2. COMPANY PROFILE
Name : JAY BHARAT MARUTI LTD.
Division : NEEL METAL PRODUCTS LIMITED
Head Quarters : DELHI
Established : 1983
Turnover: : Rs.4500 Crores(overall)
Employees (No.) : AROUND 15,000
• Multi unit, multi product group that deals in broad range of
sheet metal assemblies, die casting components and forging for
the domestic and export markets.
• Jbm group began its engineering Activity in 1983 with the
establishment of gurera gas cylinder ltd and entered the auto
component industries with the inception of SUZUKI AUTO
INDIA.
• Four plants in NCR.
3. BODY IN WHITE PARTS
CHASSIS & SUSPENSION PARTS
WELDED ASSEMBLIES
EXHAUST SYSTEMS
SEAT BELTS
FRONT/ REAR AXIS
WHEEL RIM
4. MAJOR LEARNINGS IN INDUSTRY
• Types of Welding and guns used.
• Quality & inspection Department.
• Implementation of 5-s.
• Implementation of Six-Sigma
• Study of poke yoke
• Painting Shop
5. TYPES OF WELDING AND GUNS USED
Resistance welding
• Spot welding
• Multi spot welding
• Stationary spot welding
• Portable spot welding
Projection welding
• Nut projection welding
• Stud projection welding
6. RESISTANCE SPOT WELDING
• Resistance welding is a welding process which join the metals with the heat
obtained from resistance offered by the work to the flow of electrical
current through the parts being joined.
• A pair of copper alloy electrodes conducts
electrical current through the two sheets
pressed between the interface. The two sheets
offer maximum resistance to the flow of
current, this generates heat, the interface melts
and consequently solidifies under the
pressures of the two electrodes, thereby
joining the two sheets at the spot that was
under the two electrodes.
7. TYPES OF GUN USED IN SPOT WELDING
• X- TYPE GUN
Also known as "scissors" or "pinch"
• C-TYPE GUN
C guns are generally the cheapest
and the most commonly used.
8. PROJECTION WELDING
Nut projection welding
• Projection Welding Is A Type Of Resistance
Welding.
• High current in less time is the main
feature of this welding.
Stud projection welding
• Stud is a form of spot welding where a bolt or
nut is welded on another metal sheet.
9. » Cost & Time saving
» Man power saving
» Pace of work is fast
» Production is high
» Make Product with less error
10. 5S
THE JAPANESE APPROACH
The 5- S is a JAPNESE technique used to establish and maintain quality
environment in an organization.
• 1S-SEIRI- Sort Out Unnecessary Items In The Workplace
• 2S-SEITON- Arrange Necessary Items In Order
• 3S-SEISO- Clean your work place completely
• 4S-SEIKETSU-Maintain high standard of housekeeping
• 5S-SHITSUKE-Train people to follow good housekeeping
12. POKA YOKE
• Poke yoke is Japanese term that means “Mistake-Proofing”.
• A poke yoke is a mechanism in a lean manufacturing process
