The services team’s planning and equipment sped up inspection processes while maintaining accuracy.
The feedwater heater inspection challenge
Headquartered in Pirojshanagar, Godrej & Boyce Mfg. Co. Ltd. designs and manufactures industrial products for a wide range of industries.
For this project, Godrej was contracted to supply a feedwater heater for overseas export. The heater was a large fabricated assembly, making measurement of each component and its alignment during assembly critical.
Godrej needed inspection support and a complete measurement plan. API India helped from the raw-material stage, including marking the job for CNC machine cutting and inspecting each subsequent stage to avoid rework and lost time or material.
API’s project support included:
- A responsibility assignment matrix (RACI chart) and Resource Breakdown Structure.
- Accuracy checks at each stage of fabrication.
- Support for meeting deadlines, with reported savings of more than 30 days of man-hour costs.
Godrej’s manufacturing background
Godrej & Boyce, a Godrej Group company, began manufacturing high-quality locks in 1897. At the time of this April 2020 case study, it described 15 business divisions supplying consumer, office, and industrial products and services in India and internationally.
Its products served industries from aerospace and construction to storage. The original case study reported that 750 million Indians used at least one Godrej Group product each day.
The article credited the company’s quality, attention to detail, and customer focus with winning complex manufacturing and fabrication work. Some of those projects required additional manpower and specialist support.
From API’s original April 2020 case study
Today, Godrej & Boyce Mfg. Co. Ltd. have 15 diverse business divisions offering consumer, office, and industrial products and services of the highest quality to every corner of India and across the globe.
Planning measurement through fabrication
Godrej initially planned to use conventional processes and hand tools, outsourcing inspection of some critical parts to a fixed-bed CMM. It also invited API Services India to consult on the project.
API’s team evaluated the service requirements and prepared a project charter covering the scope, milestones, and resources. Godrej selected API based on the projected savings and time benefits of that plan.
Before work began, API Services prepared and sent Godrej a RACI chart and Resource Breakdown Structure.
Measuring hard-to-reach features
The API Services team brought Radian Pro and vProbe onsite for high-accuracy measurement of components with hidden points and difficult lines of sight. The case study described Godrej’s positive response to the technology, accuracy, and ease of use.
From API’s original April 2020 case study
"Godrej was amazed with the technology and the accuracy and ease of use."
Inspection at each fabrication stage
API Services measured the raw material and completed the job marking, followed by post-machining inspection. Critical details of the feedwater heater were recorded throughout the process.
The measurement data was shared with Godrej, which then shared it with its client in the United States. Following the client’s approvals, the assembly steps proceeded in a timely manner.
Reported time, cost, and accuracy results
By contracting API Services to use Radian Pro and vProbe, Godrej saved more than 30 days of man-hour costs and met its deadlines. This figure describes man-hour costs saved; the source does not report a 30-day reduction in elapsed calendar time.
The final inspection results were all well within the specified tolerances.
From API’s original April 2020 case study
"By contracting API Services to use Radian Pro and vProbe, more than 30 days of man hour costs were saved, and Godrej met their deadlines."
The original case study reported that Godrej was pleased with API’s timely reporting and support. It also described the US client as extremely satisfied and assuring Godrej of all its future projects, with Godrej planning to contract API Services India for support on those projects.
API attributed the project’s value to the combination of experienced professionals and high-precision dimensional metrology equipment, supporting accurate, on-time work at lower cost.
