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

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Prod

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Cos

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5 S (The foundation)Seiri (Orderliness) , Seiton (Cleanliness) ,Seiso (cleaning) ,Seiketsu

(Standardization):Shitsuke (Self- Discipline)

PRODUCTION

Safe

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Prod

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Cos

t

5 S (The foundation)Seiri (Orderliness) , Seiton (Cleanliness) ,Seiso (cleaning) ,Seiketsu

(Standardization):Shitsuke (Self- Discipline)

Safe

tySa

fety

Qua

lity

Qua

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Prod

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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