Rajesh Uppal Maruti Suzuki: IT Weds OT
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How Information Tech works in conjunction with Operations Tech in manufacturing environment
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Rajesh Uppal Maruti Suzuki: IT Weds OT
- 1. Rajesh Uppal Exec Director & CIO Feb 2015
- 2. Equity Structure 56.20% Suzuki, 43.80% Public Manpower Around 16000 employees Models 15 models with over 150 variants Group Companies 28 Net Sales (13-14) Rs. 426,448 million Net Profit (13-14) Rs. 27,830 million Total Sales (2013-14) 1,155,041 units Market Share (2013-14) 42.1 % (Passenger vehicles) Our Business Card
- 3. Our Manufacturing Dimensions • 200 variants of 16 models • 3000 components make a car • Lean inventories < day • Infrastructure – Two Geographic locations – 5 Plants – 128 production shops • Approx 4 cars produced per minute
- 4. High Automation • Manesar Weld example
- 5. Operational Technology “ Operational Technology (OT) covers the spectrum of systems that deal with the physical transformation of products and services. They are task-specific systems, are highly customized for industries and considered mission-critical. “ Source: Chainlink Research
- 7. IT Orchestrates Shop Floor • Machine Interfacing
- 9. IT Orchestrates Shop Floor • Machine Interfacing • Guided Manufacturing (Pika-Pika)
- 11. IT Orchestrates Shop Floor • Machine Interfacing • Guided Manufacturing (Pika-Pika) • Fool Proofing (Poke-Yoke)
- 12. Fool Proofing (Poke Yoke)
- 13. IT Orchestrates Shop Floor • Machine Interfacing • Guided Manufacturing (Pika-Pika) • Fool Proofing (Poke-Yoke) • Shop Floor Control
- 15. IT Orchestrates Shop Floor • Machine Interfacing • Guided Manufacturing (Pika-Pika) • Fool Proofing (Poke-Yoke) • Shop Floor Control • Synchronized Production
- 17. DATA Emitters
- 19. Raw material receiving Inspect in Labs Holding area Heat treatment for melting metal Cast metal into desire shapes Machine Control Panel Finished component OKReject Dispatch to M/C shop Inspection at M/C shop handover Parameters • Metal Temperature • Metal Pressure • Pouring time • Vacuum reading • Etc… (12 parameters) Casting manufacturing process
- 20. What we did Parameters set based on experience/ Hit and Trial No historical data available for decision making End to end process traceability of casting components. Trend availability of appropriate values .
- 21. Parameter based Quality Prediction in Casting shop Control Quality in Casting shop through Proactive Defect Prediction based on Casting Process Parameters . Plant Data Process parameter Machine DataFailure Data
- 22. Quality Control
- 23. A new Horizon of OT with IT OT IT Efficiency Quality Cost Flexibility MES Prediction Systems
- 24. Thank You Drive safely with “Maruti”
Notas del editor
- Our Assets like pumps, motors, conveyors, valves, forklifts, robots, etc. fall under it.
- Parameters Capturing in Casting shop Capturing of process parameters on each unit’s production, as well as subsequent rejections. Parameters like, temperature, pressure, cycle time etc. Immediate and periodic alerts for any deviations Analytics and Dashboards for minimizing rejection. for a quick over-view on the health of Casting shop and its process outcome . Reduction in Rejection by 50% in 3 year (20% +20% +10%) Reduction in breakdowns due to process variation. Target Savings committed by business: ~Rs 40million / year
- Flexibility Quality Optimization Improving Bottom-line