Our client required products developed from special grade aluminium and compromising on quality was not an option. Because these parts were required for application in space, precise tolerance and adherence to complex domestic features and dimensions was a must.

Our Process

• Firstly, we planned the manufacturing process, which included multi-axis machining and the use of a turn mill.
• We prepared the failure modes and effects analysis (FMEA) of the process and control plan to make a first-time-right product.
• Then, we developed jigs and fixture to manufacture various complex geometric features.
• We also conducted trials on prototypes to make sure that specific features and the tolerance adhered to the requirements.

In a nutshell, we produced 72 horns for inflight use, which were thoughtfully manufactured for space application.

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Due to concerns regarding proper quality and regular supply, our Europe-based client wanted to switch from their previous supplier based in China & wanted a domestic supplier who could provide them with quality products at value pricing.

Because quality is of paramount importance when it comes to these products, they were looking for a manufacturer who could carry out precise turning and surface finish. To ensure premium products at a 35 micron, a non-conductive coating process would have to be used. Moreover, the client wanted a special grade of bronze to be processed with specific grain structure to be used in the products

Our Process

• We started by properly defining the manufacturing process and the control plan to produce precisely machined electrodes from bronze rods.
• Next, we prepared a special purpose jig for the application on non-conductive coating.
• Moreover, we used a UV based coating material to inspect the coating under UV light.
• Finally, the electrode was verified for end application by the OEM.

In a nutshell, 3 million electrodes were supplied to different parts of the world, including China.

Primary Result

• Due to our continuous efforts to improve the quality of the machining and coating process, we have been the sole supplier for the client for more than 10 years.

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Our client was developing a product which they used to source from a foreign subsidiary. They were looking for a domestic supplier who could tackle the challenges that they were facing on the first hand in development stage, when they approached us.

On one hand, the production set up had to be established within a time of 4 months, in order to meet local demand. And on the other hand, the manufacturing process was not available anymore.

To deliver this product, we had to employ a precision machining process for the holes of the tube sheet as well as surface finish, because compromising on quality was not an option.

Additionally, the client wanted parts that could function efficiently and not be prone to leakage in high pressure conditions. So, the steps of welding and fabrication were absolutely necessary for the cover.

Our Process

• We started by defining the manufacturing process on the basis of previous drawings and our interaction with the supplier.
• Then, we imported VMC machines and established the manufacturing setup for precise machining of holes and surfaces.
• Next, we developed tools and dies, so that we could carry out deep draw for dishends.
• And of course, we wanted to ensure that the products manufactured had zero defects. So, we established a fabrication and welding setup.

In a nutshell, we developed a ‘make in India’ product and localised most of the components as well. By the end of this process, we began to develop and supply 60-70% of the parts.

Primary Results

• The overall costs dropped down by about 60%.
• The lead time was shortened from 6 months to 1 month.
• Year-on-year value engineering projects were identified and implemented. As a result, the costs improved by 25%.
• Our production capacity rose from 80 sets a year to 600 sets a year.

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Our Client wanted a domestic substitute in order to avoid import of parts from China. They did not have a prior domestic supplier when they approached us.

While solving challenges such as long lead times of almost 3 months and high import costs, we had to deliver quality products. And at the same time, we had to avoid inventory pile up that happens due to high lead times and uncertain, seasonal demand based on air conditioner sales.

The client was also levied with substantial landed costs, accrued in US dollars. The demand was high, so even a slight increase in costs resulted in an immense difference. To illustrate, the demand was around 30,000 pieces per month in 2011-2012. Today, it has risen up to 2.5 lakh pieces per month.

To add to our worries, the supplier just shared part drawings, and the processes involved in the production of those were not available anymore.

Moreover, part is a functionally critical one because even a minute deviation in dimension can lead to heavy noise and vibration in the indoor unit on a split air conditioner. So, the onus was on us to develop a precisely manufactured part while saving time and money for the client.

Our Process

• We carried out a tear-down analysis of the part. Along with this, we prepared drawings of the individual parts as well as the final component.
• Next, we defined the specifications for the raw materials and the finished component. Accordingly, we determined the manufacturing process.
• In the development stage, we laid special focus on precise aluminium machining and metal rubber bonding through moulding.
• Keeping the criticality of application in mind, we defined the important characteristics. As per these, we carried out failure modes and effects analysis (FMEA) of the design and the process.
• Additionally, we prepared a control plan and a quality plan for all the respective parts.
• After conducting a successful machining moulding trial, the manufacturing process was established.
• Subsequently, manufactured a pilot lot and got the parts approved by an OEM based in Japan.
• Finally, the production capacity was ramped up to meet the demand.

In a nutshell, we reduced the landed costs in US dollars which would have been almost 63% more than what the client ended up bearing in INR as a result of collaborating with us.

Primary Results

• The lead time usually faced after placing an order was reduced from 3 months to 5 days.
• Even though timely delivery was ensured, the existing inventory pile-up was reduced by 90%.
• A year-on-year process improvement further led to 20% reduction in cost.

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