Developing a part and establishing a production facility for the same

The Challenge

Our client was developing a product which they used to source from a foreign subsidiary. They were looking for a domestic supplier who could tackle the challenges that they were facing on the first hand in development stage, when they approached us.

On one hand, the production set up had to be established within a time of 4 months, in order to meet local demand. And on the other hand, the manufacturing process was not available anymore.

To deliver this product, we had to employ a precision machining process for the holes of the tube sheet as well as surface finish, because compromising on quality was not an option.

Additionally, the client wanted parts that could function efficiently and not be prone to leakage in high pressure conditions. So, the steps of welding and fabrication were absolutely necessary for the cover.

Our Process

• We started by defining the manufacturing process on the basis of previous drawings and our interaction with the supplier.
• Then, we imported VMC machines and established the manufacturing setup for precise machining of holes and surfaces.
• Next, we developed tools and dies, so that we could carry out deep draw for dishends.
• And of course, we wanted to ensure that the products manufactured had zero defects. So, we established a fabrication and welding setup.

In a nutshell, we developed a ‘make in India’ product and localised most of the components as well. By the end of this process, we began to develop and supply 60-70% of the parts.

Primary Results

• The overall costs dropped down by about 60%.
• The lead time was shortened from 6 months to 1 month.
• Year-on-year value engineering projects were identified and implemented. As a result, the costs improved by 25%.
• Our production capacity rose from 80 sets a year to 600 sets a year.