maruti suzuki-project report.pdf

8/14/2019 Maruti Suzuki-Project report.pdf

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MARUTI SUZUKI INDIA LIMITED

ACKNOELEDGEMENT

I take this opportunity to express my sincere thanks and deep gratitude to all those

people who extended their whole hearted co-operation and have helped me in

completing this project successfully.

First of all, I would like to thank Mr. S. K Bhatia, Dy. Manager (HRD,for giving me an

opportunity to do my training in this prestigious organization. Id also like to express my

sincere gratitude towards Mr. !.K. Ar"ra (A##tt. Genera$ Manager, %$ant

Maintenan&e ,Mr. S. %ra'haar (Sr. Manager, %$ant Maintenan&e ) Mr. Man"*

Attri (Engineer, %$ant Maintenan&efor their guidance help which ena!led me to get

the re"uired data information re"uired to finish my assignments #heir inspiring

suggestions and timely guidance ena!led me to perceive the various aspects of the

projects in a new light.

I would also like to thank all senior mem!ers and workers of $lant %aintenance for

having guided and encouraged me throughout the duration of the project. In all I found a

congenial work environment in %&I'and the completion of the projects will mark a new

!eginning for me in the coming days.


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%RO+ECT RE%ORTON

&tudy of vehicle manufacturing processes from raw materialto finish vehicles.

&tudy of (ehicle #racking &ystem )(#&* e"uipment interface.

+uto closing system )oncept, design fa!rication*of floor service pit to improve safety of human.

&%I##/0 1

-------------------2#31/+4 /'/#4I+' /56I5//4I56

1%+ I5I##/ 7F /56I5//4I56

F+4I0++0


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%aruti &uzuki is one of India8s leading automo!ile manufacturers and the market leader

in the car segment, !oth in terms of volume of vehicles sold and revenue earned. ntil

recently, 9:.;:< of the company was owned !y the Indian government, and =2.;< !y

&uzuki of >apan. #he Indian government held an initial pu!lic offeringof ;=< of the

company in >une ;??@. +s of %ay 9?, ;??A, 6ovt. of India sold its complete share to

Indian financial institutions. Bith this, 6ovt. of India no longer has stake in %aruti

dyog.

%aruti dyog 'imited )%'* was esta!lished in Fe!ruary 9C:9, though the actual

production commenced in 9C:@ with the %aruti :??, !ased on the &uzuki +ltokei car

which at the time was the only modern car availa!le in India, its8 only competitors- the

3industan +m!assadorand $remier $adminiwere !oth around ;= years out of date at

that point. #hrough ;??2, %aruti has produced over = %illion vehicles. Martiare sold in

India and various several other countries, depending upon export orders. ars similar to

%aruti )!ut not manufactured !y %aruti dyog* are sold !y &uzuki and manufactured in

$akistanand other &outh +siancountries.

#he company annually exports more than =?,??? cars and has an extremely large

domestic market in India selling over A@?,??? cars annually. %aruti :??, till ;??2, was

the India8s largest selling compact car ever since it was launched in 9C:@. %ore than a

million units of this car have !een sold worldwide so far. urrently, %aruti +ltotops the

sales charts and %aruti &wift is the largest selling in +; segment.

0ue to the large num!er of %aruti :??s sold in the Indian market, the term D%arutiD is

commonly used to refer to this compact car model. #ill recently the term D%arutiD, in

popular Indian culture, was associated to the %aruti :?? model.
http://en.wikipedia.org/wiki/Government_of_Indiahttp://en.wikipedia.org/wiki/Suzukihttp://en.wikipedia.org/wiki/Japanhttp://en.wikipedia.org/wiki/Initial_public_offeringhttp://en.wikipedia.org/wiki/May_10http://en.wikipedia.org/wiki/2007http://en.wikipedia.org/wiki/2007http://en.wikipedia.org/wiki/Suzuki_Altohttp://en.wikipedia.org/wiki/Kei_carhttp://en.wikipedia.org/wiki/Hindustan_Ambassadorhttp://en.wikipedia.org/wiki/Premier_Padminihttp://en.wikipedia.org/wiki/Pakistanhttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/Maruti_800http://en.wikipedia.org/wiki/Maruti_Altohttp://en.wikipedia.org/wiki/Suzukihttp://en.wikipedia.org/wiki/Japanhttp://en.wikipedia.org/wiki/Initial_public_offeringhttp://en.wikipedia.org/wiki/May_10http://en.wikipedia.org/wiki/2007http://en.wikipedia.org/wiki/Suzuki_Altohttp://en.wikipedia.org/wiki/Kei_carhttp://en.wikipedia.org/wiki/Hindustan_Ambassadorhttp://en.wikipedia.org/wiki/Premier_Padminihttp://en.wikipedia.org/wiki/Pakistanhttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/Maruti_800http://en.wikipedia.org/wiki/Maruti_Altohttp://en.wikipedia.org/wiki/Government_of_India


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%aruti is clearly an Hemployer of choice for automotive engineers and young managers

from across the country. 5early A=,??? people are employed directly !y %aruti and its

partners.

#he company vouches for customer satisfaction. For its sincere efforts it has !een rated)!y customers*first in customer satisfaction among all car makers in India for nine years

in a row in annual survey !y > 0 $ower +sia $acific.

%aruti &uzuki was !orn as a government company, with &uzuki as a minor partner to

make a people8s car for middle class India. 7ver the years, the product range has

widened, ownership has changed hands and the customer has evolved. Bhat remains

unchanged, then and now, is %arutis mission to motorize India.

BACKGROUND O- THE INDIAN AUTO INDUSTR

+lthough the Indian car industry was esta!lished in the late forties, there was little

growth or technical progress, as passenger cars were given very low priority in the

scheme of entralized /conomic $lanning. In the 9C:?s, the car industry was

undergoing technological stagnation and was characterized !y low production volumes,

high cost and low productivity. #he consumer had very little choice and the market was

selling just around @?,??? cars per year.

#here was a clear need to provide a cost effective, relia!le and "uality car to the

customers. %aruti &uzuki India 'imited was incorporated in such a scenario as a fully

owned 6overnment ompany on Fe!ruary ;2, 9C:9 with a resolve to !ring a!out

expansion and technological modernization, of the automo!ile sector. #hus %&I', when

started was entrusted with the task of achieving the following policy o!jectivesJ


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%odernization of Indian +utomo!ile Industry.

