Automation Techniques for Enhanced Plant Operations Strategies

1. Automation Techniques for Enhanced Plant Operations Strategies Due to a shortage of skilled labor and disruptions caused by the global pandemic, manufacturers have encountered a problem. Throughput of factories has decreased and so has profitability. GCI believes that wet cast operations can solve these problems by automating their production. Automation reduced the barriers of production and increases efficiency. This year GCI has introduced a solution –Automated Precast System (APS)! We work with our clients to automate their existing operations or develop new automated plants from scratch along with our trusted partners. The working principle behind APS is simple. We subject molds to a closed loop cycle, whereby, it passes through workstations. Thus, a process flow is achieved and aims to boost your lean manufacturing initiatives. This helps precast manufacturers to increase capacity without a significant increase in their workforce. Design Methodology APS is designed to be a versatile solution. We believe that most wet cast products can be casted on this line. There are certain technical limitations (Weight, size and height) of the plant which may hinder some products from being mounted on this line. However, GCI works with its clients to design and automate your precast operation at costs which make these projects viable. Our first step is to design a plant layout based on ‘Takt Time’. APS derives its efficiency by utilizing an ‘Assembly Line Principle’ conceived by Henry Ford. Workstations are designed and specific set of tasks (SOPs) are carried out at each station. All necessary tools and fixtures needed to complete a task are provided at their respective stations. We pitch our proposed plant layout to the customer and draw from their experience about possible bottlenecks in production. To ensure line balancing, we provide buffers and/or provide equipment to solve this potential bottlenecks and reduce ‘Work in Progress’ (WIP). GCI designs and manufactures wet cast molds as per drawings provided by the customer. For quick turnaround, these molds are provided with roll back jackets, hydraulic collapsible cores etc. These molds are conveyed through workstations by

2. Roller Conveyors. These conveyors are designed to transport the heaviest mold in your production loop with sufficient factors of safety. The use of conveyors and transfer carts for mold movement reduces the need for overhead cranes and reduces dependencies of forklifts. Roller conveyors and transfer carts are placed in pits, which enables the workforce to work at floor level. Ergonomics and safe working conditions form the heart of APS. On request, GCI can introduce a plant production software which monitors key production metrics in real time. This data is stored, processed and presented in formats desired by the customer. It divulges bottlenecks in production and helps managers take action to solve these problems. Product Range (Not limited to): * Manhole Products (Base, Riser, Cone and Grade Rings) * Catch Basins * Wet-cast Pipes * Jacking Pipe * Wet-cast Box Culverts * Concrete Blocks Advantages of Automated Precast System Automation provides flexibility and durability along with speed and cost managements. As already mentioned earlier, it uses the principle of Assembly line which is to a great advantage for the manufacturers. Automation also assists with cost effectiveness and increased profitability. The environment of production plants becomes more manageable with automation into action. * Assembly Line Principle * Reduced Labor * Increase Profitability and Throughput * Improve Plant Conditions

3. GCI is client-driven. We put our maximum efforts into customer satisfaction by meeting their customised requirements. Our experts provide innovative insights for your productions.