MARUTI SUZUKI INDIA LIMITED

The Seven Mantras for Yield improvement (Truly Tried and Tested)

Count on us Optimization of Metal Working Processes

Economic Indicators
Rate of Inflation Vs. Sale Price
5.5 5 4.5 4 3.5 3 2.5 2 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07

Rate of Inflation(%)

Alto Sales price

In favor of customers when the economy is against

PRODUCTION

Productivity

Quality

Safety

Yield CutImprovement The cost driver

Every 1 % improvement in yield gives the company a 5 S (The foundation) cost advantage of Rs. 632 Lacs,Seiso per annum. Seiri (Orderliness) , Seiton (Cleanliness) (cleaning) ,Seiketsu (combined yield of
all Maruti Models)
(Standardization):Shitsuke (Self- Discipline)

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.

Cost

Manufacturing Excellence : The Next Leap

VEHICLE MANUFACTURING PROCESS

STEEL COILS
"Procured from Steel Makers"

BLANKING
" Making of blanks from Steel Coils by blanking process"

STAMPING
"Making of panels from blanks by stamping"

WELDING
"Making of body parts chassis, doors,hood from panels by spot welding"

WHITE BODY
"Completely Welded White Body"

PRESSING AND BLANKING PROCESS

WELDING PROCESS

CHASSIS LINE FINAL LINE

"Fitment of seats, AC gas filling & final adjustments" "Fitment of heavier components viz. ENGINE, axle, brakes, fuel tank, tyres, etc"

TRIM LINE
"Fitment of lighter components viz. wiring harnesses, head lamp, AC, etc"

TOUCH UP LINE / FINAL INSPECTION

"Final inspection of the Painted Body"

INTERMEDIATE / TOP COAT

"2nd & 3rd coat of paint after Ist coat"

CATHODE ELECTRO DEPOSITION

"1st coat of paint on White Body "

ASSEMBLY PROCESS

PAINTING PROCESS

FIRING TEST
"Adjustment of engine rpm and checking of other parameters"

ENGINE ASSEMBLY
"Assembling of 5 basic components and various other parts of engine"

OPERATION INSPECTION
"Inspection of critical dimension of components"

MACHINING PROCESS
"Different machining processes to manufacture machined components"

5 BASIC ENGINE COMPONENTS

"Cylinder Block, Head, Crank shaft, Camshaft, Trans case"

ENGINE ASSEMBLY PROCESS

MACHINING PROCESS

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"

FINAL APPEARANCE TESTER

"Final roll out of the vehicle after final inspections"

HANDOVER TO SALES AND DESPATCH

"Handing over to Sales & Despatch for delivery to Dealers"

VEHICLE INSPECTION PROCESS

SALES & DESPATCH

TOTAL PROCESS TIME FROM BLANKING TO ROLLING OUT OF A VEHICLE : 12.5 hours VEHICLE ROLLING OUT EVERY 23 SECONDS

Process Flow : Maruti Suzuki India Limited

Steel coil

Press

Weld

Vehicle Inspection

Assembly

Paint

Engine

Machine

Project Title : Yield Improvement of Press body panels

D M A I C

DEFINE MEASURE Analyze ANALYSE IMPROVE CONTROL

Measure Define

Improve

Control

Define Phase

Process ProcessFlow Flowin inPress PressShop Shop

POSCO

Me
Su m ito

tal

on e

mo

CR Steel Coil

Blanking Operation
Blanks

Customers
Blanks
Joint Ventures Maruti Manesar

TA TA BS SL

Stamping operation
Stamping operation Blanking operation 2 Blanking press 10 lac blanks per month 5 Transfer presses 1 Tandem press 170 variants of panels 10 lac panels per month

Panels

Customers
Joint Ventures Maruti Manesar Maruti Gurgaon GM India

Process Flow : Press Shop

OUT PUT BLANKS

PILLER 1

PILLER 2
EXIT SHEAR

PILLER 1

PILLER 2

STAMPING UNIT
CRANE SAVER

WASHING UNIT

CENTERING UNIT

1 -- DRAWING 2 -- TRIMMING & PIERCING

3 -- TRIMMING & PIERCING 4 -- BENDING & RESTRIKING 5 -- BENDING & RESTRIKING KOMATSHU
1

OUT PUT PANELS

CAM BOX

SLAT CONVEYOR

PANEL TABLE

STACK

UP STREAM

DOWN STREAM

CRANE SAVER

Case Study
Define Phase

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

60%
60 55 50 45 40 Current Value Target

48.9%

Yield : What is it ? ? ?
Define Phase

Yield = Output / Input Output : Body Panel Input : Blank

Yield = Body Panel wt. / Blank wt.