$roduction of (ehicles in large volumes, which was necessary for economic

growth.

$roduction of Fuel-efficient vehicles to conserve scarce resources.

Ch"i&e "/ 0r"1&t an1 &"$$a'"rat"r

#o achieve the a!ove o!jectives, one of the foremost tasks !efore. %aruti &uzuki

India 'imited was to determine the most suita!le product mix and to select the

most suita!le foreign partner who would !e willing to accept %&I' Ks

re"uirements in terms of product mix, technology transfer, and e"uality

participation and had the

re"uired technological expertise and experience in producing high "uality, relia!le

and fuel efficient vehicles.

+fter extensive discussion with several major /uropean and >apanese car

manufacturers, %' chose &uzuki %otor orporation )&%* further increased its e"uity

holding to =?< in the year 9CC;, converting . %aruti &uzuki India 'imited, into a 5on-

6overnment ompany with a total /"uity !ase of 4s. 9@;;.C; million.

BACKGROUND O- SMC

&LI was founded in 9C?C as &uzuki 'oom %anufacturing ompany. It started

manufacturing motorcycles in 9C=; and has !ecome a world leader in the manufacture

of two-wheelers .&LI started producing cars from 9C==.#oday it is >apans largest

manufacturers of small , fuel-efficient cars. +t present the companys name is &LI

%7#74 74$74+#I75.


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SUZUKI AND MARUTI2S 3ORLD4CLASS MANU-ACTURING

-ACILITIES AT MANESAR

7n Fe!ruary ?E,;??A %r. hupendera &ingh 3ooda , hief %inister of 3aryana

inaugurated three world-class manufacturing facilities set up !y &% and %aruti &uzuki

India 'imited.

The /a&i$itie# inagrate1 5ere a# /"$$"5#6

%&I's fourth car +ssem!ly plant.

+ diesel engine and transmission plant, set up under a joint venture

of &% and %&I'called &uzuki $ower train India 'imited )&$I'*

&%s two-wheeler plant in 6urgaon, &uzuki %otorcycle India

$rivate 'imited )&%I$'*.

INTRODUCTION TO MARUTI SUZUKI INDIA LIMITED

+ 'icense and a >oint (enture +greement was signed with &uzuki

%otor ompany of >apan, in 7#. 9C:;

%arket leader with over =2< &hare in 0omestic ar %arket

/xporting cars to over A? countries around the world including most

advance Bestern /uropean %arkets.

%aruti has revolutionized the Indian +utomo!ile and omponent

Industry and has set standards in "uality of products and service.

MARUTI INSTALLED CA%ACIT


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%LANT 7 899,999 nit#

%LANT 8 7:9,999 nit#

%ALNT ; 7:9,999 nit#

%LANT < 799,999 nit#

COM%AN MISSION

A $ea1er in the In1ian At"="'i$e In1#try.

Creating C#t"=er De$ight an1 Shareh"$1er# 5ea$th.

A 0ri1e "/ In1ia>

LEADERSHI%

By Maret #hare an1 'ran1 e?ity

By "0erati"na$ 0ra&ti&e#

By 0e"0$e #trategy

CUSTOMER DELIGHT

!a$e# /"r ="ney


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@a$ity

Seri&e

SHARE HOLDERS 3EALTH

High %r"/ita'i$ity ) I=age

A %RIDE O- INDIA

A# a &"r0"rate &itien

%r"1&t#

%e"0$e

%ra&ti&e#

C#t"=er#

!ALUES

C#t"=er O'#e##i"n

-a#t, -$ei'$e, -ir#t M"er


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Inn"ati"n an1 &reatiity

Net5"ring an1 0artner#hi0

O0enne## an1 $earning

@UALIT %OLIC

#o increase consumer satisfaction through continuous improvement of products and

services, this is achieved !y following $0+ functions and levels of %aruti

7rganizations.

PLAN

DO

CHECKACT

QUALITY

POLICY


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@UALIT TOOLS

= &

2 %

@ %

@ 6

@ L

3hat i# :S

SEIRI M $47$/4 &/'/#I75

SEITION M +44+56/%/5#

SEISO M '/+5I56

SEIKETSO M '/+5'I5/&&

SHITSUKE M 0I&I$'I5/

3hat i#


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MACHINE

MATERIAL

METHODS

3hat i# ;M

In +a0ane#e Langage ;M i#6

MURI M I575(/5I/5/

MUDA M B++6/

MURA M I575&I/51

3hat i# ;G

In +a0ane#e Langage ;G i#6

GENCHI M 67 #7 +#+' $'+/

GENBUTSU M &// #3/ +#+' #3I56

GEN+ITSU M #+L/ +$$47$4I+#/ +#I75


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INTRODUCTION TO !ARIOUS MODELS

%RODUCT RANGE

MODELS S%ECI-ICATIONS EAR O- LAUNCH

%+4#I :?? )FI4

%70/'*

ACE, 3+#3+L 0//%/4 9C:@

7%5I ACE, %( 57(/%/4 9C:2

61$&1 CC;, 2B0 0//%/4 9C:=

%+4#I :?? )%70IFI/0* ACE, 3+#3+L +$4I' 9C:E

%+4#I 9??? CCE, &/0+5 7#7/4 9CC?

/5 CCE, 3+#3+L 7#7/4 9CC@

///% 9.@' 'G 9;CE, &/0+5 57(/%/4 CC2

///% 9.@' (G 9;CE, &/0+5 57(/%/49CC=

///% 9.@' +G 9;CE, &/0+5 >5/ 9CCE

/5 +G )+#7%+#I* CCE, 3+#3+L 7#7/4 9CCE

61$&1 LI56 9;CE, 2B0 57(/%/49CCE7%5I )/* ACE, %( 0//%/4 9CCE

61$&1 )/* 9;CE, 2B0 0//%/4 9CCE

%+4#I :?? )5/B

%70/'*ACE, 3+#3+L &/$#/%/4 CCA

///% C: 9;CE, &/0+5 7#7/4 9CCA

5/B 7%5I 7%5I-/ ACE, %( F/4+41 9CC:

/5 (G /5 (G

+#7%+#ICCE, 3+#3+L

>'1 9CC:

/5 0

9;??,

3+#3+L +6 9CC:


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%aruti has !elieved, since the very !eginning that it is its employees who could make it

into an organization with a difference .+ccordingly, as against the traditional hierarchical

&ystem of management, which causes unnecessary delays in decision-making, we have

!uilt up a flat organization with a family type of atmosphere at our place of work.

