NX • Teamcenter Maruti Suzuki

Slashing product time-to-market through die design automation

Industry Using NX and Teamcenter, tooling development time, reducing die design time, reducing costs by substan- Automotive Maruti Suzuki Die Shop realizes tially decreasing the need for rework, and dramatic time savings in press improving quality. “Our die design process Business challenges die development cycle; savings clearly represented and still represents one include 90 hours in designing of the most important opportunities for Improve die design process reducing overall die development time and to accelerate time-to-market, draw die structure components thereby accelerating car-to-market time,” improve quality and reduce says Mayank Varma, assistant general costs India’s largest passenger car company Maruti Suzuki India Limited (MSIL), for- manager, Tool and Die Shop, Maruti merly Maruti Udyog Limited, a subsidiary Suzuki. Keys to success of Suzuki Motor Corporation of Japan, is Stamping domain represents Employ the die design tools India’s largest passenger car company. significant opportunity of NX and the product data Maruti Suzuki accounts for around 50 per- Maruti Suzuki Die Shop uses a number of management capabilities of cent of the car market in India. That repre- traditional and advanced processes in the Teamcenter to the die devel- sents a yearly turnover of $6 billion, one design, validation, manufacturing and opment process million+ cars sold annually and more than 800 sales dealerships in 555 cities. The commissioning of its dies, including NX™ Leverage best-practice company offers 14 brands and more than software and Teamcenter® software from standardization technology, 80 variants of these brands. Its product Siemens PLM Software. including templates and line extends from practical to powerful family of parts and from hatchback to SUV. With its corpo- Continue to invest in and rate office in New Delhi and 16 regional improve process automation offices across India, production facilities in Gurgaon and Manesar, and more than 7,000 employees, Maruti Suzuki faced a Results number of imminent business challenges. 90 hours saved in design- ing draw die structure The company was experiencing increasing components pressure to introduce new models in a 10 hours saved per die shorter time frame. There was also grow- involving cam units ing pressure to improve quality and reduce costs. To complicate matters, customer 10 hours saved per die needs and perceptions were no longer involving standard parts gradually evolving, but now rapidly chang- Higher quality dies produced ing. More specifically, certain product for tangibly reduced costs development domains represented the Opportunities for further die greatest opportunity to address these key design process automation challenges. These included reducing new and savings well underway www.siemens.com/plm Templates yield 90 hours “Our die design process saved for draw die structure clearly represented and still components represents one of the most Using NX die design tools, important opportunities for Maruti Suzuki Die Shop has reducing overall die devel- built many templates for its opment time and thereby die design stage. Here’s how it accelerating car-to-market works. The designer is pre- time.” sented with the template, which shows the parameters Mayank Varma of the parts. The designer sim- Assistant General Manager ply enters the new product Tool and Die Shop NX Die Structure Design applications specifications to update the template to Maruti Suzuki play key role in die design the current design. The mating of the standardization standard parts is captured, so that any “We plan to slash at least Data is received from the Product Design change to a part reflects the position of 50 percent off the draw die Group of Maruti Suzuki in NX format. Then the standard parts as well. This substan- design cycle in the first year, the die face, which includes addendum, tially accelerates the speed with which die then 60 percent within the binder, draw bead, etc., is designed using structures are designed. next two to three years. We NX tools. The data is transferred to exter- have a vision and we feel nal computer-aided engineering (CAE) Maruti Suzuki Die Shop accomplished this Siemens’ technology has software to do the validation of forming important time reduction through what it much to offer to make it simulation, e.g., addressing wrinkles in the describes as its “cloning concept” in which happen.” sheet metal folds, thinning, bend and trim the repeated structures in a design are line issues, etc. “This is quite time-consum- identified and treated as standard struc- Vidur Kaushik ing; however, we have plans for improve- ture parts, creating the primitive or basic Manager ments here,” notes Vidur Kaushik, template design. Mating points are Die Design, Die Shop manager – Die Design, Die Shop, Maruti defined, mounting bodies created, map Maruti Suzuki Suzuki. files identified for positioning, etc., using the template structure. Once the simulation is done, the part is tipped to the die position based on CAE “It used to take approximately 180 hours feedback and a layout is prepared via to build the components of the draw die NX 2D drafting by taking sections on the structure,” says Hardeep Singh, deputy parts. The die structures are then built. manager “Die Design, Die Shop, Maruti Finally, it’s 2D and 3D machining, die Suzuki. “Using Siemens’ product lifecycle assembly and tryout, and off to management (PLM) tools, now it takes production. about 90 hours – a 50 percent improvement.” The entire process is similar to that used by other original equipment manufactur- Standardization delivers 10 hours ers (OEMs), except Maruti Suzuki Die Shop saved per die involving cam units has made significant process advance- Similarly, Maruti Suzuki Die shop has ments in a number of areas, especially brought design standardization to its relative to its die structures preparation cam unit creation. Instead of modeling and building. each cam one by one, the company has created standard parts to automatically build the cam unit. The company has achieved a time saving of 10 hours per die involving cam units, which translates to potentially exponential savings depend- ing on the project. Solutions/Services then 60 percent within the NX next two to three years,” says www.siemens.com/nx Vidur. “We have a vision and we feel Siemens’ technology Teamcenter has much to offer to make it www.siemens.com/teamcenter happen.”

