AAF India adapting to the Japanese PDS system (Production Daikin System) for Better, Faster, and Cost Effective Manufacturing Facility
Introduction
American Air Filter (AAF) is a Daikin group of the company, the No.1 air filtration solution and industrial air pollution control equipment (dry & wet dust collector) provider in India. We are committed to strengthening product manufacturing excellence and rigorous quality aspects by adapting to various Japanese technologies, and methodologies.
The Kaizen system (a Japanese philosophy that emphasizes continuous improvement) is one of the core principles that we intend to incorporate into our manufacturing system. By implementing this system throughout all operations, we constantly strive for excellence in every aspect of our operations, from the production process to skill enhancement in the staff, warehousing, packaging, and transportation. Being a member of the Daikin group, safety is our foremost priority and we ensure to abide by all safety guidelines in our manufacturing facility.
Kaizen (Continuous Improvement) Driven System at AAF:
Our Kaizen-driven system enables us to stay ahead of the curve, adapt to evolving industry demands, and enable us to deliver quality products.
On the other hand, our customer-centric approach ensures that we consistently exceed their expectations, providing tailored solutions that address specific challenges and deliver unparalleled product performance. During the FY23 year, we aim to build strong connections with our valued customers and vendors by inviting them to our manufacturing facility. Furthermore, customer visits will provide us with an invaluable opportunity to receive direct feedback and insights from those who rely on our products. This collaborative approach strengthens the bond between us and our customers.
As a new endeavor, we are actively demonstrating AAF’s business goals (such as quality expectations from the customers) to our vendors and suppliers, thereby contributing to the enhancement of product quality and meeting customer requirements. We also train our vendors to follow the PDS system for implementing Daikin culture for producing high quality products with on time delivery.
Environmentally Friendly Solutions: Sustainability at the Core
As a leading manufacturing company, we understand the importance of minimizing our ecological footprint while delivering high-quality products to our customers. As part of this commitment, we as a team have tailored to Poka-Yoke lean manufacturing system throughout our operations.
The key factor behind choosing this Poka-Yoke Mistake proof system in our production aspects is waste reduction. At AAF India, we have anticipated implementing a comprehensive waste management system that minimizes waste generation at every stage of our manufacturing process. By accurately analyzing our production lines and identifying areas of waste, we have been able to implement innovative solutions that eliminate redundant resource consumption.
We have initiated the reduction of CO2 emissions by implementing proper energy consumption monitoring and energy savings implementations at our factory. Frequently we conduct “Tool box talk” with our workers to create awareness about safety, quality, and on time delivery to our customers.
Faster Production: Pioneering Breakthroughs
Traditional product fabrication processes often come with inherent time constraints, resulting in bottlenecks and reduced productivity. However, thanks to groundbreaking advancements in technology, our production line is now faster and more efficient than ever. With this, we have augmented the annual production capacity of 2 million filters (former production capacity 1.6 million) and 1,20,000 equipment units (prior capacity 90,000 units). We have implemented a few semi automation technologies in our process for better productivity and transforming towards industry 5.0 for supporting the large business.
Revolutionary HEPA filters, engineered in our upgraded cleanroom environments, are at the forefront of this rapid evolution. These filters are manufactured under ISO9001-2015, ISO 45001-2018 & ISO14001-2015 stringent conditions and tested using EN 1822 compliance autoscan system. With the advent of autoscan we are confident to deliver zero defect products to our customers. Apart from this, the technology also enables us to reduce the amount of wastage in the factory premises, and the reverse transportation challenges.
Cost-Effectiveness: The Triple Bottom Line Advantage
In today’s competitive landscape, cost-effectiveness is a key consideration for businesses that are seeking sustainable solutions. One such breakthrough is the investment (we have invested 140 million) of industrial automation systems that offer significant cost savings while maintaining high efficiency are now a reality.
Future Foolproof Commitment:
We also place great emphasis on product lifecycle management. From the initial design phase to product disposal, we consider the environmental impact of our products at every stage. By employing eco-friendly materials, optimizing packaging, and implementing recycling initiatives, we ensure that our products have a minimal impact on the environment throughout their lifecycle.
AAF has been awarded several certifications and eco-labels that demonstrate our commitment to sustainability. In order to expand business activities in tier 1 & 2 cities, we even planning to transform our manufacturing facilities in Noida.
These achievements not only validate our efforts but also inspire us to push the boundaries of what is possible, further solidifying AAF’s position as a leader in sustainable manufacturing practices.