#he company is divided into different divisions according to the various functional areas.

+ 0ivisional %anager heads each 0ivision. 0ivisions are further divided into

0epartments that are headed !y 0epartment %anagers who report to the respective

0ivisional %anagers. 0esignations in the company are !ased on the functional

responsi!ility and not levels as in terms of the companys philosophy designations and

functional responsi!ility are de-linked from the salary levels.

#he total operations of the ompany are divided into 0ivisions like %arketing &ales,

&pares, /ngineering, N.+. &ervices, $roduction, $roduction /ngineering, %aterials,

Information &ervices, Finance, $ersonnel +dministration, etc. /ach division is

furthering divided into 0epartments and headed !y 0epartmental %anagers who is

assisted !y &upervisory /xecutives.

The hierar&hy 1iagra= "/ MSIL


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DI!ISIONS AND DE%ARTMENTS


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C"r0"rate Seri&e# Dii#i"n

'egal &ecretarial 0epartment

orporate ommunication ell $rotocol

&trategic Initiative 6roup

4ecruitment %anagement ompensation

H=an Re#"r&e Dii#i"n

/mployee 4elations 0epartment

/sta!lishment #ime 7ffice

Factory +dministration 0epartment

7rganizational 0evelopment 0epartment

%r"1&ti"n Dii#i"n

$lant- 9

$lant- ;

$lant- @

$lant- E at %anesar

%r"1&ti"n Engineering

$roduction /ngineering 0ivision

$roduction &ervice 0ivision

Engineering Dire&t"rate


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N+I5 0ivision

&ervice 0ivision

&ervice- 9-=

%&&)0*

$arts Inspection 0ivision

/ngineering 0ivision

S00$y Chain 1ii#i"n

&upply hain- 9,;,@ 0ivision

&hipping transport 0epartment

Imports 0epartment

onsuma!les 0epartment

In/"r=ati"n Te&hn"$"gy Dii#i"n

+pplication 6roup9 )+69*

+pplication 6roup; )+6;*

+pplication 6roup@ )+6@*

Information #echnology &trategies)I#&*

I# 7peration and &ervices)I#7&*

Mareting ) Sa$e# Se&retariat

%arketing &trategy 0evelopment

%arketing

&ales


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/xports

Be!-I#, /-ommerce

S0are %art# Dii#i"n

&pare $arts $rocurement

Barehousing 0ispatch

&pare $arts &ales

+ccessories

!igi$an&e Dii#i"n

&ecurity Bing

(igilance Bing

-inan&e Dii#i"n

udget, ost +ccounts 0epartment Income +ccounting

#he total project costs, priority, completion time and personnels re"uired were

estimated. Initial plans were drawn up as to how the project would proceed to its final

implementation, while running the existing system so that companys informationneeds were not affected.


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%r"1&ti"n Dii#i"n "/ Marti Si In1ia Li=ite1

$roduction 0ivision in %aruti &uzuki India 'imited has !een renamed as

$roduction usiness (ertical )$(* after inclusion of $rojects, $roduction

/ngineering, (ehicle Inspection &upplier Nuality +ssurance divisions in it.

Ma*"r &"=0"nent# "/ %B!

$ress &hop and lanking 'ine

Beld &hop )9,; @*

$aint &hop )9,;, @*

/ngine +ssem!ly )9,;, @*

+ssem!ly &hop )9,;, @*

%achine &hop )9,;, @*

%aterials M G )9,;, @*

$lant maintenance

L asting

L /ngine

L %achine &hop

$roduction facility at %anesar $lant

&N+ )&upplier Nuality +ssurance*

$roduction /ngineering $rojects

(ehicle Inspection )(I*


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Milestones

9C:9 %aruti dyog 'td. was incorporated.

9C:; &tepped into a >( with &% of >apan.

9C:@ %aruti :??, a ACE cc hatch!ack, India8s first afforda!le car was

produced.

9C:2 Installed capacity reached 2?,??? units. 7mni, a ACE cc %(

was in production.

9C:= 'aunch of %aruti 6ypsy )CA?cc, 2B0 off-road vehicle*.

9C:E $roduced 9??,??? vehicles )cumulative production*.

9C:A /xported first lot of =?? cars to 3ungary.

9C:: Installed capacity increased to 9??,??? units.

9CC; &% increases its stake to =? per cent.

9CC2 $roduced the 9 millionth vehicle since the commencement of

production.

9CC= &econd plant launched, the installed capacity reached ;??,???

units.

9CCE 'aunch of ;2-hour emergency on-road vehicle service.

9CCA $roduced the ; millionth vehicle since the commencement of

production.

9CC: 'aunch of we!site as part of 4% initiatives.

9CCC

'aunch of %aruti - &uzuki innovative traffic !eat in 0elhi andhennai as social initiatives.

;??? I0#4 )Institute of 0riving #raining and 4esearch* launched

jointly with 0elhi government to promote safe driving ha!its.

;??9 'aunch of customer information centers in 3ydera!ad,

angalore, and hennai.

;??;

&% increases its stake to =2.; per cent. 'aunch of %aruti Finance with 9? finance companies in

%um!ai.

&tart of %aruti #rue value in %um!ai.


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;??@ $roduction of 2 millionth vehicle.

'isted on &/ and 5&/ after a pu!lic issue oversu!scri!ed 9?times.

;??2 %aruti closed the financial year ;??@-?2 with an annual sale of2A;9;; units, the highest ever since the company !eganoperations ;? years ago.

;??=. #he fiftieth lakh car rolls out in +pril, ;??=.

;??E. %aruti tops jd power csi survey for record seventh time in arow

;??A 6ovt of India awarded 7 &LI with coveted padma !husan

oard of directors give approval to new name %' to !ecomemaruti &uzuki India limited.

;??:. %-:?? crosses ;= lakh mark %&I' cele!rates &I'(/4 >I'//

%&I' launches national road safety program.

;??C apacity to manufacture expanded from :??,??? to a millionunits)6urgaon plus %anesar* annually

+ll India engineering export promotion council)//$* award.

