PGDM – RMM and PGDM – Ops & SCM’s Industrial visit to Volkswagen Pune Plant.
You are here: Home \ blog \ PGDM – RMM and PGDM – Ops & SCM’s Industrial visit to Volkswagen Pune Plant.
21 February 2018 - 12:55, by , in blog, ITM Institute, PGDM, Comments off

INTRODUCTION

Volkswagen shortened to VW, is a German automaker founded on May 28, 1937 by the German Labour Front under Adolf Hitler and headquartered in Wolfsburg. It is the flagship marque of the Volkswagen Group, the largest automaker by worldwide sales in 2016.

Volkswagen Group sells passenger cars under the Audi, Bentley, Bugatti, Lamborghini, Porsche, SEET, Skoda and Volkswagen marque; motorcycles under the Ducati brand; and commercial vehicles under the marques MAN, Scania and Volkswagen Commercial Vehicles.


Volkswagen Pune plant

The Volkswagen plant in Chakan occupies a total area of over 2.3 million square metres (572 acres), with buildings covering about 1,15,000 square metres.

A workforce of over 3,500 people was engaged in building it during its peak construction stages. The plant was built in a record time of 17 months, with an investment commitment of INR 3,800 Crores (580 million Euros) by Volkswagen India Private Limited. It is the largest investment by a German company to date in the growing Indian market.

Target Production – 550 cars per day

Actual Production – 480-490 cars per day


Safety instructions

  1. Do not touch anything

  2. Be in the queue

  3. Remain inside the green line which is for walking purpose only

  4. Listen to the instructions carefully


1ST STOP

In this section Body parts of the cars are put together and Welding activity occurs

This section is spread in 38000 sq. mtr. area

80 jobs per hour are completed

380 workers per shift

Total 3 shifts

31 % of the work was automated in that section and total of 35% automation was there in whole of the Volkswagen plant.

The reason for 35% of automation was, the manpower is cheap in India than in Germany.

And the automation is installed where the highest level of precision is required.

Also there was a dedicated area for the workers and engineers, a tea and snack section where shop floor meeting occurs between top management and middle and lower management and the workers. It is a platform for interaction and asking questions where they discuss – What brand is doing at present level, How everything is going on, the targets or any problem faced.

The workers are ITI pass out technicians


2ND STOP

INLINE MEASUREMENT SYSTEM

In this sevtion, 4 robots 2 on each side measure the body of the car for any measurement defect. Each robot is installed with a HD camera at the top, a spherical structure where setting for measurement are done different for different car models. If found any defect the door in the front will not open, and if there is no defect the car will sent to next section.


3RD STOP

ROLLER AND HAMMING PROCESS

In this section, the car doors i.e. the inner and outer part of the car doors are joined together.

This is a 100% automated process.


4TH STOP

LASER WELDING

The welding take place in a closed box and cameras are installed inside to monitor the process. Copper wire is used for better dynamics and stability.

Quality and safety is DNA of Volkswagen.

To ensure how safe car are, rigorous quality checks are carried out.

Polo and Vento model have same interior body only the exterior are different.

In prototype of both the cars there were some highlighted areas in red and black color.

Red highlighted parts are crucial zones where added reinforcement is required.

Black highlighted parts are standard reinforcement, marketing campaigns on accidents that occurs on highway are done to get the data.

And the Volkswagen Polo was the first car to get the First star rating.

Also the Volkswagen uses manipulators to transfer or attach and detach the car components life car roofs.


PAINT SHOP

Here the body of the car is primed and painted, 11 different variants of colours are available. The Volkswagen is the only brand which provides 6 year of anti-corrosion warranty which is very specific to Volkswagen.


ASSEMBLY SHOP

Here car is fully produced


Rework section

In this section the car is manually checked by the team for very defects, if the car found is up to the standard it is sent to the test drive section, a 7.5 km track where car is checked on various parameters.

Both the right and left had drive cars are produced. Right hand drive cars for domestic market i.e. for India and left hand drive for export to other countries. Mexico is the biggest exporter of cars.

A mirror was also placed in between to ensure that the workers had all their safety gears on.

The Volkswagen also incorporate Just-in-time method to ensure all the spare parts and body parts are readily available on time.

The plant layout was designed so as to utilize maximum space, the top space is accommodated by conveyors used to transfer cars from one line to another.


Assembly Process begins

Freshly painted cars are offloaded form the conveyor, doors are detached and the car is send to the cockpit assembly where dashboard is installed. Employees use manipulator to install dashboard. There are different types of dashboard like conventional dashboard with music system, touch screen dashboard, left and right hand drive dashboard.

Identity is given to every car, a sheet of paper is attached to every car where all the details are given like what is the model of car, left or right hand drive, this makes easier for the shop floor worker to understand.

Volkswagen also maintains the spare parts machinery to ensure there is no shortage of machine parts in case there is any defective part.

The Volkswagen also runs Volkswagen Academy where it trains ITI graduates for 3.5 years and after training is finished they deploy them in various line and shop.


Chassis line

Car actually become car at chassis marriage point. Car body comes form top and drive train comes form bottom, they stops at a particular point, lifter lifts the car and bolting process is done. After the car is send to the tyre assembly where car gets its tyre. Top variant car gets alloy wheel and entry level get steel wheels.

Engine comes in two variants 1.5 lt. and 2 lt.

After car is fully produced it has to undergo various tests like wheel alignment test, roller bearing test and shower test for leakage. After these tests car is send for test drive. The quality batch is send to the car dealers.


LEARNINGS

  1. How the Volkswagen maintains its brand image by providing best quality and safe cars.

  2. How top management interact with workers and work together to achieve goals.

  3. How Volkswagen keeps its employee happy.

  4. How the work is distributed from top level to lower level.

  5. Plant layout is such that so as to utilize the maximum space and maintain the free flow of man and machinery.

  6. Just in time method is used in which materials or components are delivered immediately before they are required in order to minimize storage costs.

  7. Think blue factory concept is used which is minimizing the water and electricity losses.

  8. Here are the key points of Volkswagen production system on which it works –

    1. Optimal investment

    2. Logistics

    3. Productivity

    4. Ramp up excellence

    5. Think blue factory

    6. Sustainable structure

    7. Demographics and Ergonomics

    8. Team of future

    9. Quality

    10. Designed for manufacturing

    11. Factory of the future