hll lifecare ltd

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  • 1. HLL Lifecare Limited Innovating for Healthy GenerationsTime for Profit

2. HLL Lifecare Limited, Akkulam Factory, Thiruvananthapuram Time for Profit 3. Time for Profit 4. Agenda for next 15 minutesTime for Profit 5. Time for Profit 6. HLL business segments Contraceptive Products CondomsCu -TOCPECPHospital Products Blood bagsHydrocephalus ShuntSuturesRapid test kitPharmaceutical Products Gynecological medicinesServices Infrastructure ConsultancyIron SupplementsDiagnosticsAntibioticsPCDOral Re-hydration SaltsLife Spring HospitalsTime for Profit 7. Time for Profit 8. Time for Profit 9. 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 coverTime for Profit 10. How to use?Time for Profit 11. 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 / annumTime for Profit 12. Existing production processTime for Profit 13. Time for Profit 14. WORK IMPROVEMENT TEAMTime for Profit 15. ISHIKAWA FISH BONE DIAGRAM CAUSE Non concentricity of fixtures Old technology machine Low speed operations Poor reliability Operator dependantDimensional defects of incoming materials Flash on moulded componentsEFFECTManual bevel orientation No provision for pull test No provision for markingNEEDLE ASSEMBLY LESS OUTPUT, HIGH COST, HIGH REJECTIONIncreased product handling time Higher process rejectionImproper handling of materials Higher manpower requirementExcess gate projection on moulded components Lack of training Carelessness Human fatigueTime for Profit 16. Time for Profit 17. 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 operationsTime for Profit 18. Machine overviewTime for Profit 19. PROPOSED SYSTEM FOR PRODUCTIVITY INCREASETime for Profit 20. PRODUCTIVITY TECHNIQUETime for Profit 21. Benefits / advantages on implementation of new system66.0670 60 50 40 30Man power required3020 1049.440 Old systemNew systemManpower cost/ annum (in lakh rupees) Time for Profit 22. PAYBACK PERIODTime for Profit 23. Benefits of new system for production of 9 million pieces SL NO.ASPECTEARLIER SYSTEMNEW SYSTEM1Output1000 per person7000 per person2Manpower (2 shift operation)30 per day4 per day3Manpower cost per annumRs. 66.06 lakhsRs. 9.44 lakhs4Rejection percentage3.2%1% to 1.5%5Mode of operationManualFully Automatic6Check for strengthbonding Not presentPresent7Online marking to indicate bevel Not present positionPresent8Check for bevel marking presence.Present9Leak checkPresent (not much Present & effective effective)10Fatigue of operatorYesneedleorientation, Not presentNo Time for Profit 24. Challenges faced while implementing the new systemTime for Profit 25. Needle bevel orientationThe 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 26. 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 27. 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 28. Vision systemProviding 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 29. 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 30. Cap loading and wrong orientation challenges These problems were overcome with the introduction of suitable detection and aligning mechanisms.Time for Profit 31. Curing of cover bonding operationIt 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 32. Time for Profit 33. CONCLUSIONTime for Profit 34. Productivity is never anaccident. It is always the result of a commitment toexcellence, intelligent planning, and focused effort. - Paul J. Meyer Paul J. Meyer, Founder of Success Motivation Institute, 1960Thank You Do visit : www.lifecarehll.com Time for Profit 35. Time for Profit

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