%&I' achieved highest sales ever in 0ec;??C


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%RESS SHO%

#he press shop can !e regarded as the starting point of the car manufacturing process.

entrally located !etween weld 9, weld ; and weld @ supplies components to all the

three plants. #he press shop has a !atch production system whereas the plants have a

line production system. #he press shop maintains an inventory of at least two days. #he

weld shop as per the re"uirements picks the finished !ody parts from the press shop.

#hese may !e divided as +, and . K+ components are large outer components as for

example roof, door panels etc. #hese components are manufactured in the press shop

at %aruti due to design secrecy and huge investment re"uirements. K and K

components are manufactured !y joint ventures or !ought from vendors.

%r"&e## /$"5 "/ %re## Sh"0 a&tiity 64

9. urrently $ress &hop is producing sheet metal components for : runningmodels of %aruti &uzuki and one model of 6% India - #avera

;. #he lanking and stamping shop processes 9???? metric ton of steel O monthi.e. 2?? tons a day

Ma&hineJ

Stee$ &"i$Stee$ &"i$ B$anB$an %ane$%ane$


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Five #ransfer $ress ) 2??? ton , @=?? ton , ;2?? ton -9 ;2?? ton -; ,

;??? ton in terms of total capacity i.e. drawPtrimPpierceP!endPrestrike *

9 #andem line) 9=?? ton draw capacity *

#wo oil processing lines ) 47&' M &hear line lanking line * &$%

of E?

apacity of ==,??? strokes O day from 2?? tons of steel coils


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U00er 1ie

%re## Ma&hine 6%ass production presses are continuous flow transfer presses. &et

of 2 to = dies are mounted on single press complete panel comes out from press after

going through stamping, trimming piercing.

9:C die sets )including 9= die sets of 6%I* M 9 die set has avg 2 upper P

lower dies

SMED 6H&ingle %inute /xchange of 0ies new concept !eing adopted . #his concept

helps in changing of die set up within single digit minute )!elow C minutes* #his helps us

in improving machine utilization operating efficiency. &ince press machines are very

high cost investment any idle time lost due to die exchange will !e a cost to company.

L"5er 1ie


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&teel coil is raw material used to make !ody sheet metal parts. #hese are

4& coils made of mild steel having thickness from ?.E= mm to ?.: mm

weight from 9 ton to 2 tons.

&teel coils are received in !ulk "uantities from indigenous as well asforeign suppliers in the ratio of E? to 2? stored at a centralized storage

supplied to !lank cutting areas as per plan

&teel coils are fed to lanking 47&' lines !y overhead /7# cranes.

&heet is first de-coiled , cleaned, oiled fed to cutting or shearing areas of

!lanking or 47&' lines.

B$an


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oils are fed to !lanking line continuous supply of sheet to cutting dies

result in shaping of coils to plan !lanks.

lanks are cut !y stamping or shearing process are stacked one !y one toform large mass of !lanks

#hese stacks of !lanks are further sent to press machines for forming into

shape of !ody panels

%ane$

Sta& "/ '$an#


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lanks are supplied to press lines for pressing. lanks are converted to !ody panels

!y this process. $anels are stored in pallets which are supplied to Beld &hops for

making Bhite odies.

Panels re

stacked in

pallet

trolleys


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3ELD SHO%

#he !ody panels produced in the press shop and the other small components are joined

here to give the Hwhite !ody or Hshell. In a typical car !ody 92?? different components

are welded together. #he weld shops have the following facilities.

Belding jigs

&pot welding guns

Lawasaki welding ro!ots

3emming machines

$unching machines

%ROCESS OUTLINE6#he shop has different lines for different models, each of, which

is further divided into three partsJ

UNDER BOD63ere different under!ody panels are welded together. #hese comprise

of rear under!ody, central under!ody, front engine room panel. #hese under!odies are

put on the conveyor and welded together to give the under!ody.

MAIN BODJ +s the !ody moves on, the conveyor roof and side !ody panels )prepared

on the su! lines* are welded to it to give the main !ody. #he chassis num!er is punched

on the cowl top and it is welded to the front engine room panel.

3HITE BOD6#he doors, hood and !ack door are attached on the main !ody with the

help of !olts and screws to make it a Hwhite !ody. #he !ody is checked for dent,!urr

and spatter and these defects are repaired. +fter inspection and repairs the !ody is

called B7L. It is sent to the paint shop thereafter.


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%AINT SHO%

In the 0aint #h"0 /"$$"5ing 0r"&e##e# are &arrie1 "t6 4

#here are five plantsOunits that provide a uniform painting over the white !ody coming

from the weld shop. In paint shop all the models are painted on the same line. #he five

units areJ -

%re4treat=ent (%T6#he !ody is thoroughly washed to remove the dirt and oil

scales. #hen the !ody is treated with n$72 )phosphating* to prevent corroding

of the !ody.


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ED &"at6#his is done !y electric deposition method, at ;2?(-0 supply. +fter

applying the /0 coat the !ody is !aked in oven.

S"$4#ea$er an1 n1er &"at63ere the left in the !ody )due to welding* are filled

with sol-sealer to provide water proofing. nder coat is done on the surface

a!ove wheels to prevent damage of !ody in that portion.

Inter=e1iate &"at6 #his is done !y spray-painting method using 9? Lawasaki

4o!ots. +fter applying the coat, the !ody is dried in the oven. $ainting done is

!asically an intermediate coating to provide !ase for the final coat.

T"0 &"atJ #his is done !y spray-painting method using ;? Lawasaki 4o!ots. For

metallic coating, dou!le coats are applied and aluminum flakes are provided to

shine the metallic paints.

+fter inspection and touch up, the $7L,i.e. the paint !ody ok is sent to the assem!ly

shop.

In paint shop II, only /5 and +'#7 are painted. $aint used is 5erolac. #here are 2

coatings of paint.

9Q $hosphate coating

;Q /0 coating

@Q I coating

2Q #7$ coating

Inside portion of vehicle is painted manually and outside is !y 4o!ots.


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%RE TREATMENT6

efore sending vehicle to painting process pretreatment is done to

3ot water rinse &pray degreasing Di0 1e

B4 I

B4 (IB4 (B4 I(

B4 III B4 IISUR-ACE CONTROL

%HOS%HATING B4 (II

0I B+#/4 %IED %ROCESS

B&


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ED %AINTING6

/0 is electro deposition. (ehicle is dipped in the /0 solution. In this around @??( is

passed to make paint to !e attached. /0 is 9A< of paint rest is water and some

additives )/00, %*.

