Operation management

Presented By:

Abhilas Das

Ajay Yadav

Abhash Mitra

Akansha Pathania

About Maruti’s Gurgaon Plant: Maruti Suzuki has two car facilities in India,

one at Gurgaon and the other at Manesar. The Gurgaon facility has three fully

integrated plants, spread over an area of 300 acres and rolls out 7,00,000 cars a year.

The entire facility is equipped with more than 350 robots, out of which 100 have been developed in-house.

More than 50% of the employees on the shop floor have been trained in Japan.

STEPS INVOLVED• PLANNING• REQIERMENT ANALYSIS• AQUIRING INVENTORY• SHEET PRESSING• DYEING• WELDING• PAINT SHOP• ASSEMBLY LINE• STORING• TESTING

Press Shop• PPC- Production Planning Center, provides a

plan and set a production target.

• Production dept. divides the target into batches and then further into lots based on demand.

• storage area• capacity• capital budget• then the shifts are planed

Press Shop

Inventory is acquired on the basis of plan received from production planning center.

Sheets are then pressed and feeded in the dye casting machine

Then the casted parts are given to weld shop With a target of before 4 hrs to avoid any

bottlenecks.

Weld Shop

Weld shop Plan received from vehicle belt sequence(VBS). All the parts received form dying are welded

together, with the help of Roberts and manually. 340 programmed robots are involved in spot

welding (joining sheets), handling and sealing robots come from behind to complete the welding process.

An assembly line is there to transfer the welded parts to next station

Final car from weld shop is transferred to paint shop with the help of cranes

Paint Shop

Paint shop Then the cars are painted based on models

and plan received from ppc The painting is done with the help of robots Assembly line is implanted to paint different

parts, each part is removed at different stations and the painted separately and then fixed back

Assembly line

Assembly line

Car from paint shop is transferred to assembly line.

Parts are removed and assecories are fixed on them

Parts are fixed at each station and all the parts are finally fixed togather

Then the final car is sent for washing

Quality management

Quality control is done at each station Quality check is done on each 1 pc out

of 50 pcs Daily and montly reports are prepared

with reference to all the spare parts(defective)

Final Product

Cost control

Trying minimum steel consumption in dying

Saving on power, oil, labor efficiency Timing is given priority

safety

Safety is given priority at each step All the safety equipments are mandatory

at operations safety is an integrated policy of

company Even the higher end employee can not

enter the company campus with out shoes, helmet etc.