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INTRODUCTION
In 1982 with the help of govt. of India,Maruti entered into a joint venture withSuzuki motors of Japan.
Plant was established at gurgaon inharyana.
The entire supply chain needs to be
monitored to get the best quality, so thatthey establish Maruti Center ForExcellence(MACE)
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As much as 80% of an average maruti
suzuki vehicle is made of vendor supplied
part.
Maruti Suzuki has 300 odd vendors.
Maruti Suzuki established MACE in 2004with the company and 21 vendors pooling
funds for seed money.
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Maruti classifies its vendors as Tier-1 and Tier-2while around 300 Tier-1 vendors supplycomponents a directly to the company, a handfulof Tier-2 vendors supply assembly parts of various
components to the Tier-1 vendors.
Certain child parts are got from Tier-3 vendors.
Maruti has a 500 employees strong department tomanage relationship with its suppliers includinglooking at function such as supply chainmanagement, engineering, quality control, humanresource etc.
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Quality check process
Although the quality check at the
Maruti plant, it is impossible for
manufacturers to check all the
components going to assembly line.
So, the importance given to
monitoring facilities of the vendorsincreases.
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Steps for quality
improvement. There is two steps process at the
maruti plant to improve the quality.
1 Marutisown shop floor.
2 vendors end.
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Marutisown shop floor.
Marutisproduction system in the country drawsthe best practices of parent company SUZUKI
motors.
Lean manufacturing:it stands for man, machines, materials, and
methods. 4Ms.
For the improvement of yield.
1 altering stamping technique.
2 maximise steel sheet utilisation
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In last five years MACE has channelized all
its efforts in upgrading Tier-I and Tier-II
vendors, it was noticed that both were not
getting similar initiatives.
MACE counselors provide suggestions onmanufacturing process upgradation.
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MACE arranges knowledge session for
both Tier-I & Tier-II, and this cluster
approach was very effective.
When the solution is implemented, MACE
counselors visit the vendorsfactory again.
With the relationship between Maruti and
its vendors has reduced the rejection rate.
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Motherson Sumi system started its
association with Maruti company for
supplying wiring harness and now it is
supplying grills, door handles, mirrors,lighting system and cutting tool used in
machine shop.
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If maruti were to bring a new hatchback in thecar market within the next few months.
Tier-I vendors and tier- II vender run their
factories for high-volume production trials,that problems arising on each assembly linecan be identified.
Becauseeverybody in the chain work closely,all of us are well-prepared to meet deadlines.Now we set targets for next three to fiveyears.
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Support of manufacturers and tire 1 suppliersare indispensable to the existence of tier 2suppliers.
Started with MACE it annul rejection rate was
4 % . This translated in parts per millions of0.0004 and the company kick-started its 0PPM drive by implementing Marutis QualitiyCircle (QC) in its factory.
The focus then shifts to using low-cost
automation. The company runs two drill machines on one
motors.
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This initiative resulted in a 50 per cut in the
factoryselectricity consumption.
Today close to 22 Tire=II suppliers maintain0 PPM) rejection.
Improving your bottom line while enhancinglong term customer satisfaction and the
lifetime value your customer.
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