%ROCESS6

#he whole solution of /0 acts as electrolytic solution. (ehicle !efore coming to /0 dip,

it undergoes pre treatment. In that phosphating is done, in which n phosphate is made

to attach vehicle !ody which help in electro deposition, in this, vehicle acts as cathode

and paint as positive ions. Bhen current is passed paint will !e attracted !y vehicle till

its thickness will !e covered. /0 is very accurate to apply. #his is a!out whole process.

4insing is done after to remove excessive color. In rinsing industrial water is used which

will not !e left go waste. #hat will !e filtered and used again.

ED DI%B4 I B4 II

B4 I( B4 III RINSING B DI%%ING

7(/5B4 ( 0I B+#/4


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ULTRA -ILTRATION6

ltra filtration is the process in which all the rinse pipes and dip tanks will !e filtered and

cleaned, !y this way water is recycled. 3ere 7smosis process is used to filter water.

IC 0ainting6

I is intermediate coating in which @ colors are used. #hey are white, !lue and red.

7utside portion of vehicle is painted !y ro!ots and inside is done manually. $aint

thickness is taken care, after that vehicle is sent to I oven. 7ven temperature is 9C:PO-

=.

TO% COAT %ainting6

#op coating is done after checking in 0ry sanding II. #here are ; su! coatings ase coat

and lear coat. 3ere 99 colors are usedR : metallic and @ solid. 7nly metallic colors are

coated with clear coating. 3ere also outside portion of vehicle is painted !y ro!ots and

inside is done manually.

5ext vehicle will move to final inspection and will !e sent to assem!ly.

DR SANDING

Following repairs are doneJ


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9. 4oof sanding

;. &ide repair if any.

Following checking is doneJ

9. 0osing mark

;. &anding mark

SOL SEALING LINE6

&ealer appearance is given the preference.

@ types of guns are used.

9. $encil gun

;. Flat gun

@. lind gun

2. %oti gun

In this line followings are checkedR

9. $owder dust

;. /xtra sealer

@. $in hole in lamp area

2. &ealer appearance


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%ROCESS THROUGH %ICTURES6PB ON(WHITE BODY) PRE TREATEMENT

EE!TRO DEPO"ITION PRO!E""

DRY "ANDIN# I "O "EAIN# INE P$! !OATIN#


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I! O$EN I! !OATIN#

DRY "ANDIN# II

T! O$EN T! !OATIN#

%INA IN"PE!TION TO A""EMBY "HO


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ASSEMBL SHO%

In the assem!ly shop the !ody is loaded on an overhead conveyor. +s the conveyor

moves the !ody, fitments are made at various stations. #here are three +ssem!ly

&hops named +&&1-9, +&&1-; and +&&1-@. $lant ; and $lant @ have similar setup !ut

in $lant-9 there are separate assem!ly lines for separate models. #he assem!ly shop

has a continuous production system. #he assem!ly line can !e su!divided into the

followingsJ -

(a Tri= $ine

#he vehicle proceeds through a series of #rim workstations where team mem!ers !egin

!y installing weather stripping, moldings and pads. #hen they put in wiring, vents and

lights. +fter an instrument panel, windows, steering column and !umper supports are

added, it starts to look less like a shell and more like a car.

(&) Cha##i# Line


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#his is where many safety-related items are installed. #hings like !rake lines, tor"ue,

gas tanks and power steering are dou!le-checked. #he engine is installed, along with

the starter and alternator. #hen come suspension and exhaust systems. #hen wheel is

mounted with the help of wheel nut fastening machine.

(& -ina$ Line

From there the vehicle enters Final 9, which covers many interior items such as the

console, seats, carpet, glove !ox and steering wheel. #his is also where !umpers, tires

and the !attery are added, as well as finishing touches like covers and vents. #hen,

oolant, rake oil, $ower steering oil are filled and also the +O gas are charged.

-eatre#

0ifferent assem!ly shop layouts are followed to reduce material handling operations

to facilitate material flow !etween workstations.

a) Straight4$ine $ay"t ar omni line )+ssy shop-9*J &implest layout in which

material enters at 9 end leaves at the other end.

&) U #ha0e $ay"t +ssy shop ; @J 4eceiving shipping ends of line are at

same end of plant, due to material handling considerations )same forklift for !oth

needs* or external needs.


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c) S #ha0e $ay"t /steem line )+&-9*J &erpentine layout to fit longer assy line in

s"uare shop.

&eparate door +ssy lineJ - 0oors are taken out from the vehicle at the first station of the

trim line. 0oors fitted in the final line make working easier.

OTHER SHO%SJDE%ARTMENTS

%+3I5/ &37$

#he machine shop is the source of all major components for the engine assem!ly shop.

#he un-machined crankshaft and camshaft forgings, transmission case cylinder head

and cylinder !lock castings are !rought in the form of raw materials from the vendors.

#he cylinder heads and transmission case are aluminum castings while crankshaft and

camshaft are steel forgings.

It has the following linesJ

)a* #ransmission case line

)!* ylinder head line

)c* ylinder !lock line

)d* rankshaft line

)e* amshaft line.


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ENGINE ASSEMBL

#here are four types of engines which are assem!led in the /ngine $lant

7. -C Engine Engine 5ith &a#t ir"n '$"&

a. %-:??

!. 7mni

c. +lto

d. Bagon-4

e. en /stillo

8. A$=in= Engine Engine 5ith a$=in= '$"&

a. 6ypsy

!. &G2

c. &wift )$etrol*

d. 0ezire )$etrol*

' KB Engine (Ne5 #erie# "/ engine# 5ith a$=in= '$"&

a. +-&tar

!. 4itz


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c. 4itz )0iesel*


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%r"*e&t

Sa/ety #y#te= "n /$""r 0it t" 0r"i1e 0r"te&ti"n again#t /a$$in#i1e it


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%r"*e&t De#&ri0ti"n

7pen pit 2x; s"uare meter ; meter deep is provided inside the working area for

repairing under the vehicles.

Tyre sensors

Areasensors

Air cylinder Pit coer


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#he pit is open from top , side safety railings can not !e provided as vehicles are

to !e !rought on it !y starting there were some incidents of working operators

falling inside getting serious injuries.

