50 Manufacturing Companies – Bajaj Auto

Bajaj Auto believes in two kinds of improvements: Technology and system improvement. In terms of technology improvements, it would mean seeking out ways to execute unmanned production, while improving quality. “Quality in the automotive sector means ways to improve the milli values of the component, so that clean components can be delivered to the assembly line. Often, few companies care to give importance to the washing operation and this is where we paid attention and it has paid off. Components are washed and dried before they reach the assembly line. This is an important aspect from the engine and durability point of view,” says Zanzari.

Another innovation the company carried out is ensuring higher quality of components like the washer and getting better quality in terms of bore-to-face perpendicular tip, and surface finish which has helped in improving the engine quality.
The company has preferred to rope in cobots and automate lines for fewer dependence on manpower. “Manpower saving  is a by-product, but this move has given us consistent quality and from the cost point of view helped us too. In terms of machining, Bajaj Auto is moving towards Vertical Machining Centres (VMC) from HMC as it helps bring down the CNC costs,” he adds.
Always the vigilante, it has moved to environment-friendly paints, while reducing paint sludge.

In terms of fabrication, over the last five years, Bajaj Auto has moved to installing robots and the same has been emulated in its supply chain too. Considering that seasonal demand can double or triple, hiring manpower has been challenging. “Moving to robots helped us with the required increase in numbers and eliminated the challenge of training employees too. The assembly line has seen a  recent conversion to MES (Manufacturing Execution System) and all critical SOPs, right from production scheduling to outgoing goods is managed by MES,” he says.

At the shop floor, there is a constant effort to improving assembly operations and much effort is spent in automating processes as it offers consistent quality and fulfils the aim of delightful customers, which is the focus area for Bajaj Auto.