Bajaj Auto Ltd. 3Wh Div.

Aurangabad

6th Sept, 2011 TPM The Prime Mover towards Excellence

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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
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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

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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
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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

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Bajaj Auto Ltd. 3Wh Div. Aurangabad

3Wh Products
At Present Manufacturing 22 Models

TPM The Prime Mover towards Excellence

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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Bajaj Auto Ltd. 3Wh Div. Aurangabad

Actual

TPM The Prime Mover towards Excellence

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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

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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

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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

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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

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Bajaj Auto Ltd. 3Wh Div. Aurangabad

TPM The Prime Mover towards Excellence

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