%anual covers were !eing used to cover it !ut due to a!sence of any fool proof

system many times pit remains open from top.

O'*e&tie

#o provide fool proof safe cover over pit which can !e automatically operated

when vehicle is !rought over it as soon as vehicle is taken off from it the cover

should automatically close.

$it should not !e closed when operator is standing inside pit waiting for next

vehicle to come

+uto closing to have clearance from &afety department no extra material to !e

procured from outside, only in-house material availa!le inside the %aintenance

department to !e used

Methe1"$"gy a1"0te1

Initial study was done on site to check the safety risk, it was found that the pit can

not !e reallocated to other area it is re"uired to carry on the repairs.


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%anual cover is not used to closed the pit as it is very heavy slips when

some!ody walks on it.

Idea of providing a horizontal gate over pit with guided rails came, in this a gate

was fa!ricated as per openings size rollers were provided on corners rails were

provided to guide rollers to traverse smoothly.

#he system worked well with a push of hand the cover could !e closed

opened. ut the pro!lem of this system was no!ody closed it after use it is kept in

open condition many times in open condition the risk of falling inside pit was still

persisting.

%ore study was done to provide automatic system on door so that it can open

closed automatically as per re"uirements.


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+fter the gate opened the operator could do the repair work from !eneath the vehicle.

+fter the jo! is finished the car is driven off the pit. #he issue of closing !ack the door

automatically remained.


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CASE NO48 6Bhen vehicle is driven off the pit the door remains open risk of falling

inside pit remains there, in this case the de-activation of sensors &9 &; is linked to

auto closing of pit

#he pro!lem of automatically closing opening the pit door was solved !y activating

de-activating the sensors &9 &;.

SA-ET CONCERNJ In case someone is standing !etween the closing door does not notice the movement of closing the door he can !e trapped in !etween the

door pit wall serious accident can happen.


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5ew idea of closing the door in !etween in case some one or some o!ject comes!etween at the time of closing the door !y pneumatic pressure.

CASE NO4;J +t the time of closing of door if someone or some o!ject comes in!etween the door ; area sensors )&@* provided at !oth sides of pit which will sense thepresence of human or o!ject will stop the door suddenly get it reversed to its home)7$/5* position. Bith this system no one will !e trapped !etween moving door pitwall


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CASE NO4


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CIRCUIT DIAGRAM

DOUBLE ACTING CYLINDER

5/2 DOUBLE

PILOT SOLENOID

VALVE

3/2 SPRING

RETURN PUSH

BUTTON3/2 SPRING

RETURN PUSH

BUTTON

F R L

COMPRESSOR


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#he safety project implemented !y the team is working in %&I' 6urgaon plant in

+ssem!ly &hop-@ since 9stweek of 0ecem!er;??C.

It was a great learning experience !y working in a team. %r. %anoj +ttri )/ngineer %$;*

his team has helped me in completing the project in time.

#hey provided me with every help from arranging the material getting the structures

fa!ricated.


58/79



59/79


Bithout the a!ility to locate and track units as they make their way through

manufacturing, testing and repair processes, managers lack the a!ility to achieve

optimum performance for their !usiness and are forced to rely on outdated,

inaccurate data and la!or-intensive processes.

#he most powerful tool for any manager is accurate, real-time information a!out the

location and status of the work-in-process.

#he (ehicle #racking and %anagement &ystem )(#%&*, provides real-time

information to track, measure and manage vehicles anywhere within a facility, !oth

indoors and outdoors.

(ehicle #racking and %anagement &ystem is a ground-!reaking step in automating

vehicle tracking and management in today8s vehicle assem!ly, delivery chain and

fleet operations and is the first solution to provide real-time information to todays

manufacturing management community.

(ehicle #racking and %anagement &ystem allows a vehicle manufacturer, delivery

chain or fleet operation to know in real-time or historically exactly where the vehicle

is located or has !een.

7ff-line processes are fre"uently a forgotten segment of lean manufacturing and

(ehicle #racking and %anagement &ystem is one of the worlds first systems to drive

efficiency and optimization in this area.


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In a (ehicle #racking &ystem solution, an 4FI0 tracking tag is placed in each

vehicle typically !efore the vehicle enters the off-line processing areas., the solution

delivers real-time tracking information of the vehicle.

In addition, !eyond the a!ility to locate a vehicle on demand, the tracking data can

!e used to monitor such things as adherence to process, process cycle time, and

dwell time analysis for off-line areas.

(ehicle #racking and %anagement &ystem provides for accurate planning, execution

and monitoring of performance S making it the ultimate support tool for improving

processes and creating efficiency in off-line manufacturing areas.

!ehi&$e Tra&ing an1 Manage=ent C"reSy#te= C"=0"nent#6

!ehi&$e Eent Manage=ent

#he (#& (ehicle /vent %anagement feature automates vehicle status changes,reduces la!or intensive !arcode scanning, and triggers transactions with zero human

intervention.

%r"&e## &"ntr"$ Manage=ent

onditions like &pecial omments etc can !e !roadcasted using check sheet or any

printers.omments can !e made for recheck,evaluation purposes for #rial (ehicle,

&pare (ehicle etc.#hrough (#& the position of any vehicle in the assem!ly line can !e

easily traced out using the mimic.(ehicles can !e viewed on the !asis of

hassis,$&5,(ehicle %odel /tc.


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!ehi&$e Thr"gh0t Manage=ent

#he (#& (ehicle #hroughput %anagement feature automates and

optimizes the vehicle throughput, !y creating a process map for

every vehicle, knowing the current inventory location, deducing

the Dprocess stepD or Dcontainment areaD capacity and the FIF7

ordering of vehicles, the throughput management engine actively

manages and optimizes the vehicle movement. (ehicle #racking

&ystem communicates this information with users via desktop

computers, Bindows %o!ile #erminal Bi-Fi devices, $roduction

ontrol oards, and (ideo #erminal Liosks.

!ehi&$e E&e0ti"n Ba#e1 Manage=ent

#he (#& /xception ased %anagement feature provides a goal

setting capa!ility and delivers real-time exception-!ased

information to the user community. #herefore maximizing issue

resolution time, increasing options and reducing costs. #he

exception management rules engine allows users to see

exceptions for a vehicle, as well as, for a Dprocess stepD.

