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S H R A M B H U S H A N
SHRI ASIS BHATTACHARYYA
Shri Asis Bhattacharyya was born on 7.11.1959 in Distt. Murshidabad, West Bengal. He studied up to Higher Secondary and achieved professional qualification in the Tool & Die Maker Trade, S.A.T. in Tool Maker Trade and AUTO CAD and AUTO LISP from Regional Computer Centre, Jadavpur University. Presently, he is working as CNC Operator.
Rifle Factory, Ishapore procured a number of CNC Machining Centers against 5.56mm INSAS Rifle weapon project. These machines were commissioned at RFI during the year 1994-95 in Proj. Shop-II. Shri Bhattacharyya was associated with the commissioning engineers of the firm since Jan. 1994. He volunteered to work in the then upcoming CNC shop foregoing his regular incentive earnings. This shows the inclination of the person towards learning newer technology.
The CNC Machining Centres were supplied by M/s Mysore Kirloskar Ltd. of M/S STEINEL, Germany. The manufacturer assured 16.97 minutes cycle time for manufacture of the component Barrel Extension for the 5.56 mm INSAS Rifle. However it was found that the actual cycle time was 21.29 mins. M/S Mysore Kirloskar claimed that the cycle time was more since indigenous tools were deployed.
Shri Bhattacharyya took up the challenge of reducing the cycle-time. He did a lot of experiments with toolings, cutting parameters, the part-programme, sequence of operations and alternative cutting operations for achieving a particular dimension etc. all alone, often overstaying beyond duty hours for approximately two months of hard and totally devoted working to carry out experimentation. He undertook a self-study of the Tool manufacturers' catalogues. Ultimately, he was successful in bringing down the cycle-time to 17.04 minutes inspite of two additional operations due to change of drawing requirements. This resulted in a saving Rs.56 lakhs per annum.
Shri Bhattachayya changed the sequence of operations, combined certain operations, eliminated some of the tools and replaced some tools by a different tool in order to reduce the rejection percentage and to improve quality.
Shri Bhattacharyya noticed that the existing 'CAM Programme' required 80% of the jobs rework resulting in loss of 600 mandays per annum. He took the challenge of decoding the part programme and amended the programme by replacing the R-parameters by a practical value, thereby saving of two men who could be shifted to productive area.
Shri Bhattacharyya prepared a process control card used in quality control which has helped in timely input of tool wear compensation data to the m/c and thereby reducing the rework. The benefits arising out of this are qualitative in nature.
Thus, Shri Asis Bhattacharyya through his innovations, has contributed a lot in improvement of quality and quantity of production of Barrel Extension for 5.56 mm INSAS Rifle through CNC route.
Only because of his sincere initiative, innovative thinking, dedicated hard work, exemplary zeal and enthusiasm Rifle factory, Ishapore is making recurring yearly direct saving of Rupees 56 lakhs to the Govt.