Chinas enviable growth has been GDP (USD billion) primarily driven - PowerPoint PPT Presentation

China’s enviable growth has been GDP (USD billion) primarily driven by: • China’s careful planning CHINA • huge investment in infrastructure • incentives and subsidies • progressive decentralisation • market-oriented reforms contributed to its manufacturing revolution Now, through the Made in China INDIA 2025 strategic plan, the government is incentivising Chinese companies to leapfrog on the technology forefront by encouraging manufacturers to upgrade their factories in terms of Manufacturing as a % of overall GDP quality, productivity and digitisation. INDIA 16-17 % CHINA 29-30 %

Cost and Quality of Power • Cross subsidization along with additional tax like coal cess, RPO and PAT • In terms of quality of power, India ranks 80 out of 137 countries (WEF) • highest transmission and distribution losses in electric power in Asia High Logistics costs • 60% cargo travels by road • Indian logistics costs are 14-15% of GDP, almost double of the 7-8% of GDP in developed countries Growing skill mismatch and low labour productivity • Only 4.7% of India’s workforce is formally skilled, vs 96% (South Korea) and 24% (China) • Productivity in value added/ hr: China and Brazil is 1.6 and 2.9 times India Negligible R&D Investment • India’s spending on R&D as a share of GDP is 0.6% vs China (2.1%), South Korea (4.2%) and Israel (4.3%) • Need for greater government spending, and also industrial application oriented R&D

Productivity Lower Productivity directly impacts directly either the quantity or the quality of the final product Technology Labour • Better engagement/ Motivation • Digitization • Improving the quality of • Automation India’s productivity is only 60-65% training/ education • Industry 4.0 • of that of China. This represents a Industry-government • Increase R&D huge scope to become competitive tie-ups to train expenditure workforce

 Skilled manpower shortages & increasing cost  Traceability and Data acquisition  Mass Customization  Accomplish what cannot be done manually  Consistency in quality of output  Reduce manufacturing lead time & increase production  Improve worker safety and reduce fatigue

TITAN Company TEAL AUTOMATION Provides TURNKEY ASSEMBLY & TESTING SOLUTIONS Transportation Energy Life Science Engineering Consumer Products

 Case - Secondary Packaging Line (Sorting & Stacking of Carton Boxes)  Customer concern - Operator Fatigue reduction  Solution - Fully Automatic line with 6 axis robot

 Case : CLUTCH Assembly Line  Concern of the customer : To track the product process parameters at each stages.  Solution : Tracking the product assembly using RFID technology to log the process parameters . with the ERP system.

 Case : Contactor Assembly line  Challenge : 220 Variants to be Handled  Solution : Manufacturing Order Indent for the line directly comes from Vendor through server

 Case - Pencil Sorting Machine  Concern of the customer - To avoid manual inspection of the Pencil lead  Solution - Fully Automatic Testing machine using Vision system to segregate into three categories at a rate of 25 pencils / second

 Case : MCB Assembly Line  Concern of the customer : To produce MCB at a rate 2.3 Secs / Pole  Solution : Automatic line with complete traceability of the product

 Case - Drive shaft assembly & Testing  Customer concern - Safety of operator due to high tonnage Hydraulic presses  Solution - Systematic analysis & implementation of Safety systems as per the EN standards

Jewellery making

Bling Setting – Doubling the Productivity Objective : Double Productivity of Wax Setting while Achieving Quality Equivalent to Metal Setting Existing Process • Skill dependant • Slot to be cut manually for seating the diamond • 300 Stones per /Shift / Person Improved Process • Slot taken at CAD stage itself • Deskilled the setting activity • 600 Stones per /Shift / Person Diamond is set in wax piece with an assuring “Click” Outcome : 128 designs converted in this route in phase 1 and produced products with 3.5 Lakhs Diamonds in 8 months

Doubling Capacity at Refining with Productivity Improvements Aqua-Regia Refining Process to convert impure gold to 9999 purity gold Lead Time Improvements Mar'17 Mar'18 Mar'19 Melting & Graining 60 60 35 Grains Drying 120 60 60 Aqua Regia Dissolution & Filtration 420 240 180 Precipitation & Filtration 140 90 80 Acid Treatment for 9999 gold 80 45 0 Melting & 9999 Gold granulation 90 90 70 Granules drying 60 60 60 Total (in Mins) 970 645 485 Total (in Hrs) 16.2 10.8 8.1 Key Improvements Benefit : Capacity Improved • End point Determination from 80kg/day to 150kg/ day • Tumbler Speed Optimisation & Automation • Acid Addition Sequence Change

Productivity enhancement through… Use of New Process Innovation Design Innovation Technologies

01 Setting Lever component Productivity Enhancement Through Design & Process innovation

Watch Module Setting lever component Low productivity Challenge Increasing overhead cost High skill dependency Higher volume requirement Trigger De-Skilling De - bottleneck Business capacity

Approach & Solution Developed Alternative Process • Single stage to Progressive tool Before • Automatic feeding instead Manual feed • Modified the part to suit the process After • Initial investment on tool making – One time

Benefits 81 Process Cost per Cost per % Units Componen Componen Sl. No Description Benefits Energy Energy t t Consn. / Consn. / Existing Modified 1000 Compt. 1000 Compt. 90 Lead time Lead time Rs. 31 Tons Co2 31 Tons Co2 % 1 Cost per Component Rs 1.33 0.24 Less by 81 % Reduction Reduction 70 1.33 to 0.24 kWh. % Days 30 to 3 2 Production Lead time Days 30 3 Less by 90 % 2.38 to 0.72 3 Manpower requirement Numbers 5.5 2 Less by 64 % IMPACT IMPACT Raw material required / 900% 900% Manpower Manpower Machines Machines 4 Kg. 0.326 0.191 Less by 41 % component Requirement Requirement Required Required Productivity Productivity 64 66 Improvement Improvement Standards lead time / % Nos. 5 Hours 1.467 0.16 Less by 90 % Nos. % 1000 Component 3 to 1 5.5 to 2 6 Tooling Requirement Numbers 6 1 Less by 84 % Tooling Tooling 84 Raw Material Raw Material 41 7 Machines required Numbers 3 1 Less by 66 % Requireme Requireme % Required/ Required/ Std. Time Std. Time % nt nt Component Component / K / K Energy Consumption / Kg. 8 kWh 2.38 0.72 Less by 70 % Compts. Compts. 1000 Component 0.326 to Nos. 6 to 1 90 Hrs. 0.191 % 1.467 to 0.16

Watch manufacturing

 Approach automation considering all the below factors: • No. of people • Safety • Quality • Productivity • Consistency  Automation Only for replacing the people will not be a right option  Child parts without consistency in manufacturing can bring more minor stoppages to machine operations  Automation with compromise's on safety can be disastrous  Automation without focusing on Quality & Productivity can help in achieving the final products with less output rate and more rejections