In manufacturing, where precision, efficiency, and cost-effectiveness are paramount, Mahindra & Mahindra has embraced shopfloor automation as a cornerstone of its strategy, writes Upendra Kasbekar.

Mahindra’s transition towards an automated shopfloor is underpinned by integrating smart technologies, which streamline operations while ensuring quality and consistency. Advanced systems such as robotic arms, Automated Guided Vehicles (AGVs), and data-driven monitoring platforms are central to the initiative. These technologies optimise assembly lines, reduce human errors, and enhance the overall output. For instance, Mahindra’s robotic welding systems ensure impeccable precision, achieving weld accuracy rates of over 98 per cent. This not only guarantees product integrity but also significantly reduces production defects. Jalaj Gupta, Business Head of Commercial Vehicles at Mahindra Group, highlighted, “Our automated systems are designed to enhance efficiency without compromising quality. Automation is a testament to our commitment to innovation and excellence.”

Robots in action

At the heart of Chakan’s operations lies a range of industrial robots tailored to specific tasks, each contributing to the seamless production of Mahindra’s vehicles. From welding to assembly, painting, and testing, automation ensures that every vehicle meets the company’s stringent quality standards. For instance, articulated robotic arms dominate the footprint on the welding lines, where they create the chassis and body frames with impeccable precision. These robots, sourced from global leaders like ABB, deliver weld accuracy rates exceeding 98 per cent, ensuring a robust structure for each vehicle. The robots are programmed to handle over 1,000 weld points per unit, optimising both speed and consistency.

Moving to assembly, collaborative robots (cobots) work alongside human technicians to fit intricate components such as engines and dashboards. These cobots excel in repetitive tasks, such as fastening bolts and aligning panels, reducing errors and boosting overall efficiency.

Paint automation

One of the most sophisticated processes at the Chakan plant is automated painting, executed by precision sprayer robots. These machines apply consistent layers of paint while minimising waste and environmental impact. The robots utilise electrostatic technology to ensure optimal paint adherence, reducing over spray and cutting paint consumption by 18 per cent. The facility’s automated paint booths are also equipped with real-time monitoring systems that adjust parameters such as spray pressure, temperature, and humidity. This meticulous control ensures a flawless finish, aligning with Mahindra’s commitment to quality and aesthetics.

Enhanced data-driven insights

Central to Mahindra’s automation strategy is data management and analysis, a feature comparable to its telematics solutions like iMAXX. On the shop floor, real-time data collection and processing play a critical role in predicting potential issues before they escalate. These systems monitor parameters such as machine performance, material flow, and energy consumption, enabling proactive maintenance and reducing downtime by up to 40 per cent.

Similar to the diagnostic capabilities of iMAXX, Mahindra’s automated manufacturing systems leverage predictive analytics. For example, if a machine exhibits signs of wear or deviation from optimal performance metrics, alerts are triggered to prompt timely interventions. This approach ensures that production lines remain uninterrupted, translating to consistent delivery schedules and minimised operational costs.

Fueling efficiency with automation

Efficiency has always been a hallmark of Mahindra’s operational philosophy. By incorporating smart automation, the company has achieved substantial energy savings and optimised resource utilisation. The implementation of intelligent conveyors and material handling systems ensures seamless transitions across various stages of production. Notably, Mahindra’s automated processes have reduced material wastage by 15 per cent as per claims, aligning with its sustainability goals. “Automation allows us to utilise every resource to its fullest potential. This not only benefits our bottom line but also reflects our responsibility towards the environment,” stated Gupta.

Empowering the workforce

Contrary to the notion that automation replaces human roles, Mahindra’s shopfloor automation strategy places a significant emphasis on upskilling its workforce. Through dedicated training programs, employees are equipped with the knowledge and skills required to operate and manage advanced systems. Gupta explained, “While technology takes care of repetitive and precision-intensive tasks, our workforce is empowered to focus on more strategic and creative responsibilities. This synergy of man and machine is the future of manufacturing.” Mahindra has established centralised training hubs to ensure the seamless adoption of automation technologies. These centres, located in key regions such as Pune, Chennai, and Nagpur, provide comprehensive programs covering robotic systems, data analysis, and maintenance protocols.

Advanced automation

Mahindra’s automated assembly lines stand as a testament to its commitment to modernisation. These lines are equipped with robotic systems capable of executing complex tasks, such as engine assembly and quality inspection, with unparalleled accuracy. A standout feature of the automated shopfloor is its end-of-line testing capabilities, where sensors and cameras inspect each component for deviations. With a defect detection rate exceeding 95 per cent, this system ensures that only vehicles meeting the highest standards roll off the production line.

Material Handling

The company has also implemented AGVs for intraplant logistics. These self-guided vehicles transport components across the facility, eliminating manual handling and reducing transit times by up to 25 per cent.  These self-driving vehicles navigate pre-defined routes using LIDAR technology and magnetic tracks. AGVs handle a variety of tasks, from delivering raw materials to assembly lines to transferring finished goods to storage areas. More importantly, it ensures a safer workplace by minimising human involvement in potentially hazardous zones.

Safety and reliability

Safety is a non-negotiable aspect of Mahindra’s automation strategy. The incorporation of collision detection systems and emergency stop mechanisms ensures a safe working environment for both machines and humans. In line with Mahindra’s over  arching commitment to reliability, its automated systems undergo rigorous testing and calibration. This ensures that every product meets the stringent quality standards.

Sustainability through automation

Automation has also played a pivotal role in advancing Mahindra’s sustainability initiatives. By reducing energy consumption and material waste, the company aligns its manufacturing processes with global environmental standards. For instance, the implementation of energy-efficient robotic systems has resulted in a 20 per cent reduction in electricity usage across its facilities. Moreover, Mahindra’s automated painting systems, which utilise precision sprayers, minimise overspray and reduce the consumption of hazardous materials by 18 per cent.

Challenges and overcoming resistance

Adopting shopfloor automation does not come without its set of challenges. Small-scale operators and traditionalists often perceive automation as a threat to job security. However, Mahindra has proactively addressed these concerns through transparent communication and demonstrable results. The company’s 60 per cent renewal rate for its automation systems, much like its iMAXX telematics, reflects growing acceptance among stakeholders. By showcasing the tangible benefits of automation such as cost savings, enhanced quality, and improved safety, Mahindra has successfully countered resistance, informed Gupta.

The future of manufacturing

As the automotive industry evolves, the role of automation on the shop floor is set to expand further. Mahindra’s forward-looking approach includes the integration of Advanced Driver Assistance Systems (ADAS) in its production lines and the adoption of Artificial Intelligence (AI) to enhance decision-making processes.  “Automation is not the end goal but a stepping stone towards a smarter, more connected future. We are continually innovating to stay ahead of the curve,” remarked Gupta.

The company’s focus on predictive maintenance, remote monitoring, and real-time adjustments ensures that its facilities remain at the cutting edge of manufacturing technology. Mahindra’s shopfloor automation journey exemplifies its dedication to innovation, efficiency, and sustainability. By combining cutting-edge technologies with a human-centric approach, the company has redefined manufacturing in the Indian automotive sector. ACI

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