Atlas Copco’s latest plant sets the benchmark for sustainable design and lean production practices
Wilrijk, Belgium, April 2014. When the Atlas Cocpo project team undertook the task of building a new production plant in Chakan, an industrial area near Pune, India, they also took on the challenge of building a facility that would set the benchmark for sustainable design and state-of-the-art production processes within Atlas Copco.
The factory was built in accordance with Atlas Copco’s globally accepted Sustainable Building Standard and in line with LEED (Leadership in Energy & Environmental Design) best practices has lately been certified by IGBC (Indian Green Building Council) as a GOLD rated Green Factory Building. Extra attention was given to energy-efficient design and technology to limit environmental impact and to reduce the use of energy and natural resources during the construction phase, as well as future plant operation. The project could get maximum credit points for its rainwater harvesting system. The system ensures that no rainwater will run off site during a monsoon but instead get collected in a natural pool. The collected rainwater will supplement local groundwater during dry periods.
No need for an air conditioning system
The plant’s layout was developed according to Flow manufacturing principles. From Goods Reception to Finished Goods Loading is one single, connected process flow, which focuses on the continuous flow of materials, products and information through the value-creation process. The manufacturing layout and logistics setup were designed to operate according to lean manufacturing principles. Consequently, the number of production lines and the overall assembly length were reduced considerably. Flow and transparency in logistics were created by the introduction of the “supermarket concept.” As in retail, goods in a supermarket have fixed locations and fixed quantities, and their availability is secured over time
Environment of continuous improvement
The last but most important step toward lean manufacturing is the development of an environment of continuous improvement. By creating flow and transparency in operations and logistics, it becomes easier to see and identify problems. Each workstation is equipped with a monitoring system that allows the operator to understand his performance and notify supervisors of any problems in his work area. Excellence in lean manufacturing means every individual has the responsibility to take initiative to solve problems within his or her area of operation. The new plant will support Atlas Copco’s ambition for further growth in the Indian market for years to come.
For further information please contact:
- Michael Gaar, PR Coordinator, Telephone: +32 (0) 3 750 80 88, e-mail: Michael.firstname.lastname@example.org
Atlas Copco’s Compressor Technique business area provides industrial compressors, vacuum solutions, gas and process compressors and expanders, air and gas treatment equipment and air management systems. It has a global service network. Compressor Technique innovates for sustainable productivity in the manufacturing, oil and gas, and process industries. Principal product development and manufacturing units are located in Belgium, Germany, the United States, China, India and Korea.