How VRC Helped Mahindra Save INR 800/Tractor
How VRC Helped Mahindra Save INR 800 Per Tractor by Transforming Two Plastic Parts
In the world of manufacturing, incremental improvements can lead to significant savings, especially when dealing with high production volumes. VRC Plasto Mould, a plastic moulding manufacturer renowned for its expertise in creating efficient and cost-effective plastic parts, recently partnered with Mahindra to revolutionize the plastic components used in their tractors. This collaboration resulted in converting two critical plastic parts and achieving cost savings of INR 800 per tractor—a substantial reduction when considering the large number of units produced annually.
The Challenge: Enhancing Efficiency and Reducing Costs
Mahindra, a global leader in tractor manufacturing, was facing challenges with two of their existing plastic parts. These components were essential for the proper functioning and durability of their tractors, but their existing design and material choice posed certain issues:
- High Manufacturing Cost: The plastic parts, as originally designed, were contributing significantly to the overall production cost of each tractor.
- Material Limitations: The material used was not optimized for cost-efficiency and strength, which occasionally led to durability issues.
Mahindra’s objective was to find a solution that could reduce the cost of these components without compromising on the strength and reliability that farmers depend on for their tractors.
The VRC Approach: Redesigning with Precision
VRC Plasto Mould approached the challenge with their systematic and collaborative process, leveraging their experience in plastic moulding for automotive and industrial applications. Here’s how VRC helped Mahindra transform the two plastic parts:
In-depth Analysis and Problem Identification
The first step VRC took was conducting an in-depth analysis of the existing parts. Their team of engineers and designers worked closely with Mahindra’s product development team to understand the functional requirements, current issues, and potential areas for improvement. This analysis revealed opportunities to redesign the parts to reduce weight and optimize the material usage.Material Selection and Optimization
VRC suggested switching to a new polymer blend that could provide the same strength and durability while being lighter and less expensive. The new material was carefully tested to ensure it met all performance standards, including stress resistance, UV stability, and durability under diverse weather conditions.Redesigning for Efficiency
VRC’s design team re-engineered the shape and structure of the two plastic parts. By utilizing advanced moulding techniques and incorporating design features like internal ribbing, they were able to enhance the strength of the parts while reducing the amount of material used. The redesign ensured that the parts could withstand the wear and tear typical in agricultural machinery without excess bulk or cost.Testing and Validation
Before the newly designed parts were put into production, they went through rigorous testing to ensure that they performed flawlessly in real-world conditions. The VRC team conducted stress tests, environmental simulations, and field testing to validate that the redesigned parts met or exceeded Mahindra’s quality standards.
- High Manufacturing Cost: The plastic parts, as originally designed, were contributing significantly to the overall production cost of each tractor.
- Material Limitations: The material used was not optimized for cost-efficiency and strength, which occasionally led to durability issues.
Mahindra’s objective was to find a solution that could reduce the cost of these components without compromising on the strength and reliability that farmers depend on for their tractors.
The Result: Cost Savings and Improved Quality
The collaboration between Mahindra and VRC Plasto Mould led to remarkable results:
- Significant Cost Savings: By optimizing the material and redesigning the parts for efficiency, VRC helped Mahindra save INR 800 per tractor. Given the scale of Mahindra’s production, this translated into substantial annual savings, allowing Mahindra to maintain competitive pricing while improving profit margins.
- Improved Durability: The redesigned parts were not only more cost-effective but also stronger and more durable. The new polymer blend provided enhanced resistance to wear and environmental factors, ensuring the parts would perform reliably over the long term.
- Weight Reduction: The reduction in material usage also resulted in lighter components, contributing to a marginal reduction in the overall weight of the tractor. This weight reduction helped improve fuel efficiency, providing an additional benefit to end-users.
A Win-Win Partnership
This project exemplifies how VRC Plasto Mould’s expertise can make a significant impact on product development and cost management for large manufacturers. By partnering with Mahindra, VRC was able to:
- Reduce Production Costs: The cost-saving of INR 800 per tractor has allowed Mahindra to allocate their budget more effectively, improving overall efficiency.
- Enhance Product Quality: The new design and material have improved the durability and performance of the tractors, enhancing Mahindra’s reputation for quality and reliability.
- Drive Innovation in Manufacturing: VRC’s innovative approach to plastic moulding highlights the importance of rethinking existing components to achieve better results in both cost and quality.
Conclusion
The collaboration between VRC Plasto Mould and Mahindra is a testament to the power of strategic partnerships in manufacturing. By focusing on material optimization, smart redesign, and rigorous testing, VRC was able to deliver a solution that not only met but exceeded expectations—saving Mahindra INR 800 per tractor and improving the durability of their products.
In an industry where margins are often tight and efficiency is key, these kinds of innovative solutions can make all the difference. At VRC, we pride ourselves on helping our clients reduce costs, improve product quality, and stay competitive in a rapidly evolving market. If you’re looking for ways to enhance your plastic components and achieve similar success, VRC Plasto Mould is ready to help.