Case Study 1
input
A critical sub-assembly which was manufactured in-house had a lot of process design flaws.
output
The product now is being outsourced to get the benefit of latest technology at same cost. The client is now more focused on its core areas.
challenge
- Serviceability. Onsite repair was a time taking process because the entire assembly had to be disassembled even for small faults.
- Leakage in the pneumatic assembly used in power generation. As this assembly was used in PNG distribution, so the leakage was a big problem.
- Rusting. This product was exposed to harsh weather conditions (sun and rain) which led to rusting.
- Aesthetics. This product played an important part in the aesthetics of the bigger assembly as it was externally visible.
solution
A. Eliminated welding and introduced flanges, couplers and Teflon washer without any addition in the cost. This helped in
A. Reduced repair time and eased the repair process.
B. Leakage completely eliminated.
B. Introduced special plating instead of powder coating to eliminate rusting and improved aesthetics without any additional cost. Even though the special plating was expensive but with increased efficiency and reduction in the rejection, cost was not impacted.
result
- Reduced post sales repair hassles.
- Increased shelf life.