maruti car manufacture
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MARUTI SUZUKI INDIA LIMITEDCount on us …
Optimization of Metal Working ProcessesThe Seven Mantras for Yield improvement
(Truly Tried and Tested)
Economic Indicators…
In favor of customers when the economy is against …
Rate of Inflation Vs. Sale Price
22.5
33.5
44.5
55.5
2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07
Rate of Inflation(%) Alto Sales price
• Every 1 % improvement in yield gives the company a cost advantage of Rs. 632 Lacs per annum. (combined yield of all Maruti Models)
• In House manufacturing cost was reduced by 8.3% in 2006- 07 as compared to 2005-06.
• This year, 2007- 08 we are targeting another 7% reduction in In house manufacturing cost.
Safe
ty
Qua
lity
Prod
uctiv
ity
Cos
t
5 S (The foundation)Seiri (Orderliness) , Seiton (Cleanliness) ,Seiso (cleaning) ,Seiketsu
(Standardization):Shitsuke (Self- Discipline)
PRODUCTION
Safe
ty
Qua
lity
Prod
uctiv
ity
Cos
t
5 S (The foundation)Seiri (Orderliness) , Seiton (Cleanliness) ,Seiso (cleaning) ,Seiketsu
(Standardization):Shitsuke (Self- Discipline)
Safe
tySa
fety
Qua
lity
Qua
lity
Prod
uctiv
ityPr
oduc
tivity
Cos
tC
ost
5 S (The foundation)Seiri (Orderliness) , Seiton (Cleanliness) ,Seiso (cleaning) ,Seiketsu
(Standardization):Shitsuke (Self- Discipline)
PRODUCTION
Yield ImprovementYield ImprovementCut The cost driver
Manufacturing Excellence : The Next Leap
FINAL APPEARANCE TESTER
"Final roll out of the vehicle after final inspections"
VEHICLE INSPECTION PROCESS
ASSEMBLY PROCESS
HANDOVER TO SALES AND DESPATCH
"Handing over to Sales & Despatch for delivery to Dealers"
SALES & DESPATCH
FIRST APPEARANCE"Initial inspection of the
vehicle to check appearance & adjustment related
problems"
DRUM TESTER"Inspection of brake performance & other
functions of the vehicle"
EMISSION CHECK"Checking of emission
conformity as per government regulations"
SHOWER TESTER"Endurance testing of the vehicle to pass the water
shower at 1.5kg/cm 2
pressure"
VEHICLE MANUFACTURING PROCESS
FINAL LINE"Fitment of seats, AC gas filling & final adjustments"
ENGINE ASSEMBLY"Assembling of 5 basic
components and various other parts of engine"
FIRING TEST"Adjustment of engine rpm and checking of
other parameters"
WHITE BODY"Completely Welded White
Body"
PRESSING AND BLANKING PROCESS WELDING PROCESS
CATHODE ELECTRO DEPOSITION
"1st coat of paint on White Body "
INTERMEDIATE / TOP COAT
"2nd & 3rd coat of paint after Ist coat"
STEEL COILS"Procured from Steel
Makers"
BLANKING " Making of blanks from Steel Coils by blanking process"
STAMPING"Making of panels from
blanks by stamping"
PAINTING PROCESS
WELDING"Making of body parts
chassis, doors,hood from panels by spot welding"
TRIM LINE"Fitment of lighter
components viz. wiring harnesses, head lamp, AC,
etc"
CHASSIS LINE"Fitment of heavier
components viz. ENGINE, axle, brakes, fuel tank,
tyres, etc"
TOTAL PROCESS TIME FROM BLANKING TO ROLLING OUT OF A VEHICLE : 12.5 hoursVEHICLE ROLLING OUT EVERY 23 SECONDS
ENGINE ASSEMBLY PROCESS
TOUCH UP LINE / FINAL INSPECTION"Final inspection of the
Painted Body"
5 BASIC ENGINE COMPONENTS
"Cylinder Block, Head, Crank shaft, Camshaft, Trans case"
OPERATION INSPECTION
"Inspection of critical dimension of components"
MACHINING PROCESS"Different machining
processes to manufacture machined components"
MACHINING PROCESS
Process Flow : Maruti Suzuki India Limited
Press Weld
PaintAssembly
Steel coil
Vehicle Inspection
MachineEngine
D DEFINE
M MEASURE
A ANALYSE
I IMPROVE
C CONTROL
MeasureMeasure
AnalyzeAnalyze
