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PRODUCTIVITY IMPROVEMENT Achieving maximum productivity goals

Sep 19, 2019

Among the handful of imperatives that facilitate enhanced productivity and efficiency of a manufacturing unit, lubrication plays a quintessential role. This case study talks about how ExxonMobil’s cutting-edge lubrication products helped PPAP Automotive to achieve its productivity and profitability goals, while enhancing the lifespan of the machines.

The manufacturing industry in India has poignantly grown over the decades, witnessing a series of transitions through the socio-economic and political corridors of the country. Turning a corner after liberalisation in the early-90s, the Indian manufacturing industry is today a globally competitive behemoth, powered by solid capacity expansions and multidisciplinary investments. Strong domestic demand, a growing middle class and a high rate of return on investments are among the factors that make India a credible manufacturing investment destination. The country’s manufacturing prowess has been further fuelled by the government’s innovative initiatives, such as, Make in India, Smart Cities and Skilling India.

Having emerged as a high growth sector, India is expected to become the fifth largest manufacturing country in the world by 2020. Against this backdrop, global manufacturing giants, like GE, Toshiba and Boeing are in the process of setting up manufacturing plants in the country, even as existing players are expanding capacities and operations.

With India on the path to becoming a leading manufacturing hub, there are several imperatives that drive this growth and help to maintain the momentum. With singular manufacturing units adding up to make the colossal industry, the productivity and efficiency of each of the units contributes to the growth.

If machines are the heart of the manufacturing sector, lubricants that ensure their smooth functioning are its lifeblood. It ensures routine maintenance for expensive and complex industrial equipment and even prevents permanent damage that can be caused due to extreme operating conditions.

Background/situation at hand

Established in 1978 in the industrial hub of NOIDA, the NCR-based PPAP Automotive is a leading manufacturer of automotive sealing systems, interior and exterior automotive. Their customers include leading automobile companies, like Maruti Suzuki, Honda Cars, Toyota Kirloskar Motors, etc. The company operates several injection moulding machines for manufacturing over 500 different products for its customers. These machines, with an average capacity between 650 and 2800 tonnes, operate round-the-clock in three shifts of eight hours.

With the primary focus to advance productivity of the plant and to increase profitability, PPAP Automotive turned to ExxonMobil’s Field Engineering Services (FES) – the dedicated team of technical experts who work closely with manufacturing companies to offer them advice on best-in-class lubrication and maintenance practices.

Mobil’s strategic solution

Mobil™ engineers assessed onsite usage conditions and interacted closely with the PPAP Automotive team to understand the company’s lubrication requirements. Based on their test results, Mobil recommended Mobil DTE 10 Excel 46 for the injection moulding machines in order to achieve maximum productivity and enhanced equipment protection. It is an ISO Viscosity Grade (VG) 46, non-zinc, anti-wear hydraulic fluid. Its shear-stable, high-viscosity index (VI) allows for a wide operating temperature range, maintaining maximum hydraulic efficiency and component protection, at both low as well as high temperatures. Post the switch to Mobil DTE 10 Excel 46, The company’s team conducted an analysis to monitor the condition of the oil and advised the customer on best maintenance practices for regular filtration and system cleanliness.

The outcome

Mobil DTE 10 Excel 46 helped reduce downtime and achieved ODI of 10 years in moulding machine hydraulics, resulting in potential savings of US $18,382 (₹ 12.30 lakh approx) annually. It enabled an extended oil drain interval and ensured zero component replacement in the injection moulding machines for up to ten years. The superior quality lubricant helped the machines deliver outstanding performance, eliminating unscheduled downtime and reducing planned downtime. All this, in turn, translated into a potential annual savings of US $18,382 (₹ 12.30 lakh) for PPAP Automotive.

Speaking on ExxonMobil’s success in providing a customised solution for PPAP’s requirements, Shankar Karnik, General Manager – Industrial, ExxonMobil Lubricants, said, “Mobil Industrial Lubricants supports customers with unmatched industry expertise and technical services, unsurpassed global supply capability, proven oil-analysis programs and comprehensive builder approvals. The results delivered for PPAP Automotive are perfect examples of how ExxonMobil’s technology leadership, exceptional application expertise and customised solutions can enable an industrial unit attain its productivity and profitability goals effectively.”

Courtesy:ExxonMobil Lubricants

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