Client’s Background: LTTS’ (L&T Technology Services Limited) client is a leading manufacturer of motion precision and conveyor equipment. The company wanted to upgrade its vibratory conveyor machine with new designs and technologies while reducing the power consumption and production cost. The client was looking for a partner who could help them not just develop the product as per speciﬁcation but also improve eﬃciency and productivity. After evaluating various options, the client entrusted LTTS to redesign its vibratory conveyor.
Why LTTS? LTTS has worked on numerous projects that involve building special and custom products for their clients. The company’s Special Purpose Machine (SPM) practice has delivered proven custom products, such as coil winders, robotic material picking arms and more. LTTS’ experience and expertise provided an in-depth understanding of the client’s challenges and how to overcome them.
Challenges: LTTS identified the three main challenges:
- The existing design was a decade old and sourcing components were becoming increasingly difficult
- Because of the obsolete design, it was difficult to integrate the vibratory conveyor with new technologies and processes
- The older design was noisy and did not meet the current safety standards
Solution Deployed: LTTS proposed a three-pronged approach to redesign the vibratory conveyor:
- The first step - analyze the existing vibratory conveyer and its functionalities
- Second step - brainstorming of ideas in areas involving eﬃciency improvement and cost reduction
- Last step - implementing the ideas with minimal or no change in functionality
The ﬁnal product incorporated:
Alternate Materials: There were several areas where alternate materials were used to improve eﬃciency and reduce cost. One such area was in-feed, where an expensive Italian wood was replaced by re-inforced plastic, with no change to functionality.
Manufacturing and Assembly Process: The newer design of conveyor meant an updated manufacturing process. Several areas of the manufacturing and assembly process were changed, reducing overall cost as well as the time to build the conveyor.
Weight Management: Several design changes were made that decreased the overall weight of the vibratory conveyor. One such area was the motor mount, where a design change eliminated the need of a separate mount and welding process.
Alternate Suppliers: The basic parts used by the existing conveyer belt was sourced locally, which increased the overall cost. Through LTTS’ network of vendors and suppliers, the client had access to several low-cost alternatives.
Overall Benefits: With the new design, alternate materials, and a new network of suppliers, the client saw significant improvement:
- Weight reduction by ~1000 Kg per conveyor
- Cost-saving by 31.5 percent per conveyor
- Power saving of 32.7 percent per conveyor