Not every stopped minute had the same impact.
A stopped minute on a heavy bar loses more tonnes than a stopped minute on a light bar. The total downtime figure did not show the diameter on the heater, so minutes alone were an incomplete basis for deciding which losses to clear.
Diameter changed the tonnes lost to a stop.
Neuron let production and maintenance examine each interruption against the diameter being coated and the rate of that run. A loss recorded in minutes could now be understood in the tonnes it kept the line from producing.
The team eliminated manpower delays and gun-powder jams. Time lost to unavailable material fell from 128 minutes to six minutes across the comparison.
More coating capacity from the same line.
Unplanned-stop time fell to 591 minutes. The coating rate moved from 10.3 to 10.7 metric tonnes per hour, with about 166 additional tonnes per month. The line reported ₹1.1 crore in additional monthly revenue.
The comparison behind the result.
| Measure | Month 1 | Month 3 |
|---|---|---|
| Unplanned-stop time | 1,399 min | 591 min |
| Coating rate | 10.3 tonnes/hour | 10.7 tonnes/hour |
| Material unavailable | 128 min | 6 min |
| Manpower delays | Present | Eliminated |
| Gun-powder jams | Present | Eliminated |
Month 1 to Month 3 for the measured rebar coating line. Tonnes are metric tonnes (MT). The output increase is approximately 166 tonnes per month; revenue is additional monthly revenue.
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