LT Success Story Presentation r2

8/8/2019 LT Success Story Presentation r2

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SUCCESS STORY OF WRENCH IMPLEMENTATIONAT

Larsen & Toubro LimitedMachinery & Industrial Products Division

LTM Business Unit, Chennai .


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LTM Chronology

1972 Established as a JV between L & T Limited and McNeil Akron Inc, USA under the name L&T-McNeil Limited

1974 Commenced Production of Tyre Curing Presses

1988 Technical Collaboration with Mitsubishi for Tyre Building Machines & Bias Cutters and with Demag for Plastics injection moulding machines

1995 L&T buys the complete shares of McNeil Akron Inc in L&T- McNeilLimited and forms a wholly owned business unit of L&T for Rubber & Plastics machineries

2001 JV with Demag for Plastics machinery

2003 Collaboration with Kobe for manufacture of latest range of Curex S1

series Hydraulic Tyre Curing Presses


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Growth

Rs. Million


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Mechanical Tyre Curing P ressesFrom 24" to 104"


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Some of our major CustomersSome of our major Customers


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LTM presenc e in t he Wor ld ...

CHINA

EGYPT

U.K

FINLAND

ITALY

KENYA MALAYSIA

MOROCCO

NEPAL

SRILANKA

SYRIA

TANZANIA

THAILANDTURKEY

VIETNAM

ARGENTINA

BRAZIL

CHILE

CUBA

ECUADOR

VENEZUELA

INDIA

SPAIN

INDONAESIA

PHILIPPINES

ISRAEL

SOUTH AFRICA

USA


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PRODUCT DEVELOPMENT PROCESSPRODUCT DEVELOPMENT PROCESS

NEW PRODUCTS

PRODUCTS VARIANTS TO CUSTOMER NEEDSRESULTING IN

MAJOR DESIGN MODIFICATIONS TO EXISTINGPRODUCTS

MINOR MODIFICATIONS

PRODUCT CONFIGURATION TO MEET CUSTOMER

REQUIREMENTS


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PEOCESS FLOW FOR PRODUCT DEVELOPMENT

procedure thru PLM

engg team on review

Design Department

Sales Dept.

StartReceive

Request forChange

Evaluate andAnalyseChange

Initiate ECOWorkflow in

Wrench

ECOApproved?

Rework

Release of Changed BOM/ Drawings/Specs to Other

departmentsEND

ECO PROCESS FLOW

Yes

No

ReceiveCustomerEnquiryDetails

from Sales

Follow1. Enquiry to Quote2. Quote to Sales

Order

Prepare TentativeBOM of Critical Sub-

Assemblies andProvide details for

Estimation &Quotation purpose to

Sales Dept.

Start

Design Department

Receive SalesOrder with

detailed Specs

Start designDesgin Activityas per ISO

CreateDrawings &

BOMs

Design Outputreview withconcurrent

Release ofBOM to ERPthru PLM

FinalDrawings &BOMs based

Layout DrawingApproval toCustomer ?

TechnicalReview

meeting Toconfirm Tech

Specs andcompatibility

Modify

Release ofDrawings formanufacturingthru PLM

END

PrepareEquipmentSafety (CE)file wherever

required

No

Yes

Design Department

Design Department Sales/Design Dept.


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Problems Faced before WRENCH implementation

Total dependency on individuals.

25 to 30% time spent for searching for data.

Mismatch of revision numbers between ERP data and actual drawings

No system to prevent usage of drawings to old revisions.

Delay in issue of drawing prints due to manual processs and uncontrolled

No link between drawings and BOMs and manual entry of BOM for MRP

No control over multiple copies of the same drawing.

Lack of security on intellectual data being copied out.


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Errors in product configuration due to manual process and time consuming.

No collaboration among cross functional departments.

No sharing of massive volume of digital product data available with differentdepartments like Engg,Marketing,Purchase,Manufacturing,Service,etc.

Poor visualization for the users as there was no tools to access the3D solid models created by design department.

Product history not captured and maintained systematically.

Most of the learnings /design calculations during product development lost.

Change management was manual , slow and not communicated to endusers well in time


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To overcome these problems many adhoc procedures/

systems were adopted likePrint request program.

Centralised storage of drawings with defined File namingprocedure.

View access for cross functional departments for drawingsstored in R&D server.


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VISION for an Ideal Design Environment

A l l d o

c u m e n t s

i n e l e c

t r o n i c

f o r m

3 D s o l i d

m o d e l i n g

c o n c e p t

Asse m b l y based

o n co ns t ra i n ts

As s o c i a t i o n o f D e s i g n d a t a / F E A w i t h p a r t s

C a l c u l a t i o n s /

Ideal

Design EnvironmentHow we design in future?

3 D s o l i d d i r e c t l y a s s o c i a t e d w i t h 2 D

V ie w i ng a nd

P r i n t i ng fac i l i t ies

a t use r e nd

C a l c u l a t i o n s a s s o c i a t e d w i t h As s e m b l i e s

Q ua l i t y P la nassoc ia ted w i t h

Asse m b l ies

C ha nges

assoc ia ted w i t h

3 D Asse m b l iesAut o c o st i ng a t c o nc e p t st a g e

C o n c u r r e n t E n g i n e e r i n g i n

t h e m a i n s t r e a m S c h e d u l e f o r p r o t o t y p e a t c o n c e p t

BO Msassoc ia ted w i t h

Asse m b l ies

Online costing of new tools

S i n g l e w i n d o w a c c e s s


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Challenges faced

Brain storming to list out the requirements for anideal single window access system for design.

Evaluation of available softwares to short listbased on the following priorities

Meeting the requirements as per the vision statement Seamless interface with the existing MRP-II system Customisation skills to follow good practices being followed Cost of implementation and maintenance Possibility for future upgrades / addition of new modules

Conversion of Legacy data built over many years to digital data.

Understanding the existing MRP-II system and interfacing.

Training and smooth change over to the new system.


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Benefits after implementation of WRENCH

50% Faster product development due to on-line availability ofdesign data, re-use of existing variants& flexible search capabilities

15 times faster product configuration due to BOM variant concept Single window access for design engineers & Immediate access toJDEdwards ERP without consuming the license of ERP package

No manual keying-in and duplication of engineering data into ERP

On-line access to the latest drawings with defined security

Concurrent engineering during design stage.

40% Reduction in number of drawing prints

Automatic work flow management for Draw/Check and Approval


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Benefits after implementation of WRENCH

Automatic print management

Complete security for design data in server

Faster change management.

Linking of Design calculations,FEA, Moms,check sheets, test

data & customer feed back to part master/work orders. Possibility to view and mark 200+ file formats

Sharing of information between departments

Better visualisation of the part by users by viewing the solidmodels

Quick review of project status with color codings of status


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WHAT NEXT

1. Extend access to Sales and branch offices.

2. Non conformance management.3. Provide online spare part catalogue.

4. Extend product data to vendors with restrictedaccess.

5. Online capture of customer feedback on products.

6. Extract knowledge from real time ECO & NC data.


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Thank You

Have a nice day !

LT Success Story Presentation r2

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