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SLIDESMART MFG
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Manufacturing Excellence and Innovation
to Deliver Business Growth :-
Future of Manufacturing Technologies
SMART manufacturing
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Smart Manufacturing
Current Challenges
Future organization
Road map for smart Manufacturing Plants
Examples
Contents
SLIDESMART MFG
3Slide 3Environment Management at TVSM33
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1997 - Mysore plant
2006 – Himachal Plant
2006 - 3 Wheeler Plant 2007 – Indonesia plant
TVS Motor – Sales Trend 2.0 Million Vehicles with
turn over of closely 1.3 Billion US$
1979 – Hosur plant
TVS Motor, the Journey…
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TVS Motor Company
INDIA
BANGALORECHENNAI
NEW DELHI
MUMBAI
Location of plants
KOLKATTA
•
Hosur - 3 Wheeler
Nalagarh (HP)
Hosur - 2 WheelerMysore (Karnataka)
Mysore plant view
Production started : Total Area :
Jakarta (Indonesia)
Drive towards TVS Mfg systems for growth.....
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TVS MOTOR Products…
MopedsScooters
Motorcycles Executive& Economy
Motorcycles Premium
3 Wheeler
Each product group has value to customer
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Present scenario of
Automobile sector In India
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Quick Look at Indian Economy
• India is the 10th largest economy in the world
• In last fifteen years consuming class(middle class and aspirant house holds)
have grown from 52 million to 116 million.
• India is the second largest manufacturer of small passenger vehicles, buses and
two wheelers in the world.
Source:-IMF, Dr.Rajesh Shukla and SIAM
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Indian Auto Industry: Today
• 18mn domestic units in FY15
• Production Capacity increased from11mn in FY05 to 25mn in FY15
Market Size
• Only 35 cars and 90 two wheelers per 1000 populationPotential
• In the last five years number of players increased from 18 to 44 and exports from 1.4mn to 3.1mn Global Footprint
• One commercial vehicle generates jobs for roughly 21 people.
• In the last ten years more than 19mn additional jobs
Employment Generation
• Automobile sector contributes to 7.1% of GDP with a turnover of nearly USD110bnGDP Contribution
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….And Industry at the growth threshold…
SOURCE: Credit Suisse Aug 2012
Two Wheeler Penetration and GDP Per Capita
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0
10000
20000
30000
40000
50000
60000
70000
80000
90000 Rs
Avg two Wheeler Price Nominal GDP PerCapita
Supported by Increasing Affordability…
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…And Widening Choices
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Trends.• “Customer Base is ever expanding and ever demanding – Product
Variety, Quality, Cost , Reliability, Lead times
• Green shoots of economic revival?
• Improving but fragile consumer sentiments
• Increasing competiveness.
• Technology lead innovation to define future growth
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Kanban
Flow
ManufacturingLean
Manufacturing
TQM
SOP
5S
SMED
TPM
Modern
Manufacturing
System
Jishu Hozen
Pull System
Pokayoke
QC Circle
Andon
Buzz Words in
Manufacturing6 Sigma JIT
Mizusumashi
Kobetsu Kaizen
All are interlinked ....... Towards.......improvements
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Parts Supply
System
Flow
Manufacturing
Visual
Control
Visual
Control
Flow
Manufacturing
Quality
Assurance
in Process
Business
Oriented
Manufacturing
Standardized
Operations
Good
Housekeeping
Quick Changeover
Low Cost
Automation
Modern
Manufacturing
System
Two Steps
Training
Visual
Information
System
Simple Production
Planning
Fool Proof
System
Visual
Control
Effective
Manufacturing
Organization
Operators’
Daily Checking
of Machines
Operators’
Involvement in
Improvement
Key Elements to Establish Modern
Manufacturing System
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Aim is to establish connection between and within all critical 4M of
manufacturing
(Man , Machine, Material and Methods) and use this data effectively to
produce Zero defect products.
In second phase this data was utilized for efficient performance of other
business processes
Smart Manufacturing
1990 2000 2010 2014
ERP PLM MES
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Indian GDP is expected to raise steadily
•2000 •2010 •2019
•$ 47 b
•$ 1708 b
•2013
•$1870 b
Source:IMF ,GDP USD current prices
•$ 3096b
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India and China:
2020
2000
2010
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What should be our Winning or next practices....
It is not the strongest species that survive, nor the most intelligent, but the ones most responsive to change.
Charles Darwin
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The Challenge of Change:within and across
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Business Challenges: The going gets tough…
Competition, Global Players Muscle
Squeezing Margins
Customer Preferences,Dynamic Customer Profiles
Rising Fuel Prices
Regulatory Norms,Alternate Fuels
(Diesel)
Financial Health, Strongsystem support.
