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

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

May 25, 2023 125 likes •360 views

Chinas enviable growth has been GDP (USD billion) primarily driven by: Chinas careful planning CHINA huge investment in infrastructure incentives and subsidies progressive decentralisation market-oriented

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CHINA INDIA

GDP (USD billion) Manufacturing as a % of overall GDP INDIA 16-17 % CHINA 29-30 % China’s enviable growth has been primarily driven by:

  • China’s careful planning
  • huge investment in infrastructure
  • incentives and subsidies
  • progressive decentralisation
  • market-oriented reforms

contributed to its manufacturing revolution Now, through the Made in China 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 quality, productivity and digitisation.

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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
  • riented R&D
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Productivity Technology Labour

  • Better engagement/

Motivation

  • Improving the quality of

training/ education

  • Industry-government

tie-ups to train workforce

  • Digitization
  • Automation
  • Industry 4.0
  • Increase R&D

expenditure Lower Productivity directly impacts directly either the quantity or the quality of the final product India’s productivity is only 60-65%

  • f that of China. This represents a

huge scope to become competitive

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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

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TITAN Company

TEAL AUTOMATION

Provides TURNKEY ASSEMBLY & TESTING SOLUTIONS

Transportation Energy Life Science Engineering Consumer Products

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 Case

  • Secondary Packaging Line (Sorting & Stacking of Carton Boxes)

 Customer concern - Operator Fatigue reduction  Solution

  • Fully Automatic line with 6 axis robot
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 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.

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

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 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

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 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

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 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
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Jewellery making

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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

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Doubling Capacity at Refining with Productivity Improvements

Improvements Lead Time 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 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

Benefit : Capacity Improved from 80kg/day to 150kg/ day Key Improvements

  • End point Determination
  • Tumbler Speed Optimisation & Automation
  • Acid Addition Sequence Change

Aqua-Regia Refining Process to convert impure gold to 9999 purity gold

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Productivity enhancement through…

Process Innovation Design Innovation Use of New Technologies

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Setting Lever component

Productivity Enhancement Through Design & Process innovation

01

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Setting lever component

Low productivity Increasing overhead cost High skill dependency

Challenge

Watch Module

Higher volume requirement De-Skilling De - bottleneck Business capacity

Trigger

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Approach & Solution

Developed Alternative Process

  • Single stage to Progressive tool
  • Automatic feeding instead Manual feed
  • Modified the part to suit the process
  • Initial investment on tool making – One time

Before After

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Benefits

Cost per Componen t Cost per Componen t

IMPACT

900%

Productivity Improvement

IMPACT

900%

Productivity Improvement Lead time Lead time Manpower

Requirement

Manpower

Requirement Raw Material Required/ Component Raw Material Required/ Component

  • Std. Time

/ K Compts.

  • Std. Time

/ K Compts.

Energy

  • Consn. /

1000 Compt. 31 Tons Co2 Reduction Energy

  • Consn. /

1000 Compt. 31 Tons Co2 Reduction

Machines Required Machines Required Tooling Requireme nt Tooling Requireme nt

0.326 to 0.191

Kg.

5.5 to 2

Nos.

30 to 3

Days 6 to 1 Nos.

1.467 to 0.16

Hrs. 3 to 1 Nos.

2.38 to 0.72

kWh.

1.33 to 0.24

Rs.

90 % 64 % 41 % 90 % 84 % 66 % 70 % 81 %

  • Sl. No

Description Units Process Benefits Existing Modified

1 Cost per Component Rs 1.33 0.24 Less by 81 % 2 Production Lead time Days 30 3 Less by 90 % 3 Manpower requirement

Numbers

5.5 2 Less by 64 % 4 Raw material required / component Kg. 0.326 0.191 Less by 41 % 5 Standards lead time / 1000 Component Hours 1.467 0.16 Less by 90 % 6 Tooling Requirement Numbers 6 1 Less by 84 % 7 Machines required Numbers 3 1 Less by 66 % 8 Energy Consumption / 1000 Component kWh 2.38 0.72 Less by 70 %

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Watch manufacturing

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  • No. of people
  • Safety
  • Quality
  • Productivity
  • Consistency

Approach automation considering all the below factors: 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

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