bajaj auto

Bajaj Auto Ltd. – 3Wh Div. Aurangabad

TPM – The Prime Mover towards Excellence Slide No. : 1

6th Sept, 2011



Team:

• Manoj Kelkar – Sr. Mgr. (Press & Fab 3Wh)

• Nitin Patil – Manager (Press Shop 3Wh)



Bajaj Group:

Among top 10 business houses in India

34 companies having presence in

diverse sectors

Automotive

Finance

Insurance

Home Appliances

Steel

International Trading

Power

Infrastructure

Bajaj Auto Ltd. flagship company of

Bajaj Group

Current World Market Standing

Ranked as the World’s 4th largest

Two & Three Wheeler manufacturer

Bajaj Group

FY 10-11

• Turnover – Rs. 1,69,315 million

• Net Profit – Rs. 33,397 million



BAL

Akurdi(Pune)

Head Qtr.

Engg.

R&D

Finance,

Mktg

HRD

Waluj(Aurangabad

All 3 WhDiscover

Platina

XCD

CT 100

Boxer

Proposed 4 Wheelers

Chakan

Discover

Pulsar

Avenger

Ninja

KTM

Pantanagar

Discover

Platina

Indonesia

CKD + SKD

Motorcycles

3 Wheelers

BAL : HQ & Plants



Started manufacturing at Akurdi, Pune

in 1961

In Waluj,Aurangabad From 1987

Total 3Whs on Road across the globe 4.84 million

50 Years .. Commutation to Logistics



World leader Fuel efficient Eco friendlyOptional Variants - CNG, LPG and diesel.

RE CDI RE CNG – 4 S RE – 4 S RE LPG – 4 S GC 1000

Product Portfolio 3-Wheeler



3Wh Products

At Present Manufacturing

22 Models



Our customers

No. of dealers – 196

No. of models – 22

Domestics Exports

Spread over more than 27 countries

Total no. of models – 4



0.100.12

0.160.18 0.18

0.21 0.210.01

0.01

0.07

0.140.17

0.23

0.32

0.110.13

0.23

0.32

0.35

0.44

0.53

0

0.11

0.22

0.33

0.44

0.55

97-98 00-01 03-04 06-07 09-10 10-11 11-12…

Million Nos.

Domestic Export Total

3Wh Production Growth

29%

26%

20%



2009-10 2010-11

9751116

0 141

30 K

37 K

Target v/s Manpower

Manpower Shortfall

Required Manpower

Monthly Target



Background

Guideline

( Objective - continuous improvements )

• No fresh recruitment of Permanent Labour

• No addition in Contract Labour



Kaizen Theme



Use of New Technology / Process

High investment

cost

http://www.google.co.in/imgres?imgurl=http://www.eurobots.net/files/det_588_KR125-KR150-KR200_robot.jpg&imgrefurl=http://www.eurobots.net/desc/id/17/KR125_KR150_KR200-en.html&usg=__Sp9xiXpjwtJwMwnN48N-o5Y-cNM=&h=1421&w=1172&sz=152&hl=en&start=4&zoom=1&tbnid=bUaefWlOoCM7VM:&tbnh=150&tbnw=124&ei=J8tZTsSRCsLXrQfzmrzICg&prev=/search?q=ABB+robots&hl=en&safe=active&sa=N&tbs=isz:l,itp:clipart&tbm=isch&prmd=ivns&itbs=1



Load - 1 man

Unload - 1 man

Load - 2 men

Unload - 1 man

Load - 1 man

Unload - 1 man

Press Line

Total 9

operators / shift

Windshield press part line

Load - 1 man

Unload - 1 man



Auto loading

by LCA

Auto

unloading

by LCA

Auto oil

application

Auto scrap

disposal

Oil application

Blank loading

Part unloading 1

Part loading

Scrap unloading at front side

Part unloading

Central scrap unloading

End scrap unloading

Part loading 1

Part unloading

Scrap unloading

Part loading 1

Part unloading 1

9 4 4 1 4

Final

Total

Stage wise Kaizen idea matrix

2

1

1

2

1

4

1st trim

3 2nd trim

1 Draw

KaizenSr.

