When the Atlas Copco project team undertook the construction of a new production plant at Chakan near Pune, it took care to see that the project sets a benchmark for sustainable design and state-of-the-art production processes.
The Chakan plant is for production of industrial compressors from 5 to 90 kW and portable compressors from 85 to 1350 cfm. Spread out over 23 acres, the complex houses an administrative building, assembly workshop, finished goods storage and the R&D Division. The plant construction was completed in just 18 months.
Extra attention was paid during construction to energy-efficient design and technology to limit environmental impact and to reduce the use of energy and natural resources. The rainwater harvesting system provided ensures that no rainwater will run off site during the monsoon but instead get collected in a natural pool.
No need for air-conditioning system
The building’s orientation and designing of walls and roof is such that the workshop does not need any additional lighting during the day. Natural air flow and ventilation stabilize the ambient temperature without the use of an air-conditioning system.
The plant layout was developed according to the Flow manufacturing principle. From goods receipt to finished goods loading it is one single process flow, ensuring continuous flow of materials, products and information through the value-creation process. The manufacturing layout and logistics set-up were designed to operate according to the lean manufacturing principles. Consequently, the number of production lines and the overall assembly length were reduced considerably. Flow and transparency in logistics were created with the introduction of the “supermarket concept.” As in retail, goods in a supermarket have fixed locations and fixed quantities.
Information management is a key factor for successful lean manufacturing. Therefore, a Manufacturing Execution System (MES) was developed and implemented to secure on-time, in-full data management throughout the entire process. Core assembly activities like bolting, clamping and connecting were identified, and individual training standards developed to select and train the line operators before they start assembly operations on the shop floor.
The most important step toward lean manufacturing is the development of an environment of continuous improvement. By creating flow and transparency in operations and logistics, it becomes easier to see and identify problems. Each workstation is equipped with a monitoring system that allows the operator to understand his performance and notify supervisors of any problems in his work area. Excellence in lean manufacturing means every individual has the responsibility to take the right initiative to solve problems within his or her area of operation. The new plant will support the Atlas Copco mission of further growth in the Indian market.
Atlas Copco’s Compressor Technique business area provides industrial compressors, vacuum solutions, gas and process compressors and expanders, air and gas treatment equipment and air management systems. With its global service network, Compressor Technique innovates for sustainable productivity in the manufacturing, oil & gas and process industries.