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Number of Projects
count
Total Savings in
Rs. Lakhs
count
Cycle Time Reduction
Electro Plating
Number of Responses
2
Number of Design Parameters
2
Number of Significant Design Parameters
2
Baseline
Cycle time: 60 minutes/batch
Result Achieved
Cycle time: 40 minutes/batch
New Process Establishment
Electro Polishing
Number of Responses
1
Number of Design Parameters
3
Number of Significant Design Parameters
1
Baseline
Not applicable since it is a new process
Result Achieved
Robust Parameters established
Cycle Time Reduction
Leakage Testing
Number of Responses
2
Number of Design Parameters
3
Number of Significant Design Parameters
3
Baseline
Cycle time: 35 secs/piece
Result Achieved
Cycle time: 20.5 secs/piece
Energy Consumption Reduction
Air Compressor
Number of Responses
1
Number of Design Parameters
1
Number of Significant Design Parameters
1
Baseline
Energy Consumption: 46.4 KWH/day
Result Achieved
Energy Consumption: 36.7 KWH/day
Material Cost Reduction
Water Treatment Plant
Number of Responses
2
Number of Design Parameters
3
Number of Significant Design Parameters
2
Baseline
Material cost: 185 grams/Kilo Liter of water
Result Achieved
Material cost: 160 grams/Kilo Liter of water
Energy Consumption Reduction
Paint Booth Exhaust Motor
Number of Responses
1
Number of Design Parameters
1
Number of Significant Design Parameters
1
Baseline
Energy Consumption: 9.56 KWH
Result Achieved
Energy Consumption: 6.64 KWH
Cycle Time Reduction
Projection Welding
Number of Responses
1
Number of Design Parameters
2
Number of Significant Design Parameters
1
Baseline
Production per day: 5,620 pieces
Result Achieved
Production per day: 5,928 pieces
Energy Consumption Reduction
Projection Welding
Number of Responses
1
Number of Design Parameters
2
Number of Significant Design Parameters
1
Baseline
Energy Consumption: 55 KWH per hour
Result Achieved
Energy Consumption: 51 KWH per hour
Gas Consumption Reduction
MIG Welding
Number of Responses
1
Number of Design Parameters
3
Number of Significant Design Parameters
1
Baseline
Gas Consumption: 189 gms/meter of weld
Result Achieved
Gas Consumption: 145 gms/meter of weld
Cycle Time Reduction
CO2 Welding
Number of Responses
2
Number of Design Parameters
4
Number of Significant Design Parameters
1
Baseline
Production Qty: 1,100 pieces per shift
Result Achieved
Production Qty: 1,550 pieces per shift