Low Cost Automation Case Studies, Studies by Tetrahedron Manufacturing Services Pvt Ltd Cost Reduction In Manufacturing || Manpower Reduction/Optimisation

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Low Cost Automation
Case Studies

2. Automation for Quality Improvement of Assembly
Line
India’s Largest Two Wheeler Manufacturer
(Before Tetrahedron –
1. Problems in Engine Assembly Line ; Part Mismatch and Missing
Components
2. Frame Assembly Quality Issue”)
Tetrahedron studied the Assembly line in detail and suggested
changes; more over made sure that the engineers are
comfortable with the existing technologies
Following results were achieved :-
1. Development and Implementation of Poke Yoke Device in order to
churn assailable products
2. Implementation of Low Cost Automation to reduce product
rejection issues to zero.

3. Automation Implementation and
Manpower Reduction (On going)
India’s Largest uPVC Manufacturer
(Before Tetrahedron:
1. High Cost due to High Manual Manufacturing
2. Low Productivity due to non standardized product
3. High WIP because of Material Handling
4. High Manual Packaging leading to high labour Costs ”)
Tetrahedron studied the entire production line and helped in
identify at least 43 opportunities to implement automation .
With this in mind, 17 high impact projects were taken on.
Following results were achieved:-
1. 36% Manpower Reduction
2. Ideation and Implementation of end to end Material Handling
3. Material Handling breakages reduced by 70%

4. Material Handling and Process Automation
(On- Going)
India’s Largest Precious Metal Exporters
(Before Tetrahedron
1. Extremely labour intensive operations resulting to high costs
2. High pilferage of precious raw materials
3.Quaterly INR 40 Lacs of raw material unaccountable or pilfered )
Tetrahedron helped the company to turn around the operations of
the company in an industry which resistant to change.
Following results have been achieved:-
1. 15% reduction in Manpower; 20% reduction still on going

5. Innovation & Strategy Management
Leading Manufacturer of Electric Vehicle Parts & Energy Solution
Before Tetrahedron
1. Stagnant Market for last 2 years due to competition
2. Missing Linkage between Operations and Revenue Generation
3. Top Management looking for Innovative New Approach
Tetrahedron implemented various Innovative Approach like TRIZ, Design
Thinking, Five Step Discovery Process to hand hold senior managers for
new product development with clear focus on customer need and revenue
potential. Implemented Balance Score Card, Hoshin Kanri and Daily Work
Management Principle to link each individuals activity with annual target on
Customer Focus, Financials, Internal Process and Learning & Growth

6. Gearing-Up for Industry 4.0
Leading Automotive Part Manufacturer
Before Tetrahedron
1. Struggling with managing supply chain of 12 plants across India
2. Deadline by OEM customer for implementing Industry 4.0
Tetrahedron Conducted Pre-assessment and strategizing a blueprint of
implementation of Industry 4.0 elements with respect to company’s
strengths. Conducting ROI Analysis and Cost Benefit for 9 elements of
Industry 4.0 made action plan for 2 yrs for implementation. The main focus
was to streamline supply chain of all 12 plants to reduce cost and improve
efficiency
• 3 out of 9 elements selected for Industry 4.0 implementation

7. Automation for Feeding of Rubber to Improve
Productivity and Quality
Leading Tire Manufacturer in North India
(Before TMS – Long cycle time for weighing the natural rubber and chemical
that would feed the heater for base preparation. Long Cycle time as well as
manpower fatigue, incorrect batch composition was leading to productivity
loss as well as quality problems. When enquired by TMS, the manager said
“we need more manpower to execute/produce given quantity and quality”)
Tetrahedron developed the automation map of the company and
identified 3 solutions for automating the process described
above. Following result achieved in 2 months:-
1. Cycle time standardized for all 6 Heaters
2. Batch consistency improved from 67% to 92 %
3. Manpower saved / Heater = 8 /Machine to 3 Per Machine