Multiply of process speed, quality and safety through low-cost automation – A case study

Technological upgrading proposals often come across in industries. Nowadays manufacturers take shifts from
manual operations to automation with consideration of productivity in man-hour, accuracy; timely delivery, safety, better
finish, etc. The procurement of new machines or equipment or systems demands more investment. The case study was
conducted in a leading valve manufacturing company. This research focuses on the valve end grinding operation. The
following difficulties were exercised in loading and unloading of valves in the machine due to limited operator. That is
the maximum stress for the workers in the loading and unloading process, further the time taken for the process is more,
which affects the production rate. Accuracy of setting often error which causes rejection based on variation in critical
parameters. In addition the safety for the workers involved in this process is very less. So in order to overcome the abovedifficulties, there is a need to design a more flexible system which will take care of the process and reduce the stress ofthe workers. The safety factor must also be concerned with the design. It was ensured that the proposed system increasesthe productivity, quality, accuracy, safety and comfort.