Reorganisation of manufacturing of coil type boilers using cellular manufacturing-Thermax Ltd.

Abstract

Thermax is engaged in the field of design , manufacture and commissioning of boilers over the last 25 years. We pioneered the concept of Thermic fluid heating in India. We introduced the first coil type boilers and heaters. Over the past few years we arB facing a lot of competition in this ar&a particularly so in the small capacity range. The customers have become more demanding.We have to produce boilers FASTER,BETTER AND CHEAPER. Over the past few years we have been addressing this issue using techniques like Methods engineering, Quality circles ,TQH, Value added management teams etc. These all arB Continues improvement tools. In the last two years the competition has further increased ,even in the area of Bigger capacity units.To address this we look to REORGANISATION of the manufacturing set up as a BREAK THROUGH tool. Presently the entire range of coil type boilers arB handled in the same shops. Reorganisation will lead to grouping to have focused Sub plants which will be a Competitive Advantage. A Sub plant for the small coil type of boilers will be the best strategy to attack the immediate issues which form about 287. of the total volume of the coil type products value and volume wise. Reorganisation of small coils group into a sub plant will reduce the cycle time from four weeks to two weeks .Subsequent method changes will reduce the manpower requirement from 38 to 20. The conversion cost also reduces by 26"/..The job travelling reduces from 1140 mts to 475 mts. Hence we must go in for reorganisation.