ControlControl
DefineDefine
ImproveImprove
Project Title : Yield Improvement of Press body panelsProject Title : Yield Improvement of Press body panels
Process Flow in Press ShopProcess Flow in Press Shop
CR Steel Coil
POSCOMetal oneSumitomo
TATABSS
LBlanking Operation
Stamping operation
Blanks
Blanks
Panels
Blanking operation
• 2 Blanking press
• 10 lac blanks per month
Stamping operation
• 5 Transfer presses
• 1 Tandem press
• 170 variants of panels
• 10 lac panels per month
Define Phase
Customers•Joint Ventures• Maruti Manesar
Customers
•Joint Ventures• Maruti Manesar• Maruti Gurgaon• GM India
PILLER 1
EXIT
SH
EAR
PILLER 2
PILLER 1 PILLER 2 1 2
3 4
5
OUT PUT BLANKS
CRANE SAVER
CRANE SAVER
1 2
KOMATSHU
3 4 5
CA
M B
OX
PAN
EL T
AB
LE
SLA
T C
ON
VEYO
R
STACK
WASHING UNIT
CENTERING UNIT
STAMPING UNIT 1 -- DRAWING 2 -- TRIMMING & PIERCING
UP STREAM DOWN STREAM
3 -- TRIMMING & PIERCING4 -- BENDING & RESTRIKING5 -- BENDING & RESTRIKING
1A
34
5
OUT PUT PANELS
Process Flow : Press Shop
Define PhaseCase Study
Problem Statement :Yield Percentage of Front Door Inner, Wagon R is Low i.e. 48.9 %
Goal Statement :Target Yield percentage of Front Door Inner, Wagon R : 60.0 %
Front Door Inner, Wagon R - Yield Percentage
48.9%
60%
40
45
50
55
60
Current Value Target
Yield : What is it ? ? ?Yield : What is it ? ? ?
Yield = Output / Input
Output : Body Panel
Input : Blank
Child Part
Scrap
Input : Blank Output : Body Panel
Yield = (Output panel wt. + child part wt.) / Input blank wt
Define Phase
Yield =
Body Panel wt. / Blank wt.
Yield PercentageYield PercentageMeasure Phase
Yield = (Output panel wt. + child part wt.) / Input blank wt.Panel name: Front Door Inner, Wagon R
Input : Blank wt.
9127.47gm
Scrap
1580.0 gmOutput : Body Panel wt.
4465.05gm
Yield of FDI, Wagon R = (Output panel wt. +Child part wt.) / Input blank wt.
= (4465.05 + 0) / 9127.47
= 48.9 % (Low Yield)
Problem statement : Low utilization of steel in making of press panels leading to higher rate of scrap generation
5 WHY ? ? ? ? ? ANALYSISAnalysis Phase
WHY 1 ?
WHY 2 ?
WHY 4 ?
WHY 3 ? WHY 5 ?
Yield percentage is very
low in Wagon R : 58.03%
& FDI, Wagon R : 48.9%
High Input wt. of Blank,
Low Output wt. of panel
& no scrap utilization
1. Unnecessary draw depth & extra material after drawing outside trim line2. Window scrap is not utilized
1. Older Draw Die design2. Door with sash design leading to lower yield
1. Draw Die designed in
the year 1999
2. Door scrap not utilized
SEVEN Mantras of Yield Improvement
In-House developed Techniques
Mantra 1 : Die Face Modification
Mantra 2 : Modifying the Bead Design
Mantra 3 : Reducing the Blank Size by Gauge Adjustment
Mantra 4 : Changing the Blank Shape
Mantra 5 : Modification of the Punch Profile
Mantra 6 : Open Draw Technique
Mantra 7 : Residual flat parts (scrap) utilization
Discriminant Analysis Front Door Inner Wagon R Analysis Phase
Voice Of Customer
Voice of Business
Technical Viability
Ease of Implementation
Most feasible solution
Die face modification 9 8 72
Bead modification 8 7 56
Gauge adjustment 5 8 40
Blank shape change 4 6 24
Punch profile modification 4 5 20
Open draw 2 4 8
Child component from vendor 9 7 63
Child component made inhouse 2 2 4
Low Scrap disposal
Lower Price of car
No Environmental
Impact
Better yield of Press Body
panels
Probable solutions
Reduce Input Weight of Blanks
Utilisation of the Scrap
Reduction of Input Weight Reduction of Input Weight Analysis Phase
Mantra 1:Draw Die face modificationMantra 1:Draw Die face modificationWhat is a Drawing Operation ???What is a Drawing Operation ???