Scrap

Child Part

Input : Blank

Output : Body Panel

Yield = (Output panel wt. + child part wt.) / Input blank wt

Yield Percentage
Measure Phase

Yield = (Output panel wt. + child part wt.) / Input blank wt.
Panel name: Front Door Inner, Wagon R

Scrap 1580.0 gm Input : Blank wt. 9127.47gm Output : 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)

5 WHY ? ? ? ? ? ANALYSIS
Analysis Phase

Problem statement : Low utilization of steel in making of press panels leading to higher rate of scrap generation WHY 4
ery v s i tage 8.03% n e c r :5 pe Yield Wagon R 48.9% : n low i Wagon R I, 2? D k, F Y n & H a l W f B anel o . wt fp t o u . Inp ut wt ation h Hig Outp utiliz Low scrap o &n WHY 3 ? 1. Unnecessary dra w depth & extra mate rial after drawing outs ide trim line 2. Window scrap is not utilized
WH Y1?
1. Olde r Draw

2 . D oo rw leading ith sash des ign to lowe r yield

Die de sign

? WHY 5
d in e n g i s e Die d 1. Draw 1999 tilized the year u t o n p scra 2. Door

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

Probable solutions Die face modification

Technical Viability

Ease of Implementation

Most feasible solution

9 8 5 4 4 2 9 2

8 7 8 6 5 4 7 2

72 56 40 24 20 8 63 4

Low Scrap disposal

Bead modification Reduce Input Gauge adjustment Weight of Blanks Blank shape change Punch profile modification Open draw

Lower Price of car

Better yield of Press Body panels

No Environmental Impact

Utilisation of the Scrap

Child component from vendor Child component made inhouse

Reduction of Input Weight

Mantra 1:Draw Die face modification

What is a Drawing Operation ???

Analysis Phase

Upper die

Blank holder

Lower die/punch

Die cushion Pin

Cushion Pad

Cushion bed

Reduction of Input Weight

Mantra 1: Draw die face modification

Schematic diagram of a draw die
Trim line
Modified Die face

Analysis Phase

Trim line

Before : High draw depth

Earlier Die face

30mm

After : Low draw depth

Uni-graphics Study
Contour Plot of plate height vs Crack, Wrinkle
2.0
p late h eig h t < 10 10 - 20 20 - 30 30 - 40 > 40

1.8

1.6
Crack

1.4

1.2

1.0 1.0

Most preferre d area

1.2 1.4
Wrinkle

1.6

1.8

2.0

Preferable range : 20~30mm

Reduction of Input Weight

Mantra 1: Draw die face modification

Lower die : Unnecessary draw depth simulated

Improve Phase

UG

els d mo

Plate welded in the Lower die Blank holder to modify the die face

Reduction of Input Weight

Mantra 1: Draw die face modification

Upper die machined to accommodate the lower die profile

Improve Phase

UG model After Modification panel Before Modification panel

Reduction of Input Weight

Mantra 2:Bead design modification

Concept :

Improve Phase

Low draw depth (Door Outer) Small and square (6 X 6) draw bead Higher draw depth (Side body) Small and circular draw bead Design : 15 12 BEFORE Modification : AFTER 6 6

15 x 12

6x6 CAE application for simulation

Reduction of input weight - Result

Before After
Improve Phase

1390 mm

Blank size reduced

Input : Blank Process : Die modification 1195 mm

1350 mm
9127.47

Input :Blank

1145 mm
Blank weight reduction
10000

Yield = Output wt. / Input wt.

9000 8000 7000 6000

Reductio n

8493.9

Yield %age Before After 48.91% 52.5%

5000 4000 3000 2000 1000

4465.05

Constant

4465.05

Before
Panel Wt.
Blank Wt.

