Q. What is the Arhan model of business with Japanese machines and technologies? How adaptable are these in the Indian context?
Arhan has developed concept of providing customized solutions, proven manufacturing concepts in Japanese industries for improving productivity, quality with automated systems. Our solutions consists of automated cell systems, compact line planning of machines from different manufacturers suitable for respective process. Arhan has access to many Japanese machine manufacturers, Turnkey solutions, Work holding Solutions provider. Our product range covers wide range of machines in Metal Cutting, Super precision machining, all types of Grinding Machines, Auto Inspection/ Measuring, Forging Machines, Die Manufacturers, Automation manufacturers, Machine peripherals, Work Holding solutions, Special Purpose Machines manufacturers. We allow our customers to access to wide range of manufacturers for most suitable automated and cost effective manufacturing solutions.
Indian manufacturing industry is going through great change for delivering World-Class Quality, High Productivity, Better Price and most important consistent Quality. We can offer solutions where quality will be linked to line process and not just human dependent. Indian manufacturers are now looking for new manufacturing techniques, next generation solutions to have more productivity in minimum space, reduction in manpower, built-in quality systems, most important Consistent Quality and edge over competitors than concentional production systems.
Q. What is the Arhan USP, especially when Japanese machine tool companies are already present in India?
Japanese companies in India sale their conventional machines andmachine dealers machines handled by them. Conventional machine tool manufacturers try to present how their machines are suitable, economical; however they do not present manufacturing methods adopted in Japan for cost effective & high quality production. Conventional major machine manufacturers do not focus on automated systems as their business policy is to sale more number of conventional machines. It is necessary to spend more time with Indian manufacturers for giving specialized solutions and they can’t give this.
Arhan study customer’s requirements and check most suitable, proved automated manufacturing solutions for similar parts manufacturing in Japan. Some Japanese machine manufacturers have sales & service set-up in India but mostly they supply conventional machines. There are many good Japanese companies who does not have set-up in India, their machines and automated systems are widely used by Japanese Automotive OEM, Tier 1, Tier 2 parts manufacturers. Arhan is focusing on automated cell systems, Turnkey systems and One Supplier for various machining requirements concept. We have also made contracts with automation specialized companies. So our customers do not have to depend and discuss with various machine suppliers for good solutions. We take our customers to Japan and have technical meetings, show them solutions working in the field and have proven reliable concepts in India to make their production set-up World-Class and more profitable. Arhan has own set-up in India and Japan, this gives us added advantage to closely work with Indian customers as well as Japanese machine, automation manufacturers.
Q. Arhan provides fully automated manufacturing solutions on turnkey basis. What are the customer benefits?
Arhan understand customer requirements and work out automated solutions based on customer’s budget, infrastructure, and technical expertise in discussion with Japanese manufacturers. We suggest automated cell systems as well as automated partstransfer from one manufacture’s machine to another.
Our automated systems installations have benefited our customers to improve productivity, achieve consistent in-built quality, continuous unattended production during races. Our customers have confirmed our solutions are more efficient than previously they used to have with local low cost automation. In fact they removed old automation from production lines and adopted our solutions. Some Customers improved profitability over 100% due to minimum downtime, minimum rejection and machine maintenance costs, and higher productivity. This gives leading edge over competitors.
Customers have now understood that only initial investment costs only does not decide cost/piece but more profitability comes with good production methods and reliable systems.
Q. With businesses now facing extreme competitiveness, even companies are looking for optimised solutions. How do these work in practice?
Now customers are asking for imported parts substitute solutions as well as world standard production set-up to have competitive advantage. Just purchasing Japanese top brand machine does not solve the purpose. Customers can present that they are using top brand machines to their customers, but not necessary these are optimised solutions to have business advantage to them. Automotive, Non-Automotive parts manufacturers now need to think out of box to have solutions which are proven in Japan for all types of advantages. Success stories of Japanese industries can be repeated in India.
Q. The concept of working with conventional machine tools in isolation is changing in favour of flexible manufacturing cells with multitasking abilities. Easily said than done?
Now a days Indian industries are facing new challenges: short of space, meet higher productivity in same available space, shortage of manpower & skilled operators, higher parts accuracies requirements, stringent quality norms, parts warrantee. So just adding number of machines in production line does not solve purpose when demand is increased. Just adding number of machines increases various problems and people dependent productivity.
When we set flexible manufacturing cell, with minimum set-up change multi-tasking production concept it helps customers to have real advantage. When a cell of 2 complex operations is set, it is possible to have both machines same parts machining or separate parts machining with complete flexibility. This helps customers for proper production planning.
Q. It is the age of Industry 4.0 now. Are your solutions compatible with this concept?
Today’s concept is Smart factory with automation, traceability, auto inspection, data storage. We have given solutions where inspection or gauging data can be stored in media or transfer to computer systems. Computer customized software can calculate process capability, statistical analysis, understand material or process problems. Customer can store such data for longer time and also submit to their customers. Auto correction systems through automation also enable high quality parts production. Smart factory with minimum machines and smart people is effective way to increase profitability and business competitiveness.
Q. Arhan actually takes ownership for the solutions it offers. Do your principals offer full support to this?
Arhan has taken ownership for the solutions for meeting Customers’ requirements in Quality, Tact Time, and Automation reliability, Installation and Service Support, Quicker Manufacturer Support.
Our principles are offering full support by different ways: Better Price over Japanese market prices, Simple automation, quicker deliveries, Customer trainings in Japan and in India, Proper documentation, Proving parts in Japan before machine shipment to India, Tooling solutions to reduce cycle time and so on.
Q. What is the Arhan experience of working with Indian companies? Are they more receptive to this? Or are there apprehensions?
Some of our customers informed us that they tried to adopt local or conventional automation until 2013-14 due to budget constraints, could not achieve desired results and after seeing success of our provided solutions, they are becoming more confident and are requesting further advanced solutions to replace old machines in their plants. We feel educating customers for proven Japanese manufacturing technology is best way to build their confidence and go for proper budget investments for long term higher profitability.
New generation businessmen who are frequently visiting overseas to see production methods are more convinced for new production methods. We are able to supply more economical Japanese automation than some other Japanese automation companies. This is benefitting our customers more.
Q. In effect, is Arhan not advocating less use of machines by making more productive use of them?
We suggest having minimum machines in line with multiple stations working to have cost effective production with more productivity. If our machines and automation systems are developed for 24×7 working and unattended production during races, then it gives more productivity.
Q. Can you provide a couple of examples of how customers have benefited?
We have provided specialized machines and automation system for import substitute parts production. These parts cannot be produced with conventional machines. Our solution enabled our customer to increase profitability multiple times. They could have ROI in less than 2 years against initial planned 5 years. Dependence on international suppliers was eliminated.
Another example is major automotive manufacturer using branded equipment with automation were not able to have 24 hours consistent productivity. Sometimes branded equipment manufacturer take automation from other manufacturers. This automation system faced consistent troubles and customer used to operate large system manually. Our reliable solution helped them to get consistent productivity. With new solution productivity is almost doubled by reducing all idle time, load/unload time. System efficiency greatly increased.
One of our solutions has replaced 8 manual operated grinding machines in production line with just 2 twin wheel head grinding machine. This Twin head large grinding wheel grinding machine is innovative concept in India. This solution enabled great space savings, 8 operators were reduced to just 1 skilled operator to run line. Now production will be consistent and each part will be measured on-line before delivering to feed-out conveyor. The system will make sure 100% parts produced will be within required accuracy levels.