Supply Chainwoes
Rising Aspirations, IR
Issues
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• Market is Volatile, Customer demands are
Uncertain and Complex, Action to be taken in
Ambiquity
• 50 billion – connected devices like Internet of
things(IoTs)… Smart and Artificial Intelligence( AIs)
• More than 5 devices / person and 10 devices /
connected individual
• Q Brain
VUCA World – Major disruption by 2020
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• Continue to focus on Value stream mapping but
extend to Product development, Customer service
and Logistics
• Integration of Traditional concepts and process
improvement – Lean, Six Sigma, TOC ( theory of
constraints)
• Colloborative working
• Involve Suppliers in Technology growth
• Back bone of industry
New Role for Supply chain in flat world
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• VUCA World
• Requires Change in Key Result Indicator (KRI) -
SPEED, Agility, Flexibility
• Change in Key Activity Indicator (KAI)
• Anticipate Change
• Generate Confidence
• Initiate action
• Liberate Thinking
• Evaluate Results
Actions in VUCA world KRI & KAI
End to End
Supply system
4.0
Supply
Chain
Focussed
Fast
Flexible
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Lead timeto market
Productivity
Flexibility
ProcessQuality
Cost ofownership
Energyconsumption
Environment
Challenges ofManufacturing
Uptime
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Supplier Factory Dealer Customer
IOT(internet of things)
Plan for future-End to End Connected Organisation
Information Flow
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Data lifecycle in IoT
Integration
Alerts
Dash boardingStorage
Data mining
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IOT value framework
Business Strategic & Innovation
Operational excellence
Hygiene and aesthetics
Bigdata
Connected vehicles
Traceability
Genealogy of
vehicle
Integrated
intelligence
Building
management
system
TPMSmart manufacturing
Process parameter controlConnected
supply chain
Energy management
Visitor management
Security & control
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Internet of things
Connected people
Connected devices
Connected enterprise
Smart manufacturing
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Connected assets – benefit areas
• Operational monitoring and alerting
• Remote service and repair
• Performance history
• Predictive maintenance
• Performance bench marking
• Intelligence and analytics
• Total productive maintenance (TPM)
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Smart manufacturing objectives
AutomationProcess control
Traceability
AnalyticsImprove
predictabilityZero defect
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Connected manufacturing –benefit areas
• Unified real time visibility
• Automation
• Process parameter control
• Traceability
• Condition based maintenance
• Six sigma and lean
Visibility into manufacturing drives Cost optimization and reduce wastages
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Connected manufacturing –benefit areas
• Green enterprise
– Pollution monitoring
– Water measurement
– Power meter
Visibility into manufacturing drives Cost optimization and reduce wastages
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Application areas for IoT in manufacturing supply chain
Energy efficiency
Operational efficiency
Maintenance efficiency
Service efficiency
Supply chain efficiency
Assets efficiency
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Next Practices
Speed of Action and according to opportunity
Focus on New Opportunities:Create new opportunities
Focus on Customer Value +
Combination of Systems and Tools
+ SPEED of Action
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Product Innovation
Business Excellence Manufacturing Excellence
Key Elements
Society
Business Customers
Supply Chain (Design to Delivery)
Societal factors(Culture, People,
Environment)
Economic Factors(Political, Global trends, GDP)
ProcessProduct
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Process Innovation
Manufacturing Excellence Business Excellence
Drivers
Time
Cost quality
Product Development(Market In Approach)
People & Leadership(Noble Mind,
Contributing to society)
Sustainable
Growth (Break Thru)
Externally drivenInternally driven
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System Innovation through IOT
Manufacturing Excellence SMART MFG
Drivers
Time
Cost quality
Instrumented – Real time
Visibility
IntelligentAdvanced
Optimisation
InterconnectedSystem to System
Integration
Externally drivenInternally driven
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IOT Industry 4.0 drivers
SMART MFG
Drivers
Collect
Control Configure
Instrumented – Real time
Visibility
IntelligentAdvanced
Optimisation
InterconnectedSystem to System
Integration
Externally drivenInternally driven
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Smart Manufacturing
Plant
Zero Defect Assembly
Machine data
Capturing
Dealer connectivity
Environment
Zero defect Machine/
Measuring and Gauging
Supplier connectivity
Traceability
Water consumption
Waste management
Smart Manufacturing
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Sensors available in the market
Temperature, Speed, Motion , Rotation, Presence, Absence, Level, Volume, Leak, Weight, Humidity, Lumens, Decibels,
Length, Distance, Voltage, Pressure, Torque, Angle..