After

INCREASE OUTPUT WEIGHT

Improve Phase

Mantra 3:Residual Parts utilization

First Phase :

Flat Scrap 1580 gm Output Body Panel 4465.05gm Child parts made Box fuel inlet, Wagon R : 0.31 Kg - Veegee

Child Part 310gm

INCREASE OUTPUT WEIGHT

Improve Phase

Mantra 3:Residual Parts utilization

Second Phase :

Scrap 1580 gm Output Body Panel 4465.05gm Child parts made

Child Part 700 gm

Extension Apron Upper : 0.70 kg - Veegee

Achievements
Control Phase

Front Door Inner Wagon R - Yield Percentage

70 60 50 40 30 20 10 0 06-07 Phase-I Ach. Phase -II Ach. Target

56.2% 48.9%

60.8%

60%

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

Horizontal implementation
Control Phase

YIELD ACTIVITY PLAN - YEAR 2006-07 (achievement)

RAW MATERIAL COST (Rs./Kg.) S.no. NAME OF THE COMPONENT MODEL IND IMP Thicknes Initial s width 33.1 34.61 Initial Feed for 06-07 Input Wt. FEED/ Planned WIDTH Reduction( DIRECTION F/W) width less feed thicknes Final Final feed Plan Actual less s width Implementat IMPLE. ion month MONTH production plan 06-07 1 for domestic coil, 0 for imported Achieved Achieved Ach. Annual Savings Rs/veh. saving (Rs/yr) gm / veh. Technique applied

Before modification
1 2 3 1 1 2 3 4 7 8 9 COWL TOP REAR FLOOR HOOD OUTER ROOF SBO RH SBO LH RDO,RH RDO,LH RDO,RH RDO,LH HO 3BOX 3BOX 3BOX CAR YG4 YG4 YG4 YG4 YG4 YG4 YG4 0.70 0.70 0.70 0.8 0.65 0.65 0.75 0.75 0.75 0.75 0.70 1450 1490 1415 980 1460 1460 1100 1100 1100 1100 1360 425 1680 1145 1560 2560 2560 790 790 785 785 845 3386.29 13755.08 8902.86 9600.9 19071.10 19071.10 5116.24 5116.24 5083.86 5083.86 6314.85 WIDTH WIDTH WIDTH FEED WIDTH WIDTH FEED FEED FEED FEED FEED 20 20 5 10 10 5 5 5 5 10 10 10 5 5 5 5 10 20 10 20 5

After modification
0.70 0.70 0.70 0.8 0.65 0.65 0.75 0.75 0.75 0.75 0.70 1430 1480 1395 980 1450 1450 1100 1100 1100 1100 1360 425 1680 1145 1555 2560 2560 785 785 780 780 835

Aug'06 Aug'06 DEC '06

Aug'06 Jan'07 Feb'07 JUL 06 Aug 06 JUL 06 Aug 06 Oct'06

AUG 06 Sep 06 JAN 07 Sep 06

16150 16150 16150 61500 255850 255850 255850 255850 255850 255850 255850

1 1 1

46.71 92.32 125.84 265 30.77 31

1.55 3.06 4.17 8.77 1.07 1.07 0.00 0.00 1.12 1.12 1.12 1.12 0.00 13.54 56.06 0.00 0.00 3.86 3.86 4.17 4.17 0.00 3.11 4.62 0.53 1.75 1.75 27.79 0.00 8.40 8.40 1.78 1.29 1.29

24968 49349 67267 141,584 65499 65,499 0 0 286735 286735 286735 286735 0 3,464,889 4,204,659 0 0 465606 465606 502942 502942 0 374977 557849 9541 210841 210841 3,301,145 0 119744 119744 25409 18402 18402

Raw matl reduction Raw matl reduction Raw matl reduction Bead modification Bead modification Bead modification Blank size reduction Bead modification Bead modification Bead modification PP,DF CHANGE

JUL 06 AUG 06 Oct 06 Oct 06

1 1 0 0 0 0 1

0.00 0.00 32.38 32.38 32.38 32.38 0.00 403 1,652 0.00 0.00 116.49 116.49 125.84 125.84 0.00 89.73 139.57 16.01 52.75 52.75 835 0.00 253.87 253.87 53.87 39.01 39.01

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6

SBO,LH Main Floor RDI RH RDI LH FDI RH FDI LH SBO,RH HOOD INNER BDI H I (Old) FENDER RH (MINOR) FENDER LH (MINOR) BDO SBO-RH SBO-LH REAR FLOOR REAR FRONT DOOR OUTER RH FRONT DOOR OUTER LH

YM1 YM1 YM1 YM1 YM1 YM1 YM1 YM1 YM1 YM1 YM1 YM1 YG8 YG8 YG8 YG8 YG8 YG8

0.7 0.70 0.70 0.70 0.70 0.70 0.7 0.6 0.7 0.6 0.7 0.7 0.7 0.70 0.70 0.75 0.70 0.70

