Hero MotoCorp & Royal Enfield
Production Automation
Robotic assembly, PLC integration, and Lean Six Sigma process engineering.
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Li-ion Battery Robotic Assembly
S: Li-ion battery assembly needed cycle time and throughput improvements.
A: Deployed ABB/Mitsubishi arms and applied Lean principles to cut waste.
R: Increased throughput 84.6%, saving $32,800 annually.
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PLC Roller Conveyor Integration
S: Material flow suffered from conveyor overloading issues.
A: Integrated Allen-Bradley PLCs with conveyors and created standard work docs.
R: Balanced flow and improved material handling throughput by 22%.
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TPM Predictive Maintenance
S: High unplanned equipment downtime increased maintenance costs.
A: Implemented a TPM-driven predictive maintenance program via sensor analytics.
R: Cut downtime 21.4% and saved $28,900 annually.
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Vision-Guided Defect Detection
S: Assembly anomalies resulted in high manual rework costs.
A: Developed a vision-guided defect detection system and applied SPC/8D methods.
R: Achieved 92.3% detection accuracy and reduced rework costs by $23,400 annually.
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Lean Six Sigma Optimization
S: Royal Enfield production line experienced assembly bottlenecks.
A: Applied Lean Six Sigma to optimize material loading automation.
R: Achieved a 7% reduction in assembly time and cut waste by 5%.