BENE-ITS6

Increase vehicle throughput

Improve order to delivery

4educe dwell time

Increase la!our productivity


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%inimize work-in-process inventory

Improve inventory accuracy

4educe operation costs

Increase vehicle utilizations in fleet hours .

E?i0=ent Tra&ing an1 Manage=entI=0r"e Sa/ety ) E?i0=ent Uti$iati"n

In any manufacturing environment, safety is paramount. %aterial handling e"uipment

can !e extremely dangerous if not used !y an authorized individual that has !een

properly trained.

#he /"uipment #racking and %anagement &ystem solution provides a secure

method of vehicle access and authorization, and can prevent the e"uipment from

starting or moving without proper authorization.

In addition, /"uipment #racking and %anagement &ystem provides vital information

directly from the e"uipment itself, including 4un-#ime, Idle-#ime, attery

onsumption, 'ift &ensing and Impact &ensing.

y utilizing this data, and closely monitoring the precise run-time and utilization of

the e"uipment, /"uipment #racking and %anagement &ystem can significantly

reduce the total operating costs through proper Dright-sizingD of the e"uipment fleet,

!y total "uantity and !y e"uipment type.


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/"uipment #racking and %anagement &ystem helps address the followingreal-time material handling e"uipment re"uirementsJ

A&&e## C"ntr"$ 4educes injuries !y ensuring that only approved users can operate the

e"uipment !y using a contact !utton or proximity card.

/liminates government fines associated with access controls.

0ecreases a!use or misuse !y linking incidents to specific operators.

%reentie Maintenan&e %aximizes e"uipment life through routine maintenance !ased on actual engine

runtime hours.

Increases operator productivity with improved up-time of e"uipment.

4educes costs and increases useful life !y performing usage !ased preventive

maintenance.

E?i0=ent Uti$iati"n D4ight-sizeD fleet !y tracking actual utilization.

Increases useful life of e"uipment with !etter accounta!ility and management.

4educes headcount through increased productivity.

/5/FI#& Increase productivity

Improve e"uipment utilization

4educe injuries

%aximize e"uipment life

4educe la!our

etter efficiency


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3igh &ystem availa!ility and real time response.

/na!le mixed production in various shops as per (&.

Interfacing with &hop /"uipment.

+utomatic component selection system)$ika-$ika*.

%aterial Flow &e"uence &upply.

/ngine-+ssem!ly $lanning.

/liminate human error creeping in system at manual data entry.

%odular and &cala!le.

#he (ehicle #racking &ystem or (#& was developed in house !y the cross functional

team of I#, $/ and $roduction of %aruti &uzuki India 'imited to reduce the companys

response time to market demand, and to handle the complexities of producing vehicles

across multiple variants

(#& acts as a middle layer !etween the 3ost )usiness*

computer and the &hop floor terminals and devices.

Facilitate real-time communication for data transfer !etween

computer system and $'.

$ika-$ika for omponent selection

&u! &ystem and /"uipment Interfacing

!TS OB+ECTI!ES

MAIN -EATURES


65/79


roadcasting vehicle se"uence at various control points to

different areas

#racking point +chievements

&pecial ase 3andling

Pro*ress Mana*e+ent

!TS IM%LEMENTATION

(#& acts as a intermediary !etween the data!ase server and the various shop floor

terminals and devices.

It facilitates real time communication for transferring data !etween the computer

system and the $' system which in turn provides data to the ro!ots and to the

e"uipments that ena!les them to pick up the right component and also to !roadcast

the re"uisite information to the printer.

#hus providing data to the technicians. #he technicians use this data for the

assem!ly of the vehicles and finally (#& aids the implementation of the production

plan se"uence on the shop floor.

#he production plan contains all the re"uisite information in terms of the path to !e

followed !y each vehicle through the manufacturing plant the vehicle code, its color,

the country code, and chassis num!er. It also specifies the start and end point for

each process.

#he (#& facilitates this complex planning using which a vehicle under production

can !e routed in a flexi!le manner across various shops and lines in the most

effective manner.

#he (#& ena!les the engine from multiple locations to !e tracked as manufacturing

process progresses.


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AREAS CO!ERED

Beld &hop M 9, ; @ )B- 75 B-7L*

$+I5# &37$ M 9, ; @ )$ 75 $ 7L *

+&&/%'1 &37$ M9, ; @ )+ 75 + 7L*

/56I5/ &37$ M 9, ; ,@ +' &hop

(I9, (I; (I@ )F 75 F 7L $oints*

!EHICLE TRACKING

#he manufacturing plant in 6urgaon has

@-weldshops,

@-paint shop,

@-assem!ly shops and

2-engine shops.

In the a!ove fig,each model is specified with different color and the path followed !y each is

represented !y the arrows joining different shops


67/79


SER!ER CON-IGRATION

!TS IN ASSEMBL SHO%

AREAS CO!ERED

E?i0=ent a&tiati"nM+ll e"uipment are connected through '+5 with

(#& as soon as triggering mechanism will get signal of presence of a particular

model it will pass on the signal to $' of the e"uipment the e"uipment will come in


68/79


that mode automatically. (ehicle #racking from 9stcontrol point to last control point

)B 75 to F 7L*

3I%)Bork M I5 M $rocess* !etween two control point

(For example if we want to see No. of vehicles in WIP in Paint Shop then we have to

give command to system for PB ON to PB O ! No of vehicles will "e #nder Paint Shop

WIP$

Sh"0 Se?en&ingM In multi model mix production overprized lines what

se"uence of models is in line will !e known in advance that se"uence can !e

printed !y line printers which can !e displayed for operator to see what model of

vehicle is approaching in next few hours to him.

In the +ssem!ly &hop, (#& tracks vehicle at two points

&tarts at +-75 or assem!ly !ody 75 and

/nds at +-7L or assem!ly !ody 7L.

+t the AB4ONpoint, the data is transferred to the $' and the vehicle se"uence is

!roadcast at various control points to different areas.

'et us take a closer look on some of the areas points at which such !roadcasts take

placeJ

The Main -n1"#hi %rinterS this contains the details of components, and this

information helps the operators to fix the right components in the correct vehicles.

#he D""r Mini -n1"#hi %rinter#S these printouts are stuck to the doors. ased

on this information, the doors are assem!led.


