rajesh uppal maruti suzuki: it weds ot
TRANSCRIPT
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Rajesh Uppal Exec Director & CIO
Feb 2015
IT Weds OT
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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
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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
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High Automation
• Manesar Weld example
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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
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IT Orchestrates Shop Floor
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IT Orchestrates Shop Floor
• Machine Interfacing
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Machine Interfacing
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IT Orchestrates Shop Floor
• Machine Interfacing• Guided Manufacturing (Pika-Pika)
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Guided Manufacturing (Pika-Pika)
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IT Orchestrates Shop Floor
• Machine Interfacing• Guided Manufacturing (Pika-Pika)
• Fool Proofing (Poke-Yoke)
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Fool Proofing (Poke Yoke)
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IT Orchestrates Shop Floor
• Machine Interfacing• Guided Manufacturing (Pika-Pika)
• Fool Proofing (Poke-Yoke)
• Shop Floor Control
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Shop Floor Control
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IT Orchestrates Shop Floor
• Machine Interfacing• Guided Manufacturing (Pika-Pika)
• Fool Proofing (Poke-Yoke)
• Shop Floor Control• Synchronized Production
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Synchronized Production
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DATA Emitters
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Big Data on OT
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Raw material receiving
Inspect in Labs
Holding area
Heat treatment for melting metal
Cast metal into desire shapes
Machine Control Panel
Finished component
Manual Input
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
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What we did
Parameters set based on experience/ Hit and TrialNo historical data available for decision makingEnd to end process traceability of casting components.Trend availability of appropriate values .
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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
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Quality Control
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A new Horizon of OT with IT
OT
IT
Efficiency
Quality Cost Flexibility
MES
Prediction Systems
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Thank You Drive safely with “Maruti”