Bajaj Auto Ltd. 3Wh Div.
Aurangabad
6th Sept, 2011 TPM The Prime Mover towards Excellence
Slide No. : 1
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Team:
Manoj Kelkar Sr. Mgr. (Press & Fab 3Wh)
Nitin Patil Manager (Press Shop 3Wh)
TPM The Prime Mover towards Excellence
Slide No. : 2
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Bajaj Group
Bajaj Group:
Among top 10 business houses in India
34 companies having presence in diverse sectors
Automotive
Bajaj Auto Ltd. flagship company of
Bajaj Group Current World Market Standing
Ranked as the Worlds 4th largest Two & Three Wheeler manufacturer
Finance
Insurance Home Appliances Steel International Trading Power Infrastructure
FY 10-11
Turnover Rs. 1,69,315 million Net Profit Rs. 33,397 million TPM The Prime Mover towards Excellence
Slide No. : 3
Bajaj Auto Ltd. 3Wh Div. Aurangabad
BAL : HQ & Plants
BAL
Akurdi (Pune)
Waluj (Aurangabad
Chakan
Pantanagar
Indonesia
Head Qtr. Engg. R&D Finance, Mktg HRD
All 3 Wh
Discover Platina
Proposed 4 Wheelers
Discover Pulsar Avenger Discover Platina
CKD + SKD Motorcycles
XCD
CT 100 Boxer
Ninja
KTM
3 Wheelers
TPM The Prime Mover towards Excellence
Slide No. : 4
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Started manufacturing at Akurdi, Pune in 1961
In Waluj, Aurangabad From 1987
50 Years .. Commutation to Logistics
Total 3Whs on Road across the globe 4.84 million
TPM The Prime Mover towards Excellence
Slide No. : 5
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Product Portfolio 3-Wheeler
World leader Fuel efficient Eco friendly Optional Variants - CNG, LPG and diesel.
RE CDI RE CNG 4 S RE 4 S RE LPG 4 S GC 1000
TPM The Prime Mover towards Excellence
Slide No. : 6
Bajaj Auto Ltd. 3Wh Div. Aurangabad
3Wh Products
At Present Manufacturing 22 Models
TPM The Prime Mover towards Excellence
Slide No. : 7
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Our customers
Domestics
No. of dealers 196 No. of models 22
Exports
Spread over more than 27 countries
Total no. of models 4
TPM The Prime Mover towards Excellence
Slide No. : 8
Bajaj Auto Ltd. 3Wh Div. Aurangabad
3Wh Production Growth
Domestic
Million Nos.
0.55
Export
Total
20%
0.53
26%
0.44
0.44
29%
0.35
0.33
0.32 0.23
0.32
0.23
0.22
0.07
0.14
0.17
0.13 0.11
0.11
0.01 0.01
0.16
0.10 0.12
0.18
0.18
0.21
0.21
97-98
00-01
03-04
06-07
09-10
10-11
11-12
TPM The Prime Mover towards Excellence
Slide No. : 9
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Target v/s Manpower
37 K
Monthly Target
30 K
975 0
1116
Required Manpower
141
Manpower Shortfall
2009-10
2010-11
TPM The Prime Mover towards Excellence
Slide No. : 10
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Background
Guideline
( Objective - continuous improvements )
No fresh recruitment of Permanent Labour
No addition in Contract Labour
TPM The Prime Mover towards Excellence
Slide No. : 11
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Kaizen Theme
TPM The Prime Mover towards Excellence
Slide No. : 12
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Use of New Technology / Process
High investment cost
TPM The Prime Mover towards Excellence
Slide No. : 13
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Windshield press part line
Press Line
Total 9 operators / shift
Load - 1 man Unload - 1 man
Load - 2 men Unload - 1 man
Load - 1 man Unload - 1 man
Load - 1 man Unload - 1 man
TPM The Prime Mover towards Excellence
Slide No. : 14
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Stage wise Kaizen idea matrix
Sr. No. Stage Activity No. of Operators Kaizen Auto loading by LCA Auto unloading by LCA Auto oil application Auto scrap disposal
Oil application 1 1 Draw Blank loading Part unloading Part loading 2 Scrap unloading at front side 2 1st trim Part unloading Central scrap unloading End scrap unloading Part loading 3 2nd trim Part unloading 1 Scrap unloading Part loading 4 Final Part unloading 1 1 1 1 1
4 4 1 4
Total
TPM The Prime Mover towards Excellence
Slide No. : 15
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Challenges
Scrap Handling Approach in die Consistency of Part locations Access for die Set up Impact on Press cycle time Interface between LCA & Press Auto cycle
TPM The Prime Mover towards Excellence
Slide No. : 16
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Challenges Scrap Handling
1st trim end scrap removal & collecting in scrap trolley
Before After
Horizontal deployment on 1st trim loading side.