No.Stage Activity

No. of

Operators



Challenges

Scrap Handling

Consistency of Part locations

Approach in die

Access for die Set up

Impact on Press cycle time

Interface between LCA & Press Auto cycle

http://www.google.co.in/imgres?imgurl=http://www.it.iitb.ac.in/~prathabk/egovernance/img/challenges.gif&imgrefurl=http://www.it.iitb.ac.in/~prathabk/egovernance/challenges.html&usg=__BP1wVd_X4kj-ERdIUOmXYU6JSXM=&h=231&w=244&sz=21&hl=en&start=1&zoom=1&tbnid=YvNo8yp6RrFnyM:&tbnh=104&tbnw=110&ei=TtFZTuf7O8jyrQfJlqmWCw&prev=/search?q=challenges&hl=en&safe=active&sa=N&tbas=0&tbs=itp:photo&tbm=isch&prmd=ivns&itbs=1



1st trim end scrap removal & collecting in scrap trolley

Before After

Horizontal deployment on 1st trim loading side.

Challenges ► Scrap Handling



1st trim central scrap removal & collecting in trolley

Horizontal deployment on 2nd trim unloading side.

Challenges ► Scrap Handling

Before After



Challenges ► Consistency of part location

1st trim – pneumatic end

stopper for prefect location.

1st trim – Guide rods provided

with pnue. cylinder.

Proximity sensor provided in

die for full proof location &

interlocked with press cycle.



Challenges ► Approach in die

1st Trim - Die bottom casting relieve for

easy part loading

2nd trim - Die bottom punch relieve

for gripper fingers



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

LCA with lead screw.mpg

LCA with Moving Bolster NEW.MPG



Challenges ► Interface between LCA & Press auto cycle

Ready in

once

Slide at

top

Cam

Switch

Loader

at Home

Unloader

at home

In die for

job location

Part

locator

down

Part on

gripper

In die for

part

present

Part at

unloading

stage

Press cycle starts ON ON ON ON ON ON ON OFF

Loader starts ON ON ON OFF ON OFF

Unloader starts ON ON ON ON ON ON ON ON

Scrap Ejector

startsON

Safety Quality Safety Safety QualitySafety

INPUT

OUTPUT

Interlock for →

Interlock Matrix

From Press Read switch Proximity Sensor Photo Sensor



Challenges

Scrap Handling

Consistency of Part locations

Approach in die

Access for die Set up

Impact on Press cycle time

Interface between LCA & Press Auto cycle



Actual

Chassis Shop wit Titles.mpg



Kaizen Sustenance

Sr. No. Part / Component Activity JH PM TBM

Air pressure Daily

Oil level in lubricator Daily

Filter cleaning Monthly

Quality PokaYoke Audit Daily

Safety PokaYoke Audit Weekly

3 Vacuum Developer Cleaning Fortnightly

4 Vacuum Cups Replacement 6 months

Sustenance points

FRL unit1

Sensors2



Result

30 operators transferred to Vehicle Assembly

Horizontal deployment on Shield press line

BeforeAfter

9

0

Wind Shield lineManpower / Shift

BeforeAfter

30

0

Press ShopManpower



Plant

Press Shop

Benefit - Productivity

10.5 times

17 %

5 %

171

200

140

160

180

200

220

Before After

Nos. Production / Hour

152

1600

0

400

800

1200

1600

2000

Before After

Nos. Production / Man

28

30

32

Before After

X 1000 nos.

Production / Month

30 K

31.5 K



PlantPress Shop

Benefit – Cost

90 %

88 %8.2

0.8

0

2

4

6

8

10

Before After

Nos. Labour Cost / Veh

80

10

0

20

40

60

80

100

Automation LCA

Rs. In Lacs Project Cost



12

00

4

8

12

16

Before After

Nos. Unsafe Conditions

9

00

2

4

6

8

10

Before After

Nos. Unhealthy Conditions

740

00

200

400

600

800

Before After

PPM Rejection(due to wrong location)

Benefits – Press Shop Quality

100 %

100 %

100 %

Safety

100 %

11670

00

4000

8000

12000

16000

Before After

PPM Rework

bajaj auto

Documents

part locations access

aurangabadchallenges scrap handling

press auto cycle

bajaj auto

3wh div

horizontal deployment

prime mover

lca