Upper die
Blank holder
Die cushion PinLower
die/punch
Cushion Pad
Cushion bed
Earlier Die face
Modified Die face
Trim line
Schematic diagram of a draw die
30mm
Wrinkle
Crac
k
2.01.81.61.41.21.0
2.0
1.8
1.6
1.4
1.2
1.0
plate
20 - 3030 - 40
>
height
40
< 1010 - 20
Contour Plot of plate height vs Crack, Wrinkle
Most preferred area Preferable range :
20~30mm
Uni-graphics Study
Before : High draw depth
After : Low draw depth
Trim line
Mantra 1: Draw die face modificationReduction of Input Weight
Analysis Phase
Reduction of Input Weight Reduction of Input Weight
Plate welded in the Lower die Blank holder to modify the die face
Lower die : Unnecessary draw
depth simulated
Improve Phase
UG models
Mantra 1: Draw die face modification
Reduction of Input Weight Reduction of Input Weight Improve PhaseMantra 1: Draw die face modification
Upper die machined to accommodate the lower
die profile
UG model
After Modification
panel
Before Modification
panel
Improve Phase
Concept :
Low draw depth (Door Outer) – Small and square (6 X 6) draw bead
Higher draw depth (Side body) – Small and circular draw bead
Mantra 2:Bead design modificationReduction of Input Weight Reduction of Input Weight
15 x 12 6 x 6
CAE application for simulation
6
6
BEFORE
12
15Design :
AFTER
Modification :
Reduction of input weight Reduction of input weight -- ResultResult
Input : Blank
Before
1195 mm
1390
mm Blank size reduced
Input :Blank
1145 mm
1350
mm
After
Process : Die modification
Yield = Output wt. / Input wt.
Improve Phase
Blank weight reduction
4465.05 4465.05
8493.99127.47
10002000
300040005000
600070008000
900010000
Before After
Panel Wt. Blank Wt.
Reduction
ConstantYield %ageBefore 48.91%
After 52.5%
INCREASE OUTPUT WEIGHT INCREASE OUTPUT WEIGHT
First Phase :
Child Part
310gmFlat Scrap
1580 gm
Improve Phase
Mantra 3:Residual Parts utilization
Output Body Panel
4465.05gm
Child parts made
• Box fuel inlet, Wagon R : 0.31 Kg - Veegee
Second Phase :
Child Part
700 gmScrap
1580 gm
INCREASE OUTPUT WEIGHT Improve Phase
Mantra 3:Residual Parts utilization
Output Body Panel
4465.05gm
Child parts made
• Extension Apron Upper : 0.70 kg - Veegee
Control PhaseAchievements Achievements
Material saving : 633.57gm
Cost saving : Rs 24.32 lacs
Scrap utilization cost saving : Rs 3.1 lacs
Total cost saving in FDI, Wagon R : Rs 27.42 lacs
Front Door Inner Wagon R - Yield Percentage
60.8% 60%56.2%48.9%
010203040506070
06-07 Phase-I Ach. Phase -II Ach. Target
Horizontal implementationHorizontal implementationControl Phase
RAW MATERIAL COST (Rs./Kg.) IND 33.1 forIMP 34.61 06-07
S.no. NAME OF THE COMPONENT MODEL Thickness
Initial width
Initial Feed
Input Wt. FEED/ WIDTH
DIRECTION
Planned Reduction(
F/W)
width less
feed less
thickness
Final width
Final feed Plan Implementation month
Actual IMPLE. MONTH
production plan 06-07
1 for domestic coil, 0 for imported
Achieved Savings gm / veh.
Achieved Rs/veh.
