How Universal Robots Helped Bajaj Auto to Automate Its Assembly Lines

September 13, 2019

Today’s digitization and new business models have revolutionized all industries, and the automotive sector is no exception. The industry is going through a massive transformation as breakthroughs in technology occur every matter of minutes. However, this digital transformation in the automotive sector requires talent, a huge investment and most importantly a perfect solution that can drive innovation to the industry’s business process.

Bajaj Auto Ltd. is such a company in the auto industry, commitment to producing motorcycles of best in class quality while intensifying productivity and ergonomics that accelerate the company’s growth.


The Background 

Bajaj Auto Limited is the world’s third-largest and an Indian global two-wheeler and three-wheeler manufacturing company. The company manufactures motorcycles, scooters and auto rickshaws. Based in Pune, Maharashtra, Bajaj Auto is a part of the Bajaj Group. The company is the first Indian two-wheeler manufacturer to deliver 4-stroke commuter motorcycles with a sporty performance for the Indian market, which was then dominated mostly by mileage-based products from Hero Honda and TVS Motors.


The Challenge: Bajaj Auto Seeks Solutions to Automate Its Assembly Lines

As the automation advances the manufacturing industry over the last few decades, Bajaj Auto was looking for solutions to automate its assembly lines. Because, two-wheeler assembly lines are highly labour-intensive, spatially challenged and they have physically taxing movements that require high-end precision. While trying to automate these lines, one of the basic requirements was for standardization. Moreover, the company also wanted to be cognizant of the requirements of the large women workforce at Bajaj.


The Solution: Bajaj Chooses Universal Robots and Deploys Their Cobots

After an intensive study of the options that were available in the market, Bajaj Auto chose Universal Robots primarily due to the collaborative nature of its robots. The key benefits of Universal Robots’ products such as their compactness, low payback period, flexibility, lightweight, cost-effectiveness, accuracy, and safety. Besides these key benefits, Bajaj Auto is convinced with the suitability of Universal Robots for its standardized offerings.

After three months of extensive testing of Universal Robots’ cobots at its facilities, Bajaj deployed cobots as a standardized solution for all its functional requirements. Several processes such as material handling and machine tending were collaboratively handled by cobots and Bajaj employees. Moreover, new decal applications which are now patented by Bajaj were also devised by the company to make the most out of the flexibility provided by the cobots.


The Outcome

Leveraging Universal Robots’ cobots, Bajaj Auto sees benefits such as zero annual maintenance costs, reduced power consumption and retention of IP within the company that are organically driving forward the growth of the organization. Additionally, almost 50% of Bajaj’s workforce is comprised of women on this assembly line.