Rajesh Uppal Maruti Suzuki: IT Weds OT
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Rajesh Uppal Exec Director & CIO Feb 2015 IT Weds OT
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Transcript of Rajesh Uppal Maruti Suzuki: IT Weds OT
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”