1655 1270 1400 1400 1370 1370 1655 1270 1270 1275 960 960 1510 1575 1575 1470 1420 1420

2640 1340 1060 1060 1145 1145 2640 615 1440 680 905 905 1600 3080 3080 1830 1085 1085

24008.8 9351.39 8154.58 8154.58 8619.73 8619.73 24008.8 3678.7 10049.3 4083.6 4774.1 4774.1 13275.9 26656.25 26656.25 15837.96 8466.15 8466.15

WIDTH FEED WIDTH WIDTH WIDTH WIDTH WIDTH WIDTH FEED WIDTH FEED FEED FEED WIDTH WIDTH WIDTH FEED FEED

10 20 20 20 20 20 10 15 20 5 10 10 10 15 15 5 5 5

10 20 20 20 20 20 10 0 0 5

15 20 0 10 10 10

0.7 0.70 0.70 0.70 0.70 0.70 0.7 0.6 0.7 0.6 0.7 0.7 0.7 0.70 0.70 0.75 0.70 0.70

1645 1270 1380 1380 1350 1350 1645 1270 1270 1270 960 960 1510 1560 1560 1465 1420 1420

2640 1320 1060 1060 1145 1145 2640 600 1420 680 895 895 1590 3080 3080 1830 1080 1080

Oct'06 Jan'07 Jun 06 Jun 06 May 06 May 06 Nov'06 Nov'06 Nov'06 Dec'06 Dec'06 Dec'06 Mar 07 Feb'07 Nov'06 Jan'07 MAR 07 MAR 07

Jun 06 Jun 06 May 06 May 06 Oct 06 Nov 06 Dec 06 JAN 07 Feb 07

120750 120750 120750 120750 120750 120750 120750 120750 120750 18000 120750 120750 14250 14250 14250 14250 14250 14250

1 1 1 1 1

1 1 1 1 1 1 1 1 1 1

Bead modification Bead modification Bead modification Bead modification Bead modification Bead modification Bead modification Raw matl reduction Raw matl reduction Raw matl reduction Raw matl reduction Raw matl reduction

15 15 5 5 5

Sep 06 Sep 06 Dec 06 Mar 07 Mar 07

Raw matl reduction Raw matl reduction Raw matl reduction Raw matl reduction Raw matl reduction

Residual Parts Utilization board

Control Phase

Control Mechanism
Carry out Draw panel trial of 4 - 5 blanks
Control Phase

Carry out trial run of 100 200 panel production Change the MOS (Maruti Operation Standard) Modify the fingers
~5 mm ~5 mm

Modify the skids if required

Monitor the production for next 5 lots

Monitoring of the total activity

SEVEN Mantras of Yield Improvement

In-House developed Techniques

Mantra 1 : Die Face Modification Mantra 2 : Modifying the Bead Design Mantra 3 : Residual flat parts (scrap) utilization Mantra 4 : Reducing the Blank Size by Gauge Adjustment Mantra 5 : Changing the Blank Shape Mantra 6 : Modification of the Punch Profile Mantra 7 : Open Draw Technique

Cost 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
200 180 160 140

185.48 164 169.45

125 114.53 102.69 108.70 102.88 92.13 51.60 43.64 46.57

LACS

120 100 80 60 40 20 0
04-05 05-06 06-07

13.70

26.2

34.549

Apr-07 May-07 Jun-07 Jul-07 Aug-07 Sep-07 Oct-07 Nov-07 Dec-07 Jan-08 Feb-08 Mar-08 Target 07-08

Monthly Cum.(07-08)

Monthly Cum.(06-07)

Cont

This is just the beginning The best is yet to come

Reduction of input weight

Implement Phase

Mantra 4 : Gauge adjustment

Purpose 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

Reduction of input weight

Implement Phase

Mantra 5 : Blank shape modification

R4000 R3000

a) Changing the radius from R3000 to R4000

b) Blank angle (both angle) change to reduce feed

c) Blank angle (one angle) change to reduce feed

Reduction of input weight

Mantra 6 : Punch profile modification

Blank Holder

Implement Phase

Punch Profile

Trim Line

Blank holder extended into the punch

Blank

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.

5
12

Punch Profile

Panel Size

Blank

Reduction of input weight

Mantra 7 : Open draw technique

Flow control through bead

Implement Phase

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