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Number of Projects 

count

Total Savings in

Rs. Lakhs

count

Material Cost Reduction

Sealant Application

Number of Responses

2

Number of Design Parameters 

2

Number of Significant Design Parameters

2

Baseline

Weight per assembly: 0.45 gms

Result Achieved

Weight per assembly: 0.30 gms

Material Cost Reduction

Grease Application

Number of Responses

1

Number of Design Parameters 

2

Number of Significant Design Parameters

1

Baseline

Grease weight : 10 gms/channel

Result Achieved

Grease weight: 8.2 gms/channel

Material Cost Reduction

Furnace Brazing

Number of Responses

1

Number of Design Parameters 

1

Number of Significant Design Parameters

1

Baseline

Brazing Paste per component: 21.8 gms

Result Achieved

Brazing Paste per component: 17.2 gms

Energy Consumption Reduction

Heat Treatment

Number of Responses

4

Number of Design Parameters 

1

Number of Significant Design Parameters

1

Baseline

Energy Consumption: 1,100 KWH per shift

Result Achieved

Energy Consumption: 1,000 KWH per shift

Cycle Time Reduction

Stress Relieving

Number of Responses

1

Number of Design Parameters 

1

Number of Significant Design Parameters

1

Baseline

Cycle time: 30 minutes

Result Achieved

Cycle time: 21.7 minutes

Cycle Time Reduction

Hardening and Tempering

Number of Responses

4

Number of Design Parameters 

5

Number of Significant Design Parameters

1

Baseline

Cycle time: 160 mins

Result Achieved

Cycle time: 140 mins

Cycle Time Reduction

Injection Moulding

Number of Responses

5

Number of Design Parameters 

5

Number of Significant Design Parameters

1

Baseline

Cycle time: 75 Secs/Shot

Result Achieved

Cycle time: 68 Secs/shot

Cycle Time Reduction

Injection Moulding

Number of Responses

5

Number of Design Parameters 

6

Number of Significant Design Parameters

4

Baseline

Cycle time per shot: 16 seconds

Result Achieved

Cycle time per shot: 13 seconds

Cycle Time Reduction

Injection Moulding

Number of Responses

1

Number of Design Parameters 

3

Number of Significant Design Parameters

1

Baseline

Cycle time: 55 seconds/shot

Result Achieved

Cycle time: 48 seconds/shot

Cycle Time Reduction

Injection Moulding

Number of Responses

1

Number of Design Parameters 

3

Number of Significant Design Parameters

1

Baseline

Cycle time: 36 Secs/shot

Result Achieved

Cycle time: 40 Secs/shot