hll lifecare ltd

Time for Profit

HLL Lifecare Limited

Innovating for Healthy Generations

Time for ProfitHLL Lifecare Limited, Akkulam Factory,

Thiruvananthapuram

Time for Profit

Time for Profit

Agenda for next 15 minutesAgenda for next 15 minutes

Time for Profit

Time for Profit

HLL business segments

Cu -T

OCP

Contraceptive Products

Condoms

ECP

Services

PCD

Infrastructure Consultancy

Diagnostics

Life Spring Hospitals

Blood bags

Hospital Products

Hydrocephalus Shunt

Sutures

Rapid test kit

PharmaceuticalProducts

Gynecological medicines

IronSupplements

Antibiotics

Oral Re-hydrationSalts

Time for Profit

Time for Profit

Time for Profit

Needle assembly

Most important part of the blood bag system; the only one part which comes in direct contact with the donor.

It has 3 parts: Needle holder

Stainless steel 16 / 17 G needle

Protective cover

Time for Profit

How to use?

Time for Profit

Current scenario

Annual requirement: 9 million pieces

Assembly process: Manual

Output: 1000 pcs / person / shift

Quality level: Satisfactory

Overall process rejection: 3.2%

Total manpower cost: Rs. 66.6 lacs / annum

Time for Profit

Existing production process

Time for Profit

Time for Profit

WORK IMPROVEMENT TEAM

Time for Profit

CAUSE EFFECT

ISHIKAWA FISH BONE DIAGRAM

Non concentricity of fixtures

Old technology machine

Low speed operations

Poor reliability

Operator dependant

Manual bevel orientation

No provision for pull test

No provision for marking

Increased product handling time

Higher process rejection

Dimensional defects of incoming materials

Flash on moulded components

Excess gate projection on moulded components

Improper handling of materials

Higher manpower requirement

Lack of training

Carelessness

Human fatigue

NEEDLE ASSEMBLY – LESS OUTPUT, HIGH COST, HIGH REJECTION

Time for Profit

Time for Profit

New system with higher productivity required, to meet growing production demand

Operating cost per piece to be reduced Process rejections, due to human errors to be

eliminated In process inspection systems to be strengthened to

ensure the consistency in product quality Fatigue of operators to be minimized SOLUTION: Automation of the needle assembly

operations

Time for Profit

Machine overview

Time for Profit

PROPOSED SYSTEM FOR PRODUCTIVITY INCREASE

Time for Profit

PRODUCTIVITY TECHNIQUE

Time for Profit

Benefits / advantages on implementation of new system

30

4

66.06

9.44

0

10

20

30

40

50

60

70

Old system New system

Man powerrequired

Manpower cost/annum (in lakhrupees)

Time for Profit

PAYBACK PERIOD

Time for Profit

Benefits of new system for production of 9 million pieces

SL NO.

ASPECT EARLIER SYSTEM NEW SYSTEM

1 Output 1000 per person 7000 per person

2 Manpower (2 shift operation) 30 per day 4 per day

3 Manpower cost per annum Rs. 66.06 lakhs Rs. 9.44 lakhs

4 Rejection percentage 3.2% 1% to 1.5%

5 Mode of operation Manual Fully Automatic

6 Check for needle bonding strength

Not present Present

7 Online marking to indicate bevel position

Not present Present

8 Check for bevel orientation, marking presence.

Not present Present

9 Leak check Present (not much effective)

Present & effective

10 Fatigue of operator Yes No

Time for Profit

Challenges faced whileimplementing the new system

Time for Profit

Needle bevel orientation

The needle bevel is to be oriented along the flat side of the needle holder. Initially, the job was performed using a vision system and servomechanism to do the orientation. This system lacked consistency. Later on, the system was replaced with a mechanical, much simpler and reliable system.

Time for Profit

UV curing

As per manual trial performance, 1.5 sec was sufficient to cure the adhesive (which bonds the needle with the holder). But, in real situation, it was not achievable with the original design concept. It was overcome by the introduction of additional UV curing system and changed four-probe system to two-probe system. The optical fiber probe angle and proximity to the curing part were optimized and thus achieved the required level of curing within 2.5 seconds.

Time for Profit

Siliconisation

According to the original design, the siliconisation operation was to be done using a wiping mechanism, but it lacked consistency and uniformity and also, the maintenance of the system was difficult. It was overcome by introducing a dipping mechanism, where the part is picked up, tilted to 180o, dipped into the silicon tank and placed back to the fixture.

Time for Profit

Vision system

Providing of proper backgrounds, back lights / front lights in order to get clear and consistent image acquisition. Defining of the pixel limits within which the product is to be accepted / rejected. Elimination of chances for distortion of captured images due to machine movements.

Time for Profit

Gluing on holder

According to initial design, adhesive was to be dispensed onto the component in a vertical position. But, the glue distribution was not uniform and it affected the cover bonding. Finally, the design was changed to apply the adhesive on the needle holder in a horizontal position (after tilting to 900 by a tilting mechanism). After this, the component had to be placed back properly onto the fixture. The complete operation has to be performed within the time frame of 3.5 sec, so as to match the cycle time.

Time for Profit

Cap loading and wrong orientation challenges

These problems were overcome with the introduction of suitable detection and aligning mechanisms.

Time for Profit

Curing of cover bonding operation

It was originally designed to employ UV curing system having 4- probe system. Due to the transparency issues of the outer PP cover, the UV penetration consistency was not obtained and cover bonding was not adequate. Then, the whole system was changed to a UV curing chamber system. The design of the chamber was a challenge to suit with the rotary table and minimize the UV light exposure.

Time for Profit

Time for Profit

CONCLUSION

Time for Profit

Thank You

Do visit : www.lifecarehll.com

“Productivity is never an accident. It is always the result of

a commitment to excellence, intelligent planning, and focused

effort.” - Paul J. Meyer

Paul J. Meyer, Founder of ‘Success Motivation

Institute’, 1960

Time for Profit