Overview
Engineering Mahindra’s First Automated Multi-Model Assembly Line
In 1998, Mahindra & Mahindra embarked on creating their first automated multi-model assembly line, engaging our services for a feasible solution. The new assembly line was designed to accommodate the production of diverse models such as Scorpio, Armada, Marshal, and Bolero, introducing automation to Mahindra's manufacturing processes for the first time.
Customer Profile
| Industry: | Automotive |
| Location: | Maharashtra, India |
Problem Statement
Our analysis of Mahindra & Mahindra's assembly line requirements revealed multiple challenges, such as designing a universal conveyor rest point for various vehicle models within the constraints of the existing truss height. Additionally, we needed to ensure precise vehicle positioning on the overhead conveyor for seamless automatic transfer to the assembly line.
Key Metrics
- Multi-model handling capability
- 100% automation
- On-time delivery and installation
- Minimum investment
AUTOMAG's Solution
To address the unique challenges of their multi-model assembly line, Automag implemented a solution that included an Electrified Monorail System (EMS) for transporting different vehicle models. They integrated a slat conveyor for efficient vehicle movement and designed a specialized body to chassis marriage station. This setup not only facilitated the accommodation of various vehicle types within a single assembly line but also ensured precision in vehicle positioning and transfer, thereby significantly optimizing their manufacturing process.
01.
Conveyor System
Custom-engineered to offer unparalleled flexibility, angular flow study in gravity flow to enhance tire movement. Also, proper sensor position study & implementation has assured smooth traffic at divergence / convergence.
02.
Stopper design
With seamless study on Tire jamming issue, stopper design has been updated with modified cylinder placement. This has reduced manual intervention during tire struck and overcome production loss.
03.
Belt material analysis
By real time study at line for noise & transfer friction of inclined belt, it has been replaced by PVC belting after various discussion with potential stakeholders. This activity not only reduced few decibels but also improved savings on yearly energy consumption with some reduction in motor ratings.
04.
Spare management
With suggestion of proper reliable bought out make for rollers, belt, pneumatics etc improved spare management enabling predictive maintenance and minimizing downtime.
Results
Increased Production Efficiency: Achieved 98% system efficiency. It continued to work for 15+ years without unplanned breakdowns.
Multi-Model Handling: Slat resting pads for all the carriers were custom built to suit different vehicle models.
100% Automation: All transfer points were designed with the help of sensors and guides for automatic transfer.
Minimum Investment: Localized sourcing of all system components to reduce the costs.
Conclusion
The project was successfully delivered on time, significantly enhancing the assembly line's efficiency and flexibility.