SP Nayak Maruti Suzuki 6thnov09 AIA

Value Maximization through
Flexible Manufacturing lines
Mr. S P Nayak (AGM)

Production Engineering Division
Maruti Suzuki India Limited
1
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 ?
3
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
4
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
5
Flexibility ?
Flexibility
Ability to respond changes in a timely and cost-

effective manner
Anticipate & Change

6
Levels of flexibility
7
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
8
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
Process Driven Product Design
JIG, ENGINE PALLET, INST PANEL
DEVICE, DOOR DOCK DEVICE, INST PANEL CARRIER, CONVEYOR10

Error Proofing
Component Torque
Selection
RECEIVER TRANSMITTER & TORQUE

WRENCH
11
12
13
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

15
Capability Development
Technical skills
People skills
16
Inhouse Automation
Automated Guided Vehicle
Investment :Rs 4 25 000
Capital Cost Saving :Rs 15 75 000
Shuttle Conveyor for PVC Application in PS1

Capital Cost Saving :Rs 90000 000
Hot Casting Handling System for KB Casting

Capital Cost Saving :Rs 10 00 000 17
DIGITAL MANUFACTURING
JIGS & FIXTURES ERGONOMICS MATERIAL PLANNING
DIE DESIGN
TOOL ACCESS LINE BALANCING
ROBOT SIMULATION FEASIBILTY STUDY

3D FACTORY
18
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..
19
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

20
VERIFYING WELDING PROCESS
21
ASSEMBLY FEASIBILITY STUDY
22
TOOL ACCESS
23
ERGONOMIC SIMULATION CHECK
Vision
Window
Stress
Analysis
CHECKING EASE OF OPERATION DURING FACILITY DESIGN 24

PROCESS BALANCING
25
OPERATOR TRAINING
26
BUILDING VIRTUAL FACTORY
VISUALIZE 3D PLANT LAYOUT TO REDUCE INVESTMENT 27

BUILDING VIRTUAL FACTORY
28
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
30
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.

Approx. 50% reduction in Model Build issues. 31
Flexibility =
Anticipate + Be ready to Change

+ Change effectively
32

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Value Maximization through

Flexible Manufacturing lines

Mr. S P Nayak (AGM)

DESIGN DESIGN TRIAL

Reduce Cost of New

Ability to respond changes in a timely and cost-

Anticipate & Change

JIG, ENGINE PALLET, INST PANEL

DEVICE, DOOR DOCK DEVICE, INST PANEL CARRIER, CONVEYOR10

RECEIVER TRANSMITTER & TORQUE

Model A Model B Model C 14

Shuttle Conveyor for PVC Application in PS1

Hot Casting Handling System for KB Casting

JIGS & FIXTURES ERGONOMICS MATERIAL PLANNING

TOOL ACCESS LINE BALANCING

ROBOT SIMULATION FEASIBILTY STUDY

Can we afford to design a product & scrap it

Can we build 2 manufacturing units to see which is

Design Prototype Validation Pilot SOP

CHECKING EASE OF OPERATION DURING FACILITY DESIGN 24

VISUALIZE 3D PLANT LAYOUT TO REDUCE INVESTMENT 27

6th Nov 2009, Mumbai MATERIAL FLOW ANALYSIS 29

2004 2005 2006 2007 2008

FA DMU Solution NX CAD / CAM FA and

Lead Time Reduction

More than 200 Validations in Last New Model.

Anticipate + Be ready to Change

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