Multi-Operation Machine Manufacturing SPM Component

Posted Date : 21 Jan 2025

1. Introduction: Revolutionizing Automobile AC Component Manufacturing SPM with a Multi-Operation Machine

Sanden Vikas, a leading manufacturer of automotive air conditioning systems located in Faridabad, sought a more efficient and cost-effective method to produce their Shaft and Rotor assemblies. They needed a solution that could handle multiple operations—hydraulic pressing, drilling, milling, reaming, and spring assembly—all in one machine. The result was a groundbreaking Multi-Operation Machine developed by IYALIA that performs over 10 operations on Ten different models to be done and the 25 seconds per cycle target time, requiring only one semi-skilled operator.

2. About the Client: Sanden Vikas

Sanden Vikas is a major supplier of AC compressor to prominent car manufacturers. With high-volume production demands and strict quality requirements, they constantly strive to enhance efficiency, reduce rejection rates, and maintain top-level product consistency. Overseeing multiple operations on separate machines proved both time-consuming and labour-intensive, involving up to Multiple personnel per shift.

3. The Challenge: Streamlining Operations & Reducing Rejections

• Multiple Machines & Processes: Previously, various machining tasks were performed on different machines, which complicated quality control and process management.
• High Rejection Rate: The complexity of transferring parts across machines resulted in parameter failures and inconsistent outputs, leading to frequent rejections.
• Resource-Intensive: With 7–8 operators needed to handle separate machines, labour costs and training overheads were high.
• Tight Tolerances: The Shaft and Rotor assembly requires precise length measurements and pressure checks, which are difficult to manage consistently across multiple machines.

4. The IYALIA Multi-Operation Machine: Features & Specifications

IYALIA’s Multi-Operation Customized Machine integrates:

• Hydraulic Press with load cell and also LVDT
• Servo Center Milling and Centre Drilling
• Drilling & Servo Reaming
• Automated Spring Assembly & Pin Insertion
• Automatic Ejection of Finished Components
• many poke yokes in each stage,
• Pressure monitoring system

Key Highlights

• Single Operator: A semi-skilled operator is sufficient to run the entire process, cutting manpower from 7–8 down to 1.
• Cycle Time of 25 Seconds: Over 10 operations are completed in less than half a minute.
• Top-Quality Electrical Servos: Ensures precision in machining and assembly while maintaining consistent pressure and length measurements.
• Multi-Model Capability: Handles 10 different shaft and rotor assembly models on the same machine.
• 100% Finished Parts: The final output is fully tested and verified for critical tolerances, eliminating rejections.

5. Implementation & Timeline: From Concept to Reality

• Phased Development: The first machine underwent several improvements, and subsequent machines (the second and third) incorporated enhancements based on real-world feedback.
• Commissioning & Training: IYALIA’s expert team provided on-site commissioning and comprehensive training for Sanden Vikas’ operators and technicians, ensuring a smooth handover.
• Timely Delivery: Despite typical SPM (Special Purpose Machine) challenges, the project milestones were met, showcasing IYALIA’s commitment to quality and punctuality.

6. Results & Impact: Immediate Efficiency Gains

1. Reduced Cycle Time: Achieved the 25-second cycle goal, dramatically increasing throughput.
2. Lower Rejection Rates: Enhanced process control and in-machine inspections nearly eliminated rejections.
3. Significant Labor Savings: Labor requirements dropped from 7–8 operators to just 1, reducing overhead and training costs.
4. Data Tracking & Model Versatility: The machine can save production data for up to 10 different part types, giving Sanden Vikas maximum flexibility.

“All the benefits were quickly realized, and improvements in safety, quality, and other KPIs have been achieved as per our requirements,” – Sanden Vikas Representative

7. Key Takeaways: Why Custom Multi-Operation Machines Work

The main lesson from this project is clear: when you need to perform multiple operations efficiently and at scale, a customized multi-operation machine is often the best solution. Whether it’s multi-axis machining, hydraulic pressing, or automated assembly, IYALIA can tailor each machine to match exact tolerances, production volumes, and budget constraints.

8. Future Outlook: Scalability & Mass Production

• High-Volume Production: As Sanden Vikas expands production lines, these custom SPMs (Special Purpose Machines) can be replicated or upgraded to meet increased demand.
• SPM vs. Standard CNC/VMC: While standard machines work well for batch volumes, high-volume environments benefit more from specialized SPMs due to their cycle time optimization, automation, and reduced labor requirements.
• Ongoing Innovations: IYALIA continues to refine the Multi-Operation Machine’s design with each iteration, ensuring future-proof technology for its clients.

9. Call to Action: Choose IYALIA for Your Next SPM

Considering a new metal cutting or material handling automation machine? Request a quote from IYALIA for a custom SPM (Special Purpose Machine) solution tailored to your exact needs. Compare our multi-operation systems to standard CNC or VMC setups, and discover the significant productivity and cost benefits of going with IYALIA SPM.

Ready to Get Started?

• Call/Email: + 91 9789090900/ info@italiaautomations.com
• Website: www.italiaautomations.com

“If you want to produce in mass volume and boost productivity multiple times, remember IYALIA SPM Machines—a true game-changer in manufacturing efficiency.”