AMC, Retro fitment and VAS

Industry:
Construction Equipment Manufacturing

About the Customer:
A prominent joint venture in India’s construction equipment sector, this company is a collaboration between one of India’s largest industrial corporations and a leading Japanese construction equipment manufacturer. Originally established as a division within a major Indian company in the 1960s, it has grown to become a major player in the market, manufacturing a range of heavy machinery, such as excavators, backhoe loaders, and wheel loaders. With cutting-edge manufacturing facilities across India, this company is recognized for producing durable and high-quality equipment trusted by clients across various industrial and infrastructure projects.

The Backdrop:
The relationship with Sparkline began when this company planned the setup of its major plant. Sparkline was engaged from the early installation phases, supporting crane systems that are essential for production. The plant required high-capacity cranes for moving heavy components and materials in the production of construction equipment. From the outset, the company’s cranes were sourced from Sparkline and another vendor, enabling them to evaluate both service providers’ performance. Sparkline’s extensive involvement allowed a deep understanding of the client’s operations and needs, ensuring precise installation, modifications, and quick support as needed.

The Challenge:
One of the 15-ton cranes used in the facility faced high maintenance costs, particularly due to the expense of replacement parts from the original vendor. When the motor of this crane failed, a replacement was quoted at ₹22 lakh, posing a substantial financial burden. The crane also experienced delays in service response times, which, at 2-3 days, impacted production efficiency. Given the fast-paced demands of the facility, these delays created productivity challenges and higher operational costs. To resolve these issues, the company sought a more cost-effective solution that would reduce spare part expenses, enhance reliability, and provide faster, more responsive local support.

The Expectations:
The company turned to Sparkline, aiming for a timely, economical solution to reduce spare part costs and enhance the crane’s reliability. They sought an approach that would minimize future issues with the motor and establish a dependable support framework, thus avoiding the high costs and delays experienced previously. Specifically, they wanted to retain existing crane components where feasible to control expenses while improving operational reliability.

The Solution:
Sparkline proposed a complete retrofit for the 15-ton crane, replacing essential electrical and mechanical components while keeping only the crane’s long travel (LT) system intact. The replacement involved a new high-capacity motor and a custom control panel to improve durability and withstand heavy operational loads.

Key elements of the retrofit included:

  1. Replacement of Electrical Components: Sparkline removed non-essential components from the original setup, installing a robust control panel and new motor capable of handling high-duty cycles, thereby reducing the risk of future failures.
  2. 24/7 Local Support: With a commitment to a two-hour response time, Sparkline provided local support, significantly faster than the prior service provider’s timeline, ensuring minimal downtime for the facility.
  3. Testing and Quality Assurance: Sparkline conducted thorough testing of the retrofitted crane, adhering to industry standards to ensure reliability, safety, and operational excellence. These tests confirmed the system’s durability and performance, offering assurance against overheating or motor failures.

A Statement of Overall Benefit:
Sparkline’s retrofit solution not only addressed the customer’s concerns about high spare part costs but also significantly improved crane reliability and ensured prompt, local support. The retrofit delivered substantial cost savings and operational efficiency, helping the company to achieve a dependable solution for their production needs.

Benefits:

  • Significant Cost Savings: The retrofit with Sparkline’s components, rather than high-cost original replacements, saved the company approximately ₹22 lakh in expenses.
  • Enhanced Equipment Longevity: The newly installed motor resolved previous motor burnout issues, offering greater operational reliability.
  • Unmatched Local Support: Sparkline’s commitment to rapid response, within a two-hour timeframe, minimized downtime, greatly improving production efficiency.
  • Long-Term Partnership: Sparkline’s early involvement enabled a deep understanding of the company’s needs, resulting in a solution precisely tailored to their requirements.
  • Proactive Maintenance and Warranty: Sparkline’s two-year warranty on the retrofitted crane provided the company with peace of mind and reinforced Sparkline’s dedication to quality and reliability.