automation for quality growth of organization

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

ulti-

Leve

l Car

Pa

rkin

gM

ater

ial T

rans

fer

Shut

tles

Auto

Cyl

inde

r B

lock

Loa

ding

Sys

tem

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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automation for quality growth of organization

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