Ach. Annual saving (Rs/yr)
Technique applied
1 COWL TOP 3BOX 0.70 1450 425 3386.29 WIDTH 20 20 0.70 1430 425 Aug'06 AUG 06 16150 1 46.71 1.55 24968 Raw matl reduction2 REAR FLOOR 3BOX 0.70 1490 1680 13755.08 WIDTH 10 0.70 1480 1680 Aug'06 Sep 06 16150 1 92.32 3.06 49349 Raw matl reduction3 HOOD OUTER 3BOX 0.70 1415 1145 8902.86 WIDTH 20 20 0.70 1395 1145 DEC '06 JAN 07 16150 1 125.84 4.17 67267 Raw matl reduction
265 8.77 141,5841 ROOF CAR 0.8 980 1560 9600.9 FEED 5 5 0.8 980 1555 Aug'06 Sep 06 61500 30.77 1.07 65499 Bead modification
31 1.07 65,4991 SBO RH YG4 0.65 1460 2560 19071.10 WIDTH 10 10 0.65 1450 2560 Jan'07 255850 1 0.00 0.00 0 Bead modification 2 SBO LH YG4 0.65 1460 2560 19071.10 WIDTH 10 10 0.65 1450 2560 Feb'07 255850 1 0.00 0.00 0 Bead modification 3 RDO,RH YG4 0.75 1100 790 5116.24 FEED 5 5 0.75 1100 785 JUL 06 JUL 06 255850 0 32.38 1.12 286735 Blank size reduction 4 RDO,LH YG4 0.75 1100 790 5116.24 FEED 5 5 0.75 1100 785 Aug 06 AUG 06 255850 0 32.38 1.12 286735 Bead modification7 RDO,RH YG4 0.75 1100 785 5083.86 FEED 5 5 0.75 1100 780 JUL 06 Oct 06 255850 0 32.38 1.12 286735 Bead modification8 RDO,LH YG4 0.75 1100 785 5083.86 FEED 5 5 0.75 1100 780 Aug 06 Oct 06 255850 0 32.38 1.12 286735 Bead modification9 HO YG4 0.70 1360 845 6314.85 FEED 10 10 0.70 1360 835 Oct'06 255850 1 0.00 0.00 0 PP,DF CHANGE
403 13.54 3,464,8891,652 56.06 4,204,659
1 SBO,LH YM1 0.7 1655 2640 24008.8 WIDTH 10 10 0.7 1645 2640 Oct'06 120750 0.00 0.00 0 Bead modification2 Main Floor YM1 0.70 1270 1340 9351.39 FEED 20 20 0.70 1270 1320 Jan'07 120750 1 0.00 0.00 0 Bead modification 3 RDI RH YM1 0.70 1400 1060 8154.58 WIDTH 20 20 0.70 1380 1060 Jun 06 Jun 06 120750 1 116.49 3.86 465606 Bead modification 4 RDI LH YM1 0.70 1400 1060 8154.58 WIDTH 20 20 0.70 1380 1060 Jun 06 Jun 06 120750 1 116.49 3.86 465606 Bead modification 5 FDI RH YM1 0.70 1370 1145 8619.73 WIDTH 20 20 0.70 1350 1145 May 06 May 06 120750 1 125.84 4.17 502942 Bead modification 6 FDI LH YM1 0.70 1370 1145 8619.73 WIDTH 20 20 0.70 1350 1145 May 06 May 06 120750 1 125.84 4.17 502942 Bead modification 7 SBO,RH YM1 0.7 1655 2640 24008.8 WIDTH 10 10 0.7 1645 2640 Nov'06 120750 0.00 0.00 0 Bead modification8 HOOD INNER YM1 0.6 1270 615 3678.7 WIDTH 15 0 15 0.6 1270 600 Nov'06 Oct 06 120750 89.73 3.11 374977 Raw matl reduction9 BDI YM1 0.7 1270 1440 10049.3 FEED 20 0 20 0.7 1270 1420 Nov'06 Nov 06 120750 1 139.57 4.62 557849 Raw matl reduction
10 H I (Old) YM1 0.6 1275 680 4083.6 WIDTH 5 5 0 0.6 1270 680 Dec'06 Dec 06 18000 1 16.01 0.53 9541 Raw matl reduction11 FENDER RH (MINOR) YM1 0.7 960 905 4774.1 FEED 10 10 0.7 960 895 Dec'06 JAN 07 120750 1 52.75 1.75 210841 Raw matl reduction12 FENDER LH (MINOR) YM1 0.7 960 905 4774.1 FEED 10 10 0.7 960 895 Dec'06 Feb 07 120750 1 52.75 1.75 210841 Raw matl reduction
835 27.79 3,301,1451 BDO YG8 0.7 1510 1600 13275.9 FEED 10 10 0.7 1510 1590 Mar 07 14250 1 0.00 0.00 02 SBO-RH YG8 0.70 1575 3080 26656.25 WIDTH 15 15 0.70 1560 3080 Feb'07 Sep 06 14250 1 253.87 8.40 119744 Raw matl reduction3 SBO-LH YG8 0.70 1575 3080 26656.25 WIDTH 15 15 0.70 1560 3080 Nov'06 Sep 06 14250 1 253.87 8.40 119744 Raw matl reduction4 REAR FLOOR REAR YG8 0.75 1470 1830 15837.96 WIDTH 5 5 0.75 1465 1830 Jan'07 Dec 06 14250 1 53.87 1.78 25409 Raw matl reduction5 FRONT DOOR OUTER RH YG8 0.70 1420 1085 8466.15 FEED 5 5 0.70 1420 1080 MAR 07 Mar 07 14250 1 39.01 1.29 18402 Raw matl reduction6 FRONT DOOR OUTER LH YG8 0.70 1420 1085 8466.15 FEED 5 5 0.70 1420 1080 MAR 07 Mar 07 14250 1 39.01 1.29 18402 Raw matl reduction
