This document summarizes key information about Maruti Suzuki India Limited, an automobile manufacturer. It discusses Maruti's equity structure and ownership, manufacturing operations including its production scale and automation levels, and how information technology is used to orchestrate its shop floor operations through machine interfacing, guided manufacturing, fool proofing, and synchronized production. The document also describes Maruti's efforts to analyze historical process parameter data from its casting operations to enable proactive defect prediction and improved quality control.

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

8. Machine Interfacing

9. IT Orchestrates Shop Floor
• Machine Interfacing
• Guided Manufacturing (Pika-Pika)

10. 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

14. Shop Floor Control

15. IT Orchestrates Shop Floor
• Machine Interfacing
• Guided Manufacturing (Pika-Pika)
• Fool Proofing (Poke-Yoke)
• Shop Floor Control
• Synchronized Production

16. 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
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