Maruti Udyog
Fool Proofing Application for Assembly Line at Maruti:
The largest automobile manufacturer in the Indian sub-continent, Maruti Udyog Limited's Gurgaon plant consists of six Assembly lines. On an average 2,500 cars are manufactured daily over a 16 hour shift, which roughly translates to over 900,000 cars manufactured within the plant in a single year.
The company has it's own shop to manufacture car shells.
Maruti Udyog Limited were on the lookout for an effective method for checking the chassis number of cars on their assembly lines.
The existing system was mostly manual or used outdated technology, which resulted in errors in planning, as information that passed into the system was often faulty. Additionally time, money and resources were being spent on training people.
KLG Systel suggested the use of barcodes. Extensive site surveys, solution crafting and system studies were undertaken, prior to KLG Systel implementing the Barcode System within one of Maruti's assembly shops.
A Barcode system was implemented for tracking shells. Barcode label contained information received from the PLC already running in the plant about the production schedule of the shell. The information printed on each barcode label consisted of the chassis number of the vehicle and the engine number that was to be placed within the engine compartment. Integration was also carried out at the backend to ensure that the VTS (Vehicle Tracking System) runs seamlessly with the new barcode system.