automation for quality growth of organization. maruti suzuki india limited about maruti suzuki… ...

Automation for Quality Growth of Organization

http://www.marutisuzuki.com/Home_Maruti.aspx

Maruti Suzuki India Limited

About Maruti Suzuki…

Year of inception: Setup in 1982

Equity Structure: 56.2% Suzuki, 43.8% with

Public

Market Share: 43%(approx.)

Plants: 6 Plants in Gurgaon & Manesar

Models: 14 Models with over 160+

variants

Net Production/Sales : 1.15 million units p.a./

426,448 Million Rs.

Net Profit: 27,831 Million Rs.

Manpower: 14000+ Employees

Joint ventures : 20 Joint ventures

for components Customer Satisfaction: No.1 in JD Power Customer

Satisfaction for 13 years in a row


What is Quality to Us? ? ?

“ No Surprises during Production ”

“ Creating Product First Time OK ”


What Constitutes a Quality Product ? ? ?

ManagingChanges

Quality Product

Systems

Environment People


Factors Affecting Quality Output

Process Inconsistency

Ergonomic Issues

Line Absenteeism

Handling and Transportation Concerns

Frequent Changes

http://www.google.co.in/url?url=http://www.fcpeffects.com/products/defect&rct=j&frm=1&q=&esrc=s&sa=U&ei=WneYU4GwCqmr0QWWnYDADA&ved=0CDsQ9QEwEw&usg=AFQjCNHjgINrDQGleg2SgazHZEwS08_h2w

http://www.google.co.in/url?url=http://mmdl.org/view/rosterchange&rct=j&frm=1&q=&esrc=s&sa=U&ei=nXeYU5fSDcaMuASF2YGgCw&ved=0CDsQ9QEwEw&usg=AFQjCNHshDzdJgBRzhZBJuTG07ZnTwCKEA

http://www.google.co.in/url?url=http://www.clker.com/clipart-10842.html&rct=j&frm=1&q=&esrc=s&sa=U&ei=k3iYU5aIOZeHuATkkoGwCg&ved=0CB8Q9QEwBQ&usg=AFQjCNH-nwGvXHKBYSCX_qcCmHDX6jjXHA


6

Elements of Manufacturing

PRODUCTIVITY

http://www.google.co.in/url?sa=i&rct=j&q=SAFETY&source=images&cd=&cad=rja&docid=b2c6g_JLyShvhM&tbnid=kAiFfnjkLVBBwM:&ved=0CAUQjRw&url=http://www.njaudubon.org/SectionCenters/SectionPlainsboro/SummerCamp/SafetyConsiderations.aspx&ei=DkfyUciGD43JrQeE7oFo&bvm=bv.49784469,d.bmk&psig=AFQjCNHADjVU_zKbuE5abZD90Ae2MaZSfA&ust=1374918656823188

http://www.google.co.in/url?sa=i&rct=j&q=QUALITY&source=images&cd=&cad=rja&docid=EZKRqNXWJ1RzuM&tbnid=XSV15tdbbgSQnM:&ved=0CAUQjRw&url=http://www.cpredi.com/quality/&ei=TUfyUef4H4SLrQfx3YHACg&bvm=bv.49784469,d.bmk&psig=AFQjCNGVaogGAwDftx402sHA-0mUKQt2PQ&ust=1374918853960182


Automations – Focus Areas

Enhancing Safety & Ergonomics

Empowering Operator

Imbibing Technology

Improving Operations

http://www.google.co.in/url?sa=i&rct=j&q=safety&source=images&cd=&cad=rja&docid=hVo4KM4Dn2rtGM&tbnid=DcUlGhvQQuxw4M:&ved=0CAUQjRw&url=http://www.subseauk.com/3425/safety-flashes-from-imca&ei=HwLxUcOoLofLrQfehYDwDw&bvm=bv.49784469,d.bmk&psig=AFQjCNH4AFYj7dFnsqrZSTWsZcL-gnzTCQ&ust=1374835605843983

http://www.google.co.in/url?sa=i&rct=j&q=ergonomics&source=images&cd=&cad=rja&docid=8CkdS-RPkOWYyM&tbnid=qpPciOe8MQehoM:&ved=0CAUQjRw&url=http://blog.safetyglassesusa.com/safety-articles/understanding-ergonomics-part-ii&ei=bQLxUfq7CIiQrgeE2oHoBQ&bvm=bv.49784469,d.bmk&psig=AFQjCNHrCHPX_hRWKBlt6xzNQMLKcWcqYA&ust=1374835652316562

http://www.google.co.in/url?sa=i&rct=j&q=robot&source=images&cd=&cad=rja&docid=ijSuNP9seZ2j8M&tbnid=9ZIPZlO_H8y3hM:&ved=0CAUQjRw&url=http://www.robotshop.com/clawbot-mobile-robot-w-gripper-kit-2.html&ei=EQPxUbyPEcinrge324GYCg&bvm=bv.49784469,d.bmk&psig=AFQjCNFQlNth6uVr4nXy4093KeDulC2CKg&ust=1374835842432509


Improving Operations – HandlingM

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Handling Defects reduced by more than 70% after installation


Improving Operations – Process Consistency

Improving Process Consistency of Stone Guard Coating Operation to Ensure uniform thickness across the surface.


Enhancing Ergonomics – Lifting Components

Seat Transfer System – To Aid Operator in Transferring Seat from Trolley to

Vehicle

Auto Spare Tyre Loading – To reduce Operator Effort for Transferring Tyre


Enhancing Ergonomics – Reduction in Walking

Synchro trolley

Synchronized Trolley with Assembly Conveyor - The manual walking distance eliminated by 10 steps per cycle (~7 meter)

Elimination of at least 3.7 km walking per shift


Imbibing Technology – Mistake Proofing

Pica Pica (Blink – Blink) for right component picking – Ensuring Specification Control across 150+ variants

Auto-Torque regulator to prevent over tightening


Imbibing Technology – Mistake Proofing

Transmitter Receiver with intelligent counters

Fool-proofing of 100% critical to quality bolts done


Empowering Operators - ANDON System

14

Call from stationCall prompted & display on ANDON

board

Call registered in the shop ANDON analysis call / pauseAnalysis of ANDON has improved line running to 97% of time per day

Any stoppage on line effects disturbs the natural rhythm of operator


Automations - Highlights

100% Spot Automation in Weld Shops

100% auto transfer of heavy components

Vehicle Direct Pass Improved to 93% in FY 13-14

Process Rejection Reduced to Below 5% in FY 13-

14

Handling Defects reduced by 50% in 2 years

Total Cumulative Cost Savings of 115 MRs in FY

13-14

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=EE8z6UNAOrRbUM&tbnid=4pXRFMNrTzO-2M:&ved=0CAUQjRw&url=http://www.corporatecomplianceinsights.com/whos-afraid-of-facebook-pharma-can-afford-to-speak-up-via-social-media/facebook-thumbs-up/&ei=QL9AUve0MqW5igKwroGYAQ&bvm=bv.52434380,d.cGE&psig=AFQjCNHihXC81PU-sUzFsCjNo6Qv7MHfSw&ust=1380061369172858







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Quality Excellence is a journey, not a destination . . .

automation for quality growth of organization. maruti suzuki india limited about maruti suzuki… ...

Documents

tyre slide

tightening slide

row slide

shift slide

installation slide

time ok slide

quality product

process rejection