YIELD ACTIVITY PLAN - YEAR 2006-07
Before modification After modification
(achievement)
Residual Parts Utilization boardResidual Parts Utilization boardControl Phase
Control MechanismControl Phase
Carry out Draw panel trial of 4 - 5 blanks
Carry out trial run of 100 – 200 panel production
Change the MOS (Maruti Operation Standard)
Modify the fingers
Monitor the production for next 5 lots
Modify the skids if required
Monitoring of the total activity
~ 5 mm
~5 mm
SEVEN Mantras of Yield ImprovementSEVEN Mantras of Yield Improvement
In-House developed Techniques
Mantra 1 : Die Face ModificationDie Face Modification
Mantra 2 : Modifying the Bead DesignModifying the Bead Design
Mantra 3 : Residual flat parts (scrap) utilizationResidual flat parts (scrap) utilization
Mantra 4 : Reducing the Blank Size by Gauge AdjustmentReducing the Blank Size by Gauge Adjustment
Mantra 5 : Changing the Blank ShapeChanging the Blank Shape
Mantra 6 : Modification of the Punch ProfileModification of the Punch Profile
Mantra 7 : Open Draw TechniqueOpen Draw Technique
Cost saving : By Sheet Metal Yield ImprovementCost saving : By Sheet Metal Yield Improvement
Total Die Modification done using 7 mantras : 178
Total Cost Saving by Yield Improvement :
Rs. 632 Lacs / annum
Overall Yield improved by 1%:
Saving of 3.84 Ton of steel/Day.YIELD IMPROVEMENT - COST SAVING
164185.48
43.64 46.57 51.60
102.69
125
102.8892.13
169.45
114.53108.70
26.2 34.54913.70
0
20
40
60
80
100
120
140
160
180
200
04-05 05-06 06-07 Apr-07 May-07 Jun-07 Jul-07 Aug-07 Sep-07 Oct-07 Nov-07 Dec-07 Jan-08 Feb-08 Mar-08 Target07-08
LAC
S
Monthly Cum.(07-08) Monthly Cum.(06-07) Cont…
This is just the beginning…This is just the beginning…The best is yet to come…The best is yet to come…
Reduction of input weight Reduction of input weight Implement Phase
Mantra 4 : Gauge adjustmentPurpose of gauge : To locate the blank in the desired position in the blank holder
Activities :
• Blank size change
• Lower die gauge adjustment
• Upper die machining
R4000 R3000
Reduction of input weight Reduction of input weight Implement Phase
a) Changing the radius from R3000 to R4000
Mantra 5 : Blank shape modification
b) Blank angle (both angle) change to reduce feed
c) Blank angle (one angle) change to reduce feed
Reduction of input weight Reduction of input weight Implement Phase
Blank holder extended into the punch
The Blank holder can be extended into the punch when the trim line is very far.
Punch profile is modified without hampering the shape of the panel which results into reduction of the Blank size.
Mantra 6 : Punch profile modification
Blank Holder
Punch Profile
Trim Line
12
5 Punch Profile
Blank
Panel Size
Blank
Reduction of input weight Reduction of input weight Implement PhaseMantra 7 : Open draw technique
Flow control through bead
When the cross section is small, The blank can take the shape of punch, without flowing/passing through Blank holder & Upper die. This helps in reducing the blank size.
Panel taking the shape of the punch without touching the bead
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