INDIA’S LARGEST VALVE MANUFACTURER IMPROVES PRODUCIVITY BY 22% THROUGH INDSUTRY 4.0 SOLUTIONS.

ABSTRACT

One of the largest tyre valve manufacturer struggled to scale-up due to uncertainty in cycle time. After subscribing to METI industry 4.0 solutions productivity improved by 22% and the manufacturer got clarity on cycle time.

 

CUSTOMER PROFILE

One of the largest tyre valve manufacturers in India with an unflinching focus on setting a global benchmark in tyre valve manufacturing process and quality.

 

PROBLEM

The client’s vision to set benchmark standard in tyre valve production was hurt by loss of productivity in one of the units. The main reason for this was poorly set production target based on an assumed cycle time.
The process involved loading the hot tray of the pressing machines with rubber and valve. The machine would press the rubber to the valve and it took 4mins. The time for pressing process was known to the client but the time it took to load and unload the machine by the operators was unknown. This unknown downtime contributed to uncertainty in cycle time and eventually production loss.
The client was looking for a solution to monitor the process in real-time so that decision on optimizing the target and process could be taken.

 

SOLUTIONS AND OUTCOME

METI, with its devices, provided the client with the right solution by connecting all the press machines in the unit. A platform was created for the machine to communicate with the management. The installation process was completed within days and METI started providing meaningful real-time data on the production process to the client.
By making data accessible to the concerned person at all times and through visuals and reporting via cloud, METI helped the client realize that the average cycle time they had set was very high and helped in reducing it by 20 percent. The then client quickly increased the batch target and improved productivity by 22%.