TPM The Prime Mover towards Excellence
Slide No. : 17
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Challenges Scrap Handling
1st trim central scrap removal & collecting in trolley
Before After
Horizontal deployment on 2nd trim unloading side.
TPM The Prime Mover towards Excellence
Slide No. : 18
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Challenges Consistency of part location
1st trim Guide rods provided with pnue. cylinder.
1st trim pneumatic end stopper for prefect location.
Proximity sensor provided in die for full proof location & interlocked with press cycle.
TPM The Prime Mover towards Excellence
Slide No. : 19
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Challenges Approach in die
1st Trim - Die bottom casting relieve for easy part loading
2nd trim - Die bottom punch relieve for gripper fingers
TPM The Prime Mover towards Excellence
Slide No. : 20
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Challenges Die setup
Draw - Movable loader with lead screw arrangement for die set up
2nd trim loader mounted on moving bolster for die set up
TPM The Prime Mover towards Excellence
Slide No. : 21
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Challenges Interface between LCA & Press auto cycle
Interlock Matrix
INPUT OUTPUT From Press
Ready in Slide at once top
Press cycle starts
Read switch
Proximity Sensor
Part locator down Part on gripper
Photo Sensor
In die for part present Part at unloading stage
Cam Loader Unloader In die for Switch at Home at home job location
ON ON ON
ON ON ON ON ON
ON ON ON
ON
ON OFF
ON ON ON
ON OFF ON
OFF
Loader starts
Unloader starts Scrap Ejector starts
ON
ON
Interlock for
Safety
Safety
Quality
Safety
Safety
Quality
TPM The Prime Mover towards Excellence
Slide No. : 22
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Challenges
Scrap Handling Approach in die Consistency of Part locations Access for die Set up Impact on Press cycle time Interface between LCA & Press Auto cycle
TPM The Prime Mover towards Excellence
Slide No. : 23
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Actual
TPM The Prime Mover towards Excellence
Slide No. : 24
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Kaizen Sustenance
Sustenance points
Sr. No. Part / Component Activity Air pressure 1 FRL unit Oil level in lubricator Filter cleaning Quality PokaYoke Audit 2 3 4 Sensors Safety PokaYoke Audit Vacuum Developer Cleaning Vacuum Cups Replacement Weekly Fortnightly 6 months JH Daily Daily Monthly Daily PM TBM
TPM The Prime Mover towards Excellence
Slide No. : 25
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Result
Wind Shield line
Manpower / Shift 9 30
Press Shop
Manpower
0 Before Before
After
After
Horizontal deployment on Shield press line
30 operators transferred to Vehicle Assembly
TPM The Prime Mover towards Excellence
Slide No. : 26
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Benefit - Productivity
Press Shop
Nos.
Production / Man
10.5 times
2000
1600
1600
X 1000 nos.
32
Plant
Production / Month
31.5 K
1200
800
400
0
152 30 K Before After
30
17 %
Nos. 220 200 180 160 140
Production / Hour
28
5%
171
200
Before
After
Before
After
TPM The Prime Mover towards Excellence
Slide No. : 27
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Benefit Cost
Press Shop
Nos. 10 8 6 4 2 0
Plant
Rs. In Lacs
100
Labour Cost / Veh
8.2
Project Cost
80
80
88 %
90 %
60 40
0.8 Before After
20 0
10 Automation LCA
TPM The Prime Mover towards Excellence
Slide No. : 28
Bajaj Auto Ltd. 3Wh Div. Aurangabad
Benefits Press Shop
Quality
PPM 16000 12000 8000 4000
Safety
Nos. 10
Rework
11670
Unhealthy Conditions
9 100 %
100 %
8 6 4
0
0
2 0
0 Before After
Before
PPM
After
Nos. 16
Rejection
(due to wrong location)
Unsafe Conditions
12
800 600 400 200 0
740 100 %
12 8 4
100 %
0
0
Before
After
Before
After
TPM The Prime Mover towards Excellence
Slide No. : 29
Bajaj Auto Ltd. 3Wh Div. Aurangabad
TPM The Prime Mover towards Excellence
Slide No. : 30
