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Number of Projects
count
Total Savings in
Rs. Lakhs
count
Material Cost Reduction
Core Sand Making
Number of Responses
1
Number of Design Parameters
4
Number of Significant Design Parameters
2
Baseline
Resin and Hardener Quantity : 2 Kgs for each batch
Result Achieved
Resin and Hardener Quantity : 1.6 Kgs for each batch
Material Cost Reduction
Metal Treatment
Number of Responses
1
Number of Design Parameters
1
Number of Significant Design Parameters
1
Baseline
Quantity of Magnesium per day: 1000 Kgs
Result Achieved
Quantity of Magnesium consumed: 970 Kgs
Material Cost Reduction
Power Coating
Number of Responses
1
Number of Design Parameters
3
Number of Significant Design Parameters
1
Baseline
Powder Consumption : 110 grams / Component
Result Achieved
Powder Consumption : 90 grams / Component
Cycle Time Reduction
Cast On Strap Casting
Number of Responses
1
Number of Design Parameters
2
Number of Significant Design Parameters
1
Baseline
Batteries per day: 1344/day
Result Achieved
Batteries per day: 1438/day
Cycle Time Reduction
Substrate Drying
Number of Responses
1
Number of Design Parameters
1
Number of Significant Design Parameters
1
Baseline
Production: 2,800 pieces/shift
Result Achieved
Production: 3,000 pieces/shift
Energy Consumption Reduction
Washing
Number of Responses
2
Number of Design Parameters
1
Number of Significant Design Parameters
1
Baseline
Energy Consumption: 110 KWH/Shift
Result Achieved
Energy Consumption: 70 KWH/Shift
Energy Consumption Reduction
Seat Foam Manufacturing
Number of Responses
1
Number of Design Parameters
1
Number of Significant Design Parameters
1
Baseline
Energy: 4075 KWH/day
Result Achieved
Energy: 3887 KWH/day
Gas Consumption Reduction
Drying
Number of Responses
2
Number of Design Parameters
2
Number of Significant Design Parameters
1
Baseline
Gas specific consumption: 3.5 Sm3/Metric Ton
Result Achieved
Gas specific consumption: 2.8 Sm3/Metric Ton
Energy Consumption Reduction
Ultrasonic Cleaning
Number of Responses
1
Number of Design Parameters
1
Number of Significant Design Parameters
1
Baseline
Energy Consumption: 23.32 KWH/Hour
Result Achieved
Energy Consumption: 18.72 KWH/Hour
Material Cost Reduction
Plasma Powder Welding
Number of Responses
2
Number of Design Parameters
1
Number of Significant Design Parameters
1
Baseline
Powder Weight: 2.1 grams/component
Result Achieved
Powder Weight: 1.5 grams/component