Customer’s primary business For example, Maruti Suzuki Die Shop plans to move from the Maruti Suzuki India Limited – visual editing tools of NX to its powerful also called MSIL, formerly Teamcenter manages family of parts Knowledge Fusion capabilities, such as Maruti Udyog Limited and a repository, resulting in another 10 hours saved per die for standard parts Product Template Studio, which a number subsidiary of Suzuki Motor of OEMs are already using. Corporation of Japan – is To date, Maruti Suzuki Die Shop has India’s largest passenger car 75-80 family members in its standard Maruti Suzuki Die Shop’s goal is to do the company, accounting for parts library, enabling the quick creation entire validation in a wholly integrated around 50 percent of its of thousands of standard parts. The family environment that includes forming simula- domestic market segment. of parts library is managed by Siemens’ tion, dynamic kinematics simulation, etc. Maruti Suzuki offers 13 Teamcenter, which connects people This would essentially eliminate the some- brands, as well as more than throughout the lifecycle with a single times awkward and time-draining steps 80 brand variants. source of product and process knowledge. involved in transferring data through the www.marutisuzuki.com Maruti Suzuki Die Shop’s leveraging of a initial graphics exchange specification family of parts repository has resulted in (IGES), standard for the exchange of prod- Customer location additional important die development uct model data (STEP) or other formats. New Delhi process efficiencies – 10 hours saved per As part of this new approach, the com- India die for standard parts. pany is also evaluating the dynamic colli- sion checking tools of Siemens to identify “Using the die design tools of NX and col- and eliminate any interference that may “We plan to slash at least laboration capabilities of Teamcenter – occur during die operations. one month in the first year through cloning, cam standardization and of the die development family of parts knowledge re-use – we’ve The bill of materials (BOM) represents cycle, then two months in realized significant time savings in the another item that Maruti Suzuki Die Shop the coming years. Siemens’ development cycle,” says Santosh Kumar, wants to leverage for time and cost sav- solutions are integral to deputy manager – Die Design, Die Shop, ings. Currently the designers manually making our vision a reality.” Maruti Suzuki. “Rework is dramatically enter each material item, including associ- Joy Lakra down. Quality is up. Costs per die have ated data, onto a spreadsheet – a very GM – Body Engineering decreased. Considering the number of time-consuming process. “The plan is to Maruti Suzuki brands we market, including 80 plus vari- generate the BOM automatically from the ants, we are quite excited about our 3D models,” says Vikram Kathula, deputy opportunities for exceptional results from manager – Die Design, Die Shop, Maruti a continuously improving stamping opera- Suzuki. “While this will require some pro- tion. We are definitely headed in a very cess change on our part, it’s part of our good direction.” overarching plan. We have a vision for continuous improvement across our entire A vision for continuous die process die design and related processes – one improvement that results in constant quality, time and “We plan to slash at least 50 percent off cost improvements for our customers, the draw die design cycle in the first year, partners and shareholders.” Siemens Industry Software

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