Jk files (india) limited

Redesign & Technology Infusion in “Engineering File” Manufacturing Process.

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About Us.

JK Files (India) Limited, a subsidiary of Raymond Ltd is today the largest producer of files in the world. It has an impressive 32% global market share.

The plants located in India are Ratnagiri and Chiplun (all in Maharashtra), Pithampur (in Madhya Pradesh), Kolkata, Vapi (Gujarat) and Surabaya in Indonesia are all ISO 9001: 2008 certified.

With expertise of over 60 years in the business, JK Files (India) Limited has established over 1300 Distributors and dealers networks across globe. We export 50% of our products to over 100 countries including the technologically sophisticated markets of U.S., Canada and Europe.

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Context & Background.

At JK Files, we aim at becoming the Largest and the Best manufacturer of Files in the world. And to achieve this we need to

Build - World Class plants & best manufacturing practices to retain the Competitive edge & sustainable growth.

To Build De-skilled & Robust Processes with High Capability & Reliability.

Offer wider range of products with consistent Quality and on time Availability.

This can only be achieved by dedicatedly working on each fronts of the existing process & eliminating the wastes by using breakthrough technologies.

So we have targeted a massive redesign of our operations & the machineries. Since we are the leaders in manufacturing the files in the world, the technology is not easily available outside & we need to focus on each and every minute integrity of the process & design it such away that we are miles away from our competitors.

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Drivers of the Project

PROCESS RE-ENGINEERING •ALTERNATE PROCESS /ELIMINATION/COMBINATION OF PROCESS.•TO REDUCE WASTAGE & CONVERSION COSTS

TECHNOLOGY INFUSION•INTRODUCE NEW TECHNOLOGY•FOR BETTER PRODUCTIVITY, QUALITY CONSISTENCY , BETTER ENVIRONMENT & SAFETY

OPERATIONS RE-DESIGN•VALUE STREAM BASED LAYOUTS.•TO REDUCE THROUGHPUT TIME & WORKING CAPITAL

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Value Stream Layouts

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Value Stream Layouts

Objectives:• To reduce material movement• The machines to rearrange in an organised manner (nearer to the next

work station) enabling single piece flow• Indirect workmen engaged in material handling to reduce through

reducing the TOUCHES • Reduce the working WIP

Results/Benefits Achieved:• This Re-layouting activity was done across all the plants of JK Files

leading to a Monthly cost saving of Rs. 26 Lac and the micro indicators are summarized as follows:• Productivity per Man-day was improved by 18 %.• WIP was reduced from 13.5 days to 7 days• Material Movement was reduced from 460m to 240m.• 31% Saving in Floor Space • Throughput reduced from 7 days to 2 days.

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Chiplun.

Ratnagiri.

Before After

Value Stream layouts.

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Kolkata.

Pithampur.

Before After

Value Stream layouts.

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Results / Benefits Achieved.

Indicators Ratnagiri Chiplun Kolkata PithampurSaving in Floor Space

Before Value Stream 9,782 m² 7,800 m² 8,645 m² 4,048 m²After Value Stream 5,986 m² 5,850 m² 6,484 m² 2,530 m²

Distance Traveled by MaterialBefore Value Stream 750 m 450 m 410 m 224 mAfter Value Stream 245 m 365 m 205 m 130 m

WIP Before Value Stream 16 Days 14 Days 14 Days 10 DaysAfter Value Stream 7 Days 7 Days 8 Days 5 Days

Producivity per MandayBefore Value Stream 6.2 Dz/Manday 6.8 Dz/Manday 8.4 Dz/Manday 7.5 Dz/MandayAfter Value Stream 6.8 Dz/Manday 7.8 Dz/Manday 11 Dz/Manday 8.5 Dz/Manday

Quality ConsistencyBefore Value Stream 4.5% 4.5% 4.0% 3.6%After Value Stream 4.0% 3.0% 3.0% 3.0%

Throughput timeBefore Value Stream 7 Days 7 Days 7 Days 7 DaysAfter Value Stream 2 Days 2 Days 2 Days 2 Days

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Technology Infusion – Steel Hot Rolling Mill Upgradation

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Steel Hot Rolling Mill (HRM) Upgradation.

Objectives:• Steel Hot Rolling mill being the starting point of our internal supply

chain, consistency in steel (output and quality) obtained from hot rolling determines the operational efficiency in file manufacturing .

• In our previous process of hot rolling, we were losing substantial quantity of steel as scrap.

• The capacity of our HRM is 600 MT per month.• So as to minimize the wastages we have adopted the latest techologies

like Induction heating in Neutral atmosphere, Peeling etc.

Results/Benefits Achieved:• An Annual Saving in Raw material of 384 MT (Rs. 173 Lac) is being

achieved by minimizing the process scrap by Infusion of New Technology in the Manufacturing. The micro details of savings in discussed in the following slides.

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Semis Manual Gas Cutting

Heating in oil fired furnace

Section RollingShearing in multiple mood lengths

Stock / Dispatch to plants

Present Hot Steel Rolling Process.

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Semis Manual Gas Cutting

Heating in oil fired furnace

Section RollingShearing in multiple mood lengths

Stock / Dispatch to plants

Technology Infusion in Hot Rolling Process.

