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Value Maximization through

Flexible Manufacturing lines

Mr. S P Nayak (AGM)


Production Engineering Division
Maruti Suzuki India Limited
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6th Nov 2009, Mumbai
PRODUCT CYCLE

DESIGN DESIGN TRIAL


PRODUCT DEVELOPMENT
CYCLE

MASS PRODUCTION 2
6th START OF PRODUCTION
Nov 2009, Mumbai TRIAL
KEY FUNCTION AREAS
Produce at High quality
& Lower Cost
PRODUCTION
WHEN ?
WHERE ?

PRODUCTION
ENGINEERING
ENGINEERING
New product design & Process Engineering
Design changes & Facility Preparedness

WHAT ? HOW ?
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6th Nov 2009, Mumbai
KEY BUSINESS CHALLENGES
Production Engineering
challenges

Increase Speed of
introduction for New
Models/ Minor changes

Reduce Cost of New


Model Introduction,
Facilities & Raw Material

Process Improvement
(Quality, productivity &
Safety, Environment)

Enhance Capability of
Production Engineering,
Vendors & Suppliers
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6th Nov 2009, Mumbai
KEY CHALLENGES
How to reduce COST? TIME TO MARKET?
(KEY: Innovation, Waste Elimination..)
CONVENTIONAL NEW AREAS

PRODUCT Product
Components development Time
& Cost

PROCESS Process
Manpower,
Reduction &
Rejection Cost
Stabilization
RESOURCE Robots, Tools, New Plant
Jigs, Conveyors Cost & Time
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6th Nov 2009, Mumbai
Flexibility ?

Flexibility

Ability to respond changes in a timely and cost-


effective manner

Anticipate & Change


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Levels of flexibility

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Model Flexibility..
What is meant by Multi-model manufacturing on single line ?

If we are able to make more than one model on one manufacturing line

Plant G1

Plant G2

Plant G3

Plant M1

Flexi Line
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6th Nov 2009, Mumbai
FLEXIBILITY Common Platform
OLD- NORMAL CLAMP NEW- PIN WITH CLAMP
UNDER BODY -
12 NS
LOCATION PIN F
U
F

F
U
R
M
F

M
F FOR LOCATION 2 PIN & EXTERNAL CLAMP
CHANGED TO PIN CLAMP
F
R R
U
R F
U
R

NC LOCATOR -300 MM
SHIFT POSSIBLE IN 3
DIRECTION

USED FOR UNDER BODY LOCATION IN UNDER BODY & MAIN BODY LINES 9
6th Nov 2009, Mumbai
Process Driven Product Design

JIG, ENGINE PALLET, INST PANEL

DEVICE, DOOR DOCK DEVICE, INST PANEL CARRIER, CONVEYOR10


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Error Proofing
Component Torque
Selection

RECEIVER TRANSMITTER & TORQUE


WRENCH

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100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

0%
2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09

Model A Model B Model C 14


6th Nov 2009, Mumbai
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6th Nov 2009, Mumbai
Capability Development

Technical skills

People skills

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6th Nov 2009, Mumbai
Inhouse Automation
Automated Guided Vehicle
Investment :Rs 4 25 000
Capital Cost Saving :Rs 15 75 000

Shuttle Conveyor for PVC Application in PS1


Investment :Rs 80 00 000
Capital Cost Saving :Rs 90000 000

Hot Casting Handling System for KB Casting


Investment :Rs 5 00 000
Capital Cost Saving :Rs 10 00 000 17
6th Nov 2009, Mumbai
DIGITAL MANUFACTURING

JIGS & FIXTURES ERGONOMICS MATERIAL PLANNING

DIE DESIGN

TOOL ACCESS LINE BALANCING

ROBOT SIMULATION FEASIBILTY STUDY


3D FACTORY

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6th Nov 2009, Mumbai
WHY DIGITAL MANUFACTURING

Can we afford to design a product & scrap it


because it can not be manufactured ?

Can we build 2 manufacturing units to see which is


running best & then shutdown the inefficient one ?

No..
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6th Nov 2009, Mumbai
WHY DIGITAL ENGINEERING
Virtual Problem Identification
at earlier stage
(Concurrent Engineering) High reworking cost
Higher time to market

Problems
PROBLEM BOMB

Design Prototype Validation Pilot SOP


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6th Nov 2009, Mumbai
VERIFYING WELDING PROCESS

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ASSEMBLY FEASIBILITY STUDY

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TOOL ACCESS

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6th Nov 2009, Mumbai
ERGONOMIC SIMULATION CHECK

Vision
Window

Stress
Analysis

CHECKING EASE OF OPERATION DURING FACILITY DESIGN 24


6th Nov 2009, Mumbai
PROCESS BALANCING

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OPERATOR TRAINING

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BUILDING VIRTUAL FACTORY

VISUALIZE 3D PLANT LAYOUT TO REDUCE INVESTMENT 27


6th Nov 2009, Mumbai
BUILDING VIRTUAL FACTORY

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6th Nov 2009, Mumbai
LAYOUT EVALUATION

LAYOUT A

LAYOUT B

6th Nov 2009, Mumbai MATERIAL FLOW ANALYSIS 29


IMPLEMENTATION
Measurement of Success
Faster Product introduction
Reduced Vehicle Cost
Key Mile stones
NX CAD / CAM NX CAD / CAM
for Freshening Factory Modeling and
Validation

2004 2005 2006 2007 2008

FA DMU Solution NX CAD / CAM FA and


FA & BIW BIW solution
Process Planning &
Validation
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6th Nov 2009, Mumbai
BENEFITS
Reduction in Time to Market (Design to Launch)

Lead Time Reduction


Time in Months

BEFORE 3D NEW
SWIFT
CAD & DM MODEL

More than 200 Validations in Last New Model.



6th Nov 2009, Mumbai
Approx. 50% reduction in Model Build issues. 31
Flexibility =

Anticipate + Be ready to Change


+ Change effectively

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6th Nov 2009, Mumbai