Scrap Reduction Improvement Roop Polymers Limited

Roop Group
Unit – VI, Chennai

Problem : Scrap weight high - 1GC Duct Roki Minda

Before After Part

Weld & Closed 1 runner

Double Gate

Scrap Reduction Kgs

Single Gate 300

150
260 167
0
Before After

Savings - TCM 70
Desc. Month Year
> Blank weight is high - Due to 2 > Runner point reduced 2 to 1 by
Weight- Kg 93 1116
way runner point PLUGED 1 runner point

Cost - Rs 13513 162165

> Scrap weight - 14.77 % > Scrap % - 10 %

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www.rooppolymers.com
 Productivity Improvement Roop Polymers Limited
Roop Group
Unit – VI, Chennai

Problem : Low Productivity - 15363 Grommet

Before After Part

Output delay - mold waiting for Additional plate used for

next production nonstop production

Day Production Qty - Nos

30000

20000

24840
10000 19872

0
Before After

Efficiency
> Low productvity and Machine > Additional core plate made Desc. Before After
requirement is high > 1 plate RUNNING while between
Shot 8 10
Due to Un-loading time high unloading time

M/c Req. 2.52D 2.01D

Shot / Hr - 8 Shot / Hr - 10
M/c Req. - 2.52D M/c Req. - 2.01D
© Roop Polymers Limited. All Rights Reserved
www.rooppolymers.com
 Safety Improvement Roop Polymers Limited
Roop Group
Unit – VI, Chennai

Problem : Emergency Button not available in backside of machine.

Before After

> No emegency switch is available in back side of

> Now we provided emergey switch in machine back
machin, it will lead the operator to operate the
side to avoid any incident during mold loading or
machine during some one work in back side of mold
process work in back side of machine.
or mold loading

© Roop Polymers Limited. All Rights Reserved

www.rooppolymers.com
 Morale Improvement Roop Polymers Limited
Roop Group
Unit – VI, Chennai

Problem : Helmet Stand not available

Before After

> Now we made the rotatable helmet stand to keep

> Earlier no avaialblity to keep the helmet the staff helments inside the factory and it will
acomodate 24 nos.

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www.rooppolymers.com
 Quality Improvement Roop Polymers Limited
Roop Group
Unit – VI, Chennai

Problem : Deformation- Cover Filler

Before After

> Stopped two side flow . Gate point blocked and

> Earlier Gate strength is high than part thickness material injected at one gate point

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www.rooppolymers.com