Plastics part supplier to Hero Group raises productivity using Yudo's solution

In the modern era biggest challenge in the manufacturing industries is manpower, productivity and running cost of production. Nowadays, skilled manpower is not available easily in India and cost of hiring them is very high. At the same time, increasing productivity with conventional system is next to impossible. It is very difficult to keep one’s margin intact in a highly competitive market.
 
Offering a complete solution
To overcome all these problems, Yudo has designed, developed and installed automatic production lines for the Bawal (NCR Area) based Gmax Auto Ltd, which supplies high-end solution to Hero Group for all plastics parts for its two wheelers. This plant is designed to reduce the running cost of the plant in terms of electric power consumption, manpower free production lines and space management and most important to increase productivity.
 
Some of the key highlights of this plant are:

• Automatic production lines for the plastic parts
• Operator free machines, no operator is required on the machine
• Manpower management by automation
• Space management through elegant design of the production lines
• Energy-efficient electric injection machines
• Automatic takeout robots: High speed, high efficiency, collision-free robot
• Specially designed chiller using special refrigerant. Latest technology used in pipe line to arrest temperature drop. It saves more than 30% electric power
• Delicately designed heating and cooling units to ensure perfect quality
• Mass storage silos with load cell to handle raw material efficiently and minimum handling with minimum man power; high efficient thrust loading; and easy access of the stored resin
• Matrix based automatic centralised feeding system with SS304 piping to ensure to meet all the requirement of different machines
• Efficient drying to ensure quality and dosing unit to ensure correct feeding and mixing
• PC base supervisions installed for feeding system and chiller
• High speed robots integrates with all machines to ensure optimum cycle time
• Specially designed conveyors to control the movement of finished goods
• Traffic controlled conveyors to ensure smooth movement of all products

 Yudo together with Gmax team together designed the plant, as a result Gmax is producing approximately 30% more parts with same number of machines compare to others in India with very less manpower and saving 30% electric power too.
 
(This was featured in Business Standard newspaper on April 15, 2014)