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Photos 23-Jan
Lean Manufacturing - Crescent Foundry

 

Crescent has a combined capacity of 75000 tons between the 3 plants focusing on the municipal counterweight and industrial products. Crescent is the largest producer of counterweight and agricultural rings in India. The company started its operations in 1982 with only a single client in the USA. Today, the crescent has customers in over 50 countries.

 

Sector: Foundry

Engagement:  2 years

Workplace:  2 Facilities

Website: https://crescentfoundry.com/

 

Objectives:

  • Create a lean layout
  • Become a world-class organization
  • Reduce throughput time
  • Reduce WIP inventory & free-up space
  • On-time shot blasting
  • Reduce in-process rejection
  • Create workplace excellence
  • Saving of Energy

 

Problems:

  • Longer distance traveled by material within the workstation
  • Safety problem
  • High WIP inventory
  • The higher cost of quality
  • Higher lead time
  • Cluttered workplace
  • Customer complaints

 

Approach:

  • Total flow management & one-piece flow
  • Low-cost automation
  • Cell formation & line balancing
  • 5S & visual management system implementation
  • Poka-yoke
  • Production maintenance partnership
  • Daily work management system

 

Outcome:

  • Created a lean layout for creating flow: Relay outing shot blasting, fettling cell concept
  • Shot blasting uptime improved & fettling output enhancement up by 25 ton/ day
  • Shot blasting time reduced from 15 min to 8 min
  • Labor productivity improved by 18% through cell & line balancing
  • Reduced WIP inventory & 25% space released from the shop floor
  • Increased productivity by 3 times
  • Total process time reduced by 33%
  • In process rejection reduced by 48%
  • Workplace organization score improved up to 70%
  • Saving of energy by 20 units/MT

 

 


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