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EXAMPLES
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Currently Implemented :Zero Defect Cell in Engine Assembly Line
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Zero Defect Machine
AUTO COMPENSATION
AUTO CORRECTION
PROBING PROBING
TOOL BREAKAGE SENSOR TOOL BREAKAGE SENSOR
BURR FREE FIXTURE BURR FREE FIXTURE BURR FREE FIXTURE
PRE OPN CHECK PRE OPN CHECK PRE OPN CHECK
PART SENSOR PART SENSOR PART SENSOR PART SENSOR
PRESSURE SWITCH PRESSURE SWITCH PRESSURE SWITCH PRESSURE SWITCH
Level -1 Level-2 Level -3 Level-4
2015-16
Idea:-Integrate smart sensors for checking & correcting accuracy to ensure zero
defect to next customer
Checks for a Smart Machine
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Traceability system
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360 degree view of Vehicle
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Business Objectives
• On-line measurement of OEE
• PDCA to be improved from week to shift to hours
• Analysis should help the shop floor managers to take corrective action
Actions Implemented
• Two critical operations in a cell are provided with DAQ
• 400 DAQ are connected on-line to centralized server for OEE calculation
• Data entry touch boards to 400 machines
• WiFi in shop floor
• Patented DAQ
Future plan
• Predictive maintenance
On-line OEE
Background
• OEE is important for
• Measuring efficiency
• Capacity calculation
• Continuous improvement in productivity
• Loss of capacity to be analyzed
• Faster PDCA will help in faster action to reduce waste
Benefits
• On-line production, scrap and OEE report
• Hourly PDCA enabled
• Significant improvement in productivity
• OEE improved 85-
Further Improvement
• To extend DAQ for Welding, painting process
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Business Objectives
• Ground water level
should be monitored
before drawn
• Water drawn should be
measured and reported
• Cost effective automated
system
Actions Implemented• Remote measurement of
water drawal
Future plan
• Standardization in other plants
Integrated EHS systems
Background• 14 Wells collect water
• Collection of water based on ground water level
Benefits
• Manpower saving
• Prevention of pump breakdown
• Even drawl of water across all wells
Further Improvement
• Sensors for ground water level monitoring and drawl
Results achieved• Automated
system and no manual intervention
• Automated reports to PCB
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Truck locator• On-line monitoring
of truck movement from Hosur, Mysore and HP
• Vehicle availability to promise
• Predictability improvement
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Digital Inspection and Process control
Automated adjustment in
process parameters
Digital Inspection and process
controls
Manufacturing Execution System
Manufacturing Operations Management
SQC/SPC interact with machines
Auto part transfer
Machines talks each other
Automated
correction between
machine parameter/
adjustments
Robot / pick and place setup
Auto Part transfer
from line
stores
Automated part feeding
Intelligent Machines
(Dark room
Industry)
Interaction between cells
Unmanned Machining line
Intelligent Machining line
plantsInteraction
Cells talk to
each other
Multiple plants
interact
Automated material movement, RFID, Barcode, Intelligent Sensors
Automated material handling, Machine monitoring & maintenance (MTBF)
Measure Product specification and
monitor SQC charts
SQC monitoring
SQC
SPC
Pressing Fabrication
Painting MachiningEngine assy Vehicle assySQC
SPC
SQC
SPC
Road Map for Smart Machining lines
SQC
SQC SPC
Control plan
PD
CA
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Digital Inspection and Process control
Automated adjustment in
process parameters
Convert Analogue to Digital
Inspection and process controls
Manufacturing Execution System
Manufacturing Operations Management
SQC/SPC interact with machines
Main line, sub system
interaction
Assembly automation
Automated feedback &
correction of system and sub system
assembly
Fit and Finish
Inspection
Intelligent Assembly stations
Interaction between cells
Intelligent Assembly Line
Automated material movement, RFID, Intelligent Sensors, closed loop feedback
Automated material handling
Online Data captured-VIN
SQC monitoring
SQC
Fabrication MachiningEngine assy
Road Map for Intelligent assembly line
Measure Product specification and
monitor SQC chartsagainst VIN
SQC SPC
Control plan
PD
CA
Robot/ Semi automated assembly
Automated Fit
and Finish
Inspection
Automated feedback/
correction of feeder units
Automated part feeding
Auto Part transfer from
stores
SQC
SPC
SQC
SPC
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53Smart factory
through IoT
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End of Presentation
The Transformation to Smart
Manufacturing is happening
Faster than one thinks……