Circular Saw Cutting

Heating in Induction furnace

Yield improvement by 6% equivalent to 380 MT material saving per year.

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Consistency in the size of billets for input to Induction heating Consistency in the length of rolled sections Faster throughput Perpendicular cutting of billets reducing material loss

BILLET CUTTING –CIRCULAR SAW

INDUCTION BILLET HEATING

Consistency of Heating temperature resulting in Dimensional consistency No over-heating of billets. Uniform temperature at the surface and the core Reduction in the De-carb levels Reduction in Scale and Burning losses Automatic Accept-Reject mechanism

Benefits

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Technology Infusion – Yield Improvement by Hot Point Rolling for Taper files.

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Hot Point Rolling for Taper Files

Objectives: For Triangular files we need to have 1/3rd of its length in a taper form.

Previously this was achieved by Grinding process. Avg. 237 MT of material is lost in Grinding during point preparation

process. (which is not recoverable) Poor Dimensional consistency of files. Low productivity.

Body length

Tang lengthTaper length

W

Results/Benefits Achieved:• An Annual Saving of Raw material by 237 MT is being achieved by

elimination of the Grinding process. The micro details of savings in discussed in the following slides.

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Stage I Stage II


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Technology Infusion – New Generation File Grinding machine.

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New Generation Files Grinding Machine

Objectives:• Grinding being the operation for Surface preparation for Teeth Cutting,

which requires good surface finish & accuracy to control the quality of cut being produced.

• In the present Grinding machine the material removal rate cannot be controlled in Microns, it is only designed for heavy material removal.

• Today we are using a Magnesite bonded grinding wheel which is going obsolete day by day. To upgrade the present technology we need to switch over to vitrified bonded grinding wheel.

Results/Benefits Achieved:• An Annual Saving of Rs. 32 Lac is achieved with the new design of the

machine & use of Vitried bond grinding wheel. The micro details of savings in discussed in the following slides.

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New Generation Grinding Machine.

Benefits:

3 times Productivity.

Power requirement reduced by 50 %

Use of Low Power High Efficiency Electrical Motor.

Use of Vitrified Bond Grinding Wheel.

Multi Station Grinding with PLC control Feed to improve the productivity.

Deskilled Process with Auto Dressing & Compensation.

Higher Productivity with Auto Indexing.

Conventional Grinding Machine.

Drawback in Current

Process:

High Energy Consumption.

Low Productivity & Machine

Utilization.

Low Safety.

Constrain in Grinding wheel

avalibility.

No precise control.

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New Generation Files Grinding Machine

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Technology Infusion – New Generation Teeth Cutting Machine.

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New Generation File Teeth Cutting Transfer Line.

Objectives:• We were using conventional individual cutting machine for cutting

operation on different sides of the file, after each operation the files are manually transferred to the next operation resulting in higher foot print & WIP. Following were the major concerns in the earlier process :• Low Productivity & Low Machine Utilization.• Skill is required to set the machine properly.• Age old design.• High consumption of lubricating oil & spare parts.

Results/Benefits Achieved:• Productivity improvement by 6 times leading to an annual Saving of Rs.

39 Lac with the new design of the machine. The micro details of savings in discussed in the following slides.

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Prototype of New Concept for File Teeth Cutting .Conventional File Teeth Cutting Machine.

Drawbacks in Current Process:

Low Productivity. Monotonous work cycle. High Skill Requirement

for Quality output. Complicated Setting

parameters. High Maintenance

required.

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Benefits:

Multi-Machine operation,

Productivity Improvement by 6 times

De-skilling of operation

Consistency in Quality

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Technology Infusion – Robotic Hardening.

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Robotic Hardening.

Objectives:• Previously we were using conventional MANUAL hardening process of

the files, where each & every file is hardened manually one by which requires a lot of skill for achieving the hardness & straightness of the files. Due to this below were major concerns in the manual process:

• Low Productivity & Low furnace Utilization.• Hazardous work Environment. (continuous exposure to temp. of

appx. 600 to 700° C)• Poor Quality consistency.• Monotonous work cycle.

Results/Benefits Achieved:• Productivity improvement by 5 times.• An Annual Saving of Rs. 125 Lac is being achieved with the introduction

of Robots in Hardening.

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Robotic Hardening.

Benefits:

Manpower productivity Improvement by 5 times.

Low manual interface.

Quality Consistency.

Hazard free process.

Manual Hardening.

Drawbacks in Current Process:

Low Productivity. Monotonous work cycle. Poor consistency &

Accuracy Hazardous work

environment.

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Redesign of Packaging.– Single Piece Packing.

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Single Piece Laminate Packing.

Benefits:

Brand take away by the end user.

Difficult to counterfeit & Temper proof.

Longer shelf life.

Eye-catching display

Bef

ore

Aft

er

New Packaging inline with new merchandise for modern trade

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Alternate Power Source– Solar Rooftop PV cells.

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Solar Power: JK Files (india) Ltd, Thane Office

Generation of 69,000 units annually.

Savings of Rs. 8.8 Lac per annum

48 MT of CO2 is avoided.

Life of the system – 25 Years.

Solar power by Roof top PV cells of 60 kW.

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Business

Jk files (india) limited