawing Ready

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 Project Savings Model Existing New Part Drawing Readiness Drawing CQF Drawing r
in lacs Part No. No. Status Submission Comments statu
to CQF

Brazing TO 20 Model-U 646210- 646210- Drawing Ready

Caulking 3670-1-H 3670-4-H

646210- 646210- Drawing Ready

4440-1-H 4440-3-H

646210- 646210- Drawing Ready

3690-0-H 3690-4-H

646210- 646210- Drawing Ready

3750-0-H 3750-1-H

Xenon PAB 646180- 646180- Drawing Ready

LHD & RHD 4050-0-H 4050-1-H

BUS AC 646180- 646180- Drawing Ready

3290-0-H 3290-1-H

Drawing Ready
646180- 646180-
3910-0-H 3910-1-H
© Subros Limited. All rights reserved 646180- 646180- Drawing Ready
© Subros Limited. All rights reserved
 Project Savings Model Existing New Part Drawing Readiness Drawing CQF Drawing r
in lacs Part No. No. Status Submission Comments statu
to CQF

Brazing TO 20 Model-U 646210- 646210- Drawing Ready

Caulking 3670-1-H 3670-4-H

646210- 646210- Drawing Ready

4440-1-H 4440-3-H

646210- 646210- Drawing Ready

3690-0-H 3690-4-H

646210- 646210- Drawing Ready

3750-0-H 3750-1-H

Xenon PAB 646180- 646180- Drawing Ready

LHD & RHD 4050-0-H 4050-1-H

BUS AC 646180- 646180- Drawing Ready

3290-0-H 3290-1-H

Drawing Ready
646180- 646180-
3910-0-H 3910-1-H
© Subros Limited. All rights reserved 646180- 646180- Drawing Ready
© Subros Limited. All rights reserved