GetZetGo

Project case - New product development

Sastry — Sat, 31 Jul 2010 18:25:26 +0000

A West Indian auto electrical manufacturer, supplier to major Indian automobile manufacturer was looking for developing new starter motors and wiper motors for two wheelers and three wheelers. Five different types of starter motors and two different types of wiper motors were developed over a period of three years. A team of four engineers was involved from conceptualization to commercialization phases.

Back to Manf-services

Project cae - Process planning

Sastry — Sat, 31 Jul 2010 18:25:19 +0000

A West Indian auto electrical manufacturer, supplier to major Indian automobile manufacturer wanted to evolve production process plan for systematically manufacturing the component in production lines including built in QC systems.

Systematic Process planning was evolved for 5 different starter motors and two different wiper motors for Bajaj Auto Ltd, which later were introduced in production lines of client facility.

Back to Manf-services

Project case - Low cost automation

Sastry — Sat, 31 Jul 2010 18:25:12 +0000

A south Indian auto electrical supplier was supplying starter motor yokes to an international auto electrical manufacturer. The field pole fixing holes were made by a multi spindle horizontal drilling machine. This operation was producing enormous burrs which was difficult to clean and also hazardous to the operators. It consumed nearly 90 seconds per components.

A team of three engineers worked on the project and a new system was developed to carry-out the same operation. The new operation was totally burr free, much faster (20 seconds) and occupied 25% of the floor of the horizontal drilling machine. The machine used was a general purpose machine.

Back to Manf-services

Project case - Design and manfacturing of tools

Sastry — Sat, 31 Jul 2010 18:25:03 +0000

More than 1000 press tools and molding tools were designed and manufactured for various components of different products like starter motors, wiper motors, head lights, horns, rice cookers, seat sliders, seat recliners. The team also developed the assembly lines and fixtures for all the above products.

Back to Manf-services

Project case - Reverse engineering

Sastry — Sat, 31 Jul 2010 18:21:26 +0000

A south Indian domestic appliances manufacturer was trying to differentiate product offering on health and enhanced functionalities. A rice cooker modeled on imported rice cooker was developed by reverse engineering. The imported rice cooker had inherent drawbacks like improper functioning and health hazards. A new cooker was developed after eliminating the defects. The samples of new design were developed and tested successfully.

Back to Manf-services

Project case - Value engineering

Sastry — Sat, 31 Jul 2010 18:20:08 +0000

A south Indian auto electrical supplier was supplying starter motor yokes to an international auto electrical manufacturer. The yoke was manufactured by rolling and welding. Due to the inherent process deficiencies, a substantial part of production (as high as 30%) has been found defective (leaky). This defect had forced the 100% segregation of the component (each component weighing about 2.5 Kgs of steel and occupying 0.25cft of shop volume). Also the company was experiencing scrapping of components worth about Rs.18 lakhs per year.

A team of three engineers worked for three months on the project. 30% of 20,000 components were separated, reworked and rechecked by shop inspectors. Sometimes, defective parts were passed due to fatigue and over sight. This situation was rectified by modifying the existing process without adding any extra operations, tested and introduced successfully.

Back to Mech-eng-services

Project case - Prototyping

Sastry — Sat, 31 Jul 2010 18:15:25 +0000

A north Indian manufacturer of electrical desert coolers was looking for power saving switches for differentiating product features to capture major seasonal demand in dry areas.

A team of two engineers worked on the project for three months to design and develop the prototype. These switches were be used to switch on and switch off any electric unit.

The units were used with a desert cooler; the usage of power was be reduced by 50%, which meant a saving of about 0.5 units per day. The usage of water also was also reduced by approximately 50% of normal usage. The reduced water usage eliminated the discomfort of higher humidity in the closed rooms.

Back to Mech-eng-services

Project case - Design services

Sastry — Sat, 31 Jul 2010 12:57:04 +0000

A south Indian based electrical appliances manufacturer was interested to explore new model mosquito repeller that would function for four hours with out power supply. The client approached us for a design and prototype development.

A team of two worked from concept to prototype development. The mosquito repeller system which can perform its function without powers supply 4 hours has been developed from concept. The prototype was developed and tested to match the requirement set by the client.

Back to Mech-eng-services