Innovations

With Smart People and Smarter Engineering

Toughest Machining Challenge Ever (Fuel Injection Component)

Challenge: Diameter 8 having a tolerance of 10 microns & concentricity of both ends to be within 30 microns. The length of Diameter 8 is 138mm means an L/D ratio of 17:1. If we check in the design, Diameter 8 has intermittent cuts. Bore tolerance 10 microns, concentricity over 138 mm of 30 microns, these complexities further aggravated by an intermittent cut
- "A nightmare for an engineer".


Innovation: A unique combination of cutting tools beginning with drilling operation, followed by primary & secondary reaming, has been developed and established by the SOM Engineering team. The European counterpart used to machine these features on large size HMCs. Here in INDIA, we have been performing these operations on VMCs with 4th Axis.


Result: Accuracy & precision sustained for the last four years.

Simulation of LPDC machine in Die maintenance.

Challenge: High Die Changeover times on Low Pressure Die Casting Machine for proper alignment of sliders & sand cores.


Innovation: A die simulator was introduced on which the alignment of sliders & sand cores was pre-checked before loading the die on the machine.


Result: Drastic reduction in setup changeover time, leading to increased availability of the machine. In a further step, this simulator is being used to train operators before the actual handover of the machine.

Two-layer Die Coating Process

Challenge: Frequent Die changeover, i.e. every three days for re-coating for prevention of defects like soldering, catching.


Innovation: Two-layer die-coating process designed and implemented, i.e. all the plates of the cores were now being applied two coats against previous single layer application.


Result: Die coating interval has been changed from after every 9 shifts to after every 18 shifts thereby availability of machine has been enhanced drastically.

Seat Check Blockage Elimination

  • Continuous Improvement & Automation
  • Driving automation and robotics across manufacturing and material-handling processes to improve productivity, consistency and safety.
  • Upgrading machines and process infrastructure to enhance capacity, reliability and operational efficiency.
  • Strengthening quality through digitalisation, smart gauging and automated inspection for real-time process control and traceability.
  • Continuously investing in technology and process improvement to build a more efficient, scalable and future-ready manufacturing environment.