hll lifecare ltd
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HLL Lifecare Limited
Innovating for Healthy Generations
Time for ProfitHLL Lifecare Limited, Akkulam Factory,
Thiruvananthapuram
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Agenda for next 15 minutesAgenda for next 15 minutes
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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
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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
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How to use?
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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
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Existing production process
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WORK IMPROVEMENT TEAM
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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
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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
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Machine overview
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PROPOSED SYSTEM FOR PRODUCTIVITY INCREASE
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PRODUCTIVITY TECHNIQUE
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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)
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PAYBACK PERIOD
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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
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Challenges faced whileimplementing the new system
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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.
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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.
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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.
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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.
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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.
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Cap loading and wrong orientation challenges
These problems were overcome with the introduction of suitable detection and aligning mechanisms.
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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.
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CONCLUSION
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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
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