Reducing Press Line Cycle Time with Automated Crane Solution

Industry:
Automotive Manufacturing

About the Customer:
A major global automotive manufacturer with a longstanding presence in India, this company operates two large-scale facilities in Chennai and Sanand. The Sanand facility, spread over 460 acres, was established in 2015 to meet growing demand and produce popular car models. To achieve its ambitious production targets, the company sought efficient material handling solutions across its press lines.

The Backdrop:
Sanand, Gujarat, has become a hub for automotive OEMs, and this facility is designed to produce 240,000 cars and 270,000 engines annually. To meet these goals, each step in the manufacturing process needed to be efficient, from material handling to finished goods transfer. A critical area for improvement was the die-handling process within the press lines and the adjacent die maintenance and storage bay.
The manual double girder electric overhead traveling (DG EOT) cranes initially used for die handling took around 25-30 minutes per operation, creating a bottleneck in the production process. To speed up these operations and reduce downtime, the company opted for Sparkline’s automated crane solution.

The Challenge:
The key challenge was to reduce the time taken to replace dies, a task that directly affected the efficiency of the press line and impacted production targets. Specific challenges included:

  • High Cycle Time for Die Replacement: Manual crane handling required 25-30 minutes per die replacement operation, slowing down the process.
  • Safety and Precision Requirements: The process demanded precise positioning and safe handling due to the size and weight of the dies.
  • Streamlined Integration with Adjacent Lines: The two press lines and the die storage area needed efficient, coordinated operations to maintain smooth workflow.

The Solution:
To meet these needs, Sparkline installed a suite of cranes optimized for die handling, including two fully automated DG EOT cranes. Key aspects of the solution included:

    1. Automated High-Capacity Cranes: Sparkline installed two automated 63-ton DG EOT cranes specifically designed for die handling. Each automated crane was paired with a 60-ton standby crane to ensure continuous operation in case of maintenance or downtime.
    2. Semi-Gantry Crane for Die Storage: In the die storage and maintenance area, Sparkline installed a 50/20-ton DG semi-gantry crane to facilitate safe and efficient die storage, transfer, and maintenance.
    3. Significant Reduction in Cycle Time: The automated DG EOT cranes reduced die replacement time by 75%, bringing it down from 25-30 minutes to just 7 minutes per operation. The automation achieved precise handling with an accuracy of +/- 2-3 mm, ensuring safe, exact placement every time.
    4. Wireless Connectivity and Safety Design: Sparkline connected all five cranes wirelessly, enabling smooth, coordinated operation. Safety was prioritized by ensuring that no EOT crane traveled over the semi-gantry, eliminating the potential for accidental collisions and enhancing operational safety

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A Statement of Overall Benefit:
Sparkline’s automated crane solution enabled the facility to drastically reduce cycle time for die handling, achieving a 75% time reduction. The precision and safety built into the system supported the company’s high production targets, creating an efficient, reliable workflow across press lines.

Benefits:

  • Enhanced Production Efficiency: By reducing die replacement time to 7 minutes, the automated cranes increased press line throughput, supporting production goals.
  • Minimal Maintenance and High Reliability: The cranes have operated with minimal maintenance for over six years, ensuring uninterrupted production.
  • Improved Safety and Coordination: Wireless connectivity and strategic layout prevented potential collisions, enhancing safety in the facility.
  • Precise, Automated Handling: The cranes’ accuracy (+/- 2-3 mm) provided precise positioning, essential for efficient die handling and production quality.

Sparkline’s automated crane solution optimized the die-handling process, enabling the Sanand plant to operate efficiently, maintain high safety standards, and meet its production targets year after year.