CLIENT PROFILE
Industry: Automotive component manufacturing
Location: IMT Manesar, Gurugram, Haryana
Application: Engine bracket sub-assembly line
Challenge: Aging conveyor causing 40–50 minutes of unplanned downtime daily, belt tracking issues, and inconsistent speed affecting downstream assembly quality.
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THE CHALLENGE
━━━━━━━━━━━━━━━━━━
The client's existing conveyor — purchased from a different supplier 6 years prior — was showing multiple failure symptoms simultaneously: belt drifting off-centre daily, drive motor overheating during the second shift, and roller noise audible from 10 metres away. Spare parts from the original supplier had a 3–4 week lead time. Daily production loss was estimated at ₹80, 000–₹1, 20, 000.
━━━━━━━━━━━━━━━━━━
NEO CONVEYORS SOLUTION
━━━━━━━━━━━━━━━━━━
After a site visit by our senior application engineer, we designed and manufactured:
• 2 × flat belt conveyors, each 18m length × 500mm width
• Anti-static PVC belt — appropriate for precision metal component handling
• VFD-controlled drive allowing speed range of 0.3 m/s to 2.2 m/s
• 4 × flush-mounted workstation stop positions with operator call buttons
• Centre drive configuration to eliminate head pulley crowding issue
• Full MS painted frame — RAL 5015 (sky blue) to match plant colour code
• Integrated cable tray and panel mounted on conveyor frame
• Steel mesh safety guarding on all rotating parts
━━━━━━━━━━━━━━━━━━
DELIVERY & INSTALLATION
━━━━━━━━━━━━━━━━━━
• Order confirmed: Day 0
• Fabrication completed: Day 11
• Dispatch from Ghaziabad: Day 12
• Installation & commissioning: Day 13–14
• Operator training: Day 14 (commissioning day)
• Total elapsed time: 14 working days
━━━━━━━━━━━━━━━━━━
RESULTS — 14 MONTHS AFTER COMMISSIONING
━━━━━━━━━━━━━━━━━━
✅ Zero unplanned downtime incidents in 14 months of 2-shift operation
✅ Line speed increased by 30% (from 0.8 m/s to 1.1 m/s sustained)
✅ Operator ergonomics improved — workstation stop positions eliminated manual holding
✅ Downstream assembly rejection rate dropped by 12% (consistent speed = consistent part positioning)
✅ Client ordered a second identical system for their Plant 2 facility within 6 months
━━━━━━━━━━━━━━━━━━
CLIENT FEEDBACK
━━━━━━━━━━━━━━━━━━
'Neo Conveyors delivered exactly what they promised, on the date they promised. The commissioning engineer stayed until 7pm to make sure our team was confident running the system. That is the kind of supplier we want long-term.'
— Production Manager, Auto Component Plant, Manesar
━━━━━━━━━━━━━━━━━━
Is your assembly line conveyor showing warning signs?
🌐 www.neoconveyors.com
auto component conveyor case study Manesar
assembly line belt conveyor Gurugram manufacturer
automotive conveyor supplier Delhi NCR, belt conveyor replacement Ghaziabad fast delivery
VFD belt conveyor automotive plant India
Industry: Automotive component manufacturing
Location: IMT Manesar, Gurugram, Haryana
Application: Engine bracket sub-assembly line
Challenge: Aging conveyor causing 40–50 minutes of unplanned downtime daily, belt tracking issues, and inconsistent speed affecting downstream assembly quality.
━━━━━━━━━━━━━━━━━━
THE CHALLENGE
━━━━━━━━━━━━━━━━━━
The client's existing conveyor — purchased from a different supplier 6 years prior — was showing multiple failure symptoms simultaneously: belt drifting off-centre daily, drive motor overheating during the second shift, and roller noise audible from 10 metres away. Spare parts from the original supplier had a 3–4 week lead time. Daily production loss was estimated at ₹80, 000–₹1, 20, 000.
━━━━━━━━━━━━━━━━━━
NEO CONVEYORS SOLUTION
━━━━━━━━━━━━━━━━━━
After a site visit by our senior application engineer, we designed and manufactured:
• 2 × flat belt conveyors, each 18m length × 500mm width
• Anti-static PVC belt — appropriate for precision metal component handling
• VFD-controlled drive allowing speed range of 0.3 m/s to 2.2 m/s
• 4 × flush-mounted workstation stop positions with operator call buttons
• Centre drive configuration to eliminate head pulley crowding issue
• Full MS painted frame — RAL 5015 (sky blue) to match plant colour code
• Integrated cable tray and panel mounted on conveyor frame
• Steel mesh safety guarding on all rotating parts
━━━━━━━━━━━━━━━━━━
DELIVERY & INSTALLATION
━━━━━━━━━━━━━━━━━━
• Order confirmed: Day 0
• Fabrication completed: Day 11
• Dispatch from Ghaziabad: Day 12
• Installation & commissioning: Day 13–14
• Operator training: Day 14 (commissioning day)
• Total elapsed time: 14 working days
━━━━━━━━━━━━━━━━━━
RESULTS — 14 MONTHS AFTER COMMISSIONING
━━━━━━━━━━━━━━━━━━
✅ Zero unplanned downtime incidents in 14 months of 2-shift operation
✅ Line speed increased by 30% (from 0.8 m/s to 1.1 m/s sustained)
✅ Operator ergonomics improved — workstation stop positions eliminated manual holding
✅ Downstream assembly rejection rate dropped by 12% (consistent speed = consistent part positioning)
✅ Client ordered a second identical system for their Plant 2 facility within 6 months
━━━━━━━━━━━━━━━━━━
CLIENT FEEDBACK
━━━━━━━━━━━━━━━━━━
'Neo Conveyors delivered exactly what they promised, on the date they promised. The commissioning engineer stayed until 7pm to make sure our team was confident running the system. That is the kind of supplier we want long-term.'
— Production Manager, Auto Component Plant, Manesar
━━━━━━━━━━━━━━━━━━
Is your assembly line conveyor showing warning signs?
🌐 www.neoconveyors.com
auto component conveyor case study Manesar
assembly line belt conveyor Gurugram manufacturer
automotive conveyor supplier Delhi NCR, belt conveyor replacement Ghaziabad fast delivery
VFD belt conveyor automotive plant India
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