Multiply of process speed, quality and safety through low-cost automation-A case study

Abstract

Technological upgrading proposals often come across in industries. Nowadays manufacturers take shifts from manual operations to automation with consideration of productivity in man-hour, accuracy; timely delivery, safety, better finish, etc. The procurement of new machines or equipment or systems demands more investment. The case study was conducted in a leading valve manufacturing company. This research focuses on the valve end grinding operation. The following difficulties were exercised in loading and unloading of valves in the machine due to limited operator. That is the maximum stress for the workers in the loading and unloading process, further the time taken for the process is more, which affects the production rate. Accuracy of setting often error which causes rejection based on variation in critical parameters. In addition the safety for the workers involved in this process is very less. So in order to overcome the above difficulties, there is a need to design a more flexible system which will take care of the process and reduce the stress of the workers. The safety factor must also be concerned with the design. It was ensured that the proposed system increases the productivity, quality, accuracy, safety and comfort.