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#he %r"&e## Che& SheetS this document is used to check the completion of the

processes at various checkpoints along the assem!ly line.

Engine St"rage Ot Sengines are put on the /ngine 0ocking 'ine according to

the +-75 se"uence, which is !roadcast to the printer at the time of +-75. +t the

/ngine-ody marriage point, the /ngine 5um!er is matched against the hassis

5um!er !y scanning the !arcode sticker.

(arious other se"uence printers are used for different su!-assem!ly linesJ

#yre su!-assem!lyR

Instrument panel su!-assem!lyR

Bindshield su!-assem!lyR

0oor su!-assem!lyR

0oor latch su!-assem!lyR and

I0 plate

+t certain points, %C M"nit"rapplications are also used to !roadcast the se"uence.

#he marriage of the engine with the vehicle is done at the /6 &torage-7ut point S this

is integrated with the (#& to avoid the possi!ility of wrong engine marriage.

#he process ends with the AB4OKse"uence.

Key /eatre#

#racking pointsJ +-75 , +-7L.

$& 7ut se"uence check at +-75


70/79


roadcasting of +-75 se"uence at different &u! +ssem!lies )/xJ- Instrument

$anel, /ngine &torage 7ut etc..*

omponent selection using $ika-$ika.

&e"uence display through 67# s and $-%onitor )/xJ- 6lassO0oor,radiator,#yre

etc*

Interfaced with /"uipmentsJ'' filling,reak-oil,+ charging etc

+ir !ag 4egistration for export vehicles.

Interfaces with machinesJ I0 $late, (in 5o marking machines.

/ngine &torage 7ut )/ngine (ehicle*

SCHEMATIC LAOUT


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Li#t "/ e?i0=ent &"nne&te1 thr"gh !TS $ikka-$ikka

Id plate mOc

+ gas charging machine

6asoline filling machine

oolant filling machine

rake oil filling machine

/ngine oil filling machine


72/79


E?i0=ent inter/a&ing

%LC4E@UI%MENT INTER-ACING

(#& interacts with the e"uipments in assem!ly shop through line $'s.

(#& gives the input to the $'s as per current vehicle model

$' controls the e"uipment and automatically gives the desired

commands as per vehicle model


73/79


+s soon as the vehicle comes in position it hits the limit switch which is

connected to the line $' #he line $' then interacts with the server to collect the information a!out the

vehicle )which in this case is amount of engine !reak oil*

#he $' then passes this information to the fuel filling machine for the particularvehicle

#he information is also displayed in the 67#

%IKKA4%IKKA SSTEM


74/79


#he selection of components in the main areas is carried out through the (#&using

%ia4%ia.

#his is a '/0-!ased system.

+ '/0 glows on the !in from which the operator is supposed to pick the component,

there!y guiding the operator to pick up the correct component.

+s soon as he picks the component, the '/0 turns off.

3owever, if the operator puts his hand into the wrong in, a warning signal is

generated.

-""$ 0r""/ing /"r &"=0"nent #e$e&ti"n

thr"gh %IKKA4%IKKA


75/79


(#& provides Fool-proofing !y means of $ika-$ika.

#he information pertaining to the vehicles in line is passed !y the (#& to the line

$' which in turn controls the pika-pika.

$ikka-pikka system has series of rows columns of the component for the

particular vehicle model,there!y guiding the operator to pick up the correct

component

7n the vehicle arrival,$ika-$ika indicates the user which component is to !e

selected as per the vehicle model.

+ '/0 glows a!ove the particular column having components for the coming

vehicle model

#he '/0 goes off as soon as the operator picks up the correct component

Green $ightg$"5# "n&"rre&t 0art


76/79


3owever a warning signal is generated if wrong component is selected !y the

operator

#hus through the pika-pika ,the (#& fool proofs the component selection

process.

(#& I5 /56I5/ &37$

4FI0 #4+LI56

#o control the production and

"uality in the highly

automated Engine a##e='$y

line, 4adio Fre"uency

Identification )or 4FI0*

technology is used.

#o communicate with the

4FI0 tag and to pass on the production plan information, a $roduction %anagement

system )$%&* is re"uired.

#he system acts as an interface !etween the host computer and the production floor

and is used to transfer production plan information, dressing data to plant devices

and tags and o!taining production process data, tracea!ility data and "uality data from

the tag.


77/79


#he system then stores the data to the host computer for storing analyzing and for

future use#he data related to testing is handled !y the test management system or

#%& which in turn interacts with the $%&.

+t these stations the magnetic 4FI0 #ag communicates with the tracking system

known as $%& system via the #ag ontroller to exchange and verify the data.

+dditionally, the 4FI0 tags also exchange data with other e"uipment and machines

on the assem!ly line in the same way, using the #ag ontroller. #he #ag contains

the data related to the engine kept on the palate.

#he 4FI0 #ag will start receiving data from set up station S for example, type of

engine, engine num!er, master data, etc. +s the pallet goes along the line and

different operations are performed on the engine !y various machines, the 4FI0 #ag

continues collecting data from machines recording the operation done, its status, etc.

Bhen the pallet reaches the release station, the entire data in the 4FI0 #ag is

transferred to the $%& and after updating, it is flushed from the #ag. 5ow the tag is

ready for the next engine loading.


78/79


(#& I5 (/3I'/ I5&$/#I75)(I*

In the !ehi&$e In#0e&ti"n Sh"0, tracking is done at two pointsJ

-C4ONand

-C4OK.

+fter F-7L, an F-7L confirmation &ticker is attached to rear window of the

vehicle, and then the vehicles are transferred to the dispatch area.

In the vehicle inspection shop, the (#& is integrated with the #/3-9 system

which carries out the emission check and the air !ag check.

Bithout the #/3-9 check F-7L of the vehicle cannot !e done.

#his ensures that the vehicle has !een passed through all the necessary checks.

7n the Nuality Front, the (#& interacts with the "uality gate system to provide faults

tolerance. +ll defects details are tracked through the (#& to ensure that no vehicle gets

F-7L clearance without rectifying the defects.


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%ence& 'S is a system that offers real time data to facilitate )#ic* decision. It carries

o#t real time monitoring to detect errors and )#ality iss#es well in time+ it "roadcasts

messages that facilitate in,line correct evection at the shop floor.

maruti suzuki-project report.pdf

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