Quality Focus at Maruti Suzuki India Limited
Automation for
Quality Growth of Organization
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 ? ? ?
Managing
Changes
Factors Affecting Quality Output
Ergonomic Issues
Handling and Transportation Concerns
Frequent Changes
6
Elements of Manufacturing
Automations – Focus Areas
Enhancing Safety & Ergonomics
Empowering Operator
Imbibing Technology
Improving Operations – Handling
Improving Operations – Process Consistency
Enhancing Ergonomics – Lifting Components
Enhancing Ergonomics – Reduction in Walking
Synchro trolley
Imbibing Technology – Mistake Proofing
Imbibing Technology – Mistake Proofing
Empowering Operators - ANDON System
14
Call from station
Call prompted & display on ANDON
board
Call registered in the shop
ANDON analysis call / pause
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
Ownership
Perform
People
Learn
Connect
Commit
Share
Quality Excellence is a journey, not a destination . . .
|
Dream
Imagine
|
Achieve
Maruti Suzuki India Limited, established in 1982, is a leading automobile manufacturer known for its commitment to quality and customer satisfaction. With a strong equity structure and impressive market share, the company emphasizes creating products right the first time with no surprises during production. They prioritize managing changes, environment, people, and systems to ensure quality output, despite challenges like process inconsistency and ergonomic issues. Through automation and a focus on improving operations, Maruti Suzuki continually enhances safety, productivity, and efficiency in its manufacturing processes.
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http://marutistoragenew.blob.core.windows.net/msilintiwebimages/images_main_logo.pnghttp://marutistoragenew.blob.core.windows.net/msilintiwebimages/images_main_logo.png Automation for Quality Growth of Organization
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: Customer Satisfaction: 20 Joint ventures for components No.1 in JD Power Customer Satisfaction for 13 years in a row Maruti Suzuki India Limited
What is Quality to Us? ? ? Creating Product First Time OK No Surprises during Production Maruti Suzuki India Limited
What Constitutes a Quality Product ? ? ? Managing Changes Environment People Systems Quality Product Maruti Suzuki India Limited
Factors Affecting Quality Output Process Inconsistency Ergonomic Issues https://encrypted-tbn2.gstatic.com/images?q=tbn:ANd9GcR5X4ZJJGVVywDIigk98OQeN9vjKaXqeHXwPCGjsJNolmxg-0ZJrYhcNVM Line Absenteeism https://encrypted-tbn0.gstatic.com/images?q=tbn:ANd9GcR6X-05UO19aet-4g4_7yNmK6EMpO1EvUV94a7yJdmm54z7gN_jF6FX10A Handling and Transportation Concerns https://encrypted-tbn2.gstatic.com/images?q=tbn:ANd9GcQ90vjwkgBnxCa5M_xbi80egMqwrge_XKonqV8y8ZpBC84N9FMmcZTkCg Frequent Changes Maruti Suzuki India Limited
Elements of Manufacturing http://t3.gstatic.com/images?q=tbn:ANd9GcT_uiqPIkawpjQUYystmyY8Oc1xZBRhw9ub1tSbClBZkmYebL6N http://t1.gstatic.com/images?q=tbn:ANd9GcQMVV0Ma_rsJGVxQwXG8H46-zPMuL7C70KmQZZCJ6DMgn5blPsD PRODUCTIVITY 6 Maruti Suzuki India Limited
Automations Focus Areas Improving Operations http://www.robotshop.com/content/images/clawbot-mobile-robot-w-gripper-kit-1-large.jpg Imbibing Technology http://www.subseauk.com/editorialimages/safety.jpg Enhancing Safety & Ergonomics http://t0.gstatic.com/images?q=tbn:ANd9GcQNunW_PQfED0WPu_FTH5dyoivS82VYllgW0x04DsdoCOC3VmcRKA Empowering Operator Maruti Suzuki India Limited
Improving Operations Handling Material Transfer Shuttles Auto Cylinder Block Loading System Multi-Level Car Parking Handling Defects reduced by more than 70% after installation Maruti Suzuki India Limited
Improving Operations Process Consistency Improving Process Consistency of Stone Guard Coating Operation to Ensure uniform thickness across the surface. Maruti Suzuki India Limited
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 Maruti Suzuki India Limited
Enhancing Ergonomics Reduction in Walking Synchronized Trolley with Assembly Conveyor - The manual walking distance eliminated by 10 steps per cycle (~7 meter) Synchro trolley Elimination of at least 3.7 km walking per shift Maruti Suzuki India Limited
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 Maruti Suzuki India Limited
Imbibing Technology Mistake Proofing Transmitter Receiver with intelligent counters Fool-proofing of 100% critical to quality bolts done Maruti Suzuki India Limited
Empowering Operators - ANDON System Any stoppage on line effects disturbs the natural rhythm of operator Call from station Call prompted & display on ANDON board Call registered in the shop ANDON analysis call / pause Analysis of ANDON has improved line running to 97% of time per day 14 Maruti Suzuki India Limited
Automations - Highlights http://www.corporatecomplianceinsights.com/wp-content/uploads/2013/06/Facebook-thumbs-up.jpg 100% Spot Automation in Weld Shops http://www.corporatecomplianceinsights.com/wp-content/uploads/2013/06/Facebook-thumbs-up.jpg 100% auto transfer of heavy components http://www.corporatecomplianceinsights.com/wp-content/uploads/2013/06/Facebook-thumbs-up.jpg Vehicle Direct Pass Improved to 93% in FY 13-14 http://www.corporatecomplianceinsights.com/wp-content/uploads/2013/06/Facebook-thumbs-up.jpg Process Rejection Reduced to Below 5% in FY 13-14 http://www.corporatecomplianceinsights.com/wp-content/uploads/2013/06/Facebook-thumbs-up.jpg Handling Defects reduced by 50% in 2 years http://www.corporatecomplianceinsights.com/wp-content/uploads/2013/06/Facebook-thumbs-up.jpg Total Cumulative Cost Savings of 115 MRs in FY 13-14 Maruti Suzuki India Limited
Perform Connect Share Ownership People Learn Commit Quality Excellence is a journey, not a destination . . . Maruti Suzuki India Limited
