Rajesh Uppal Exec Director & CIO

Feb 2015

IT Weds OT

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

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

High Automation

• Manesar Weld example

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

IT Orchestrates Shop Floor

IT Orchestrates Shop Floor

• Machine Interfacing

Machine Interfacing

IT Orchestrates Shop Floor

• Machine Interfacing• Guided Manufacturing (Pika-Pika)

Guided Manufacturing (Pika-Pika)

IT Orchestrates Shop Floor

• Machine Interfacing• Guided Manufacturing (Pika-Pika)

• Fool Proofing (Poke-Yoke)

Fool Proofing (Poke Yoke)

IT Orchestrates Shop Floor

• Machine Interfacing• Guided Manufacturing (Pika-Pika)

• Fool Proofing (Poke-Yoke)

• Shop Floor Control

Shop Floor Control

IT Orchestrates Shop Floor

• Machine Interfacing• Guided Manufacturing (Pika-Pika)

• Fool Proofing (Poke-Yoke)

• Shop Floor Control• Synchronized Production

Synchronized Production

DATA Emitters

Big Data on OT

Raw material receiving

Inspect in Labs

Holding area

Heat treatment for melting metal

Cast metal into desire shapes

Machine Control Panel

Finished component

Manual Input

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

What we did

Parameters set based on experience/ Hit and TrialNo historical data available for decision makingEnd to end process traceability of casting components.Trend availability of appropriate values .

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

Quality Control

A new Horizon of OT with IT

OT

IT

Efficiency

Quality Cost Flexibility

MES

Prediction Systems

Thank You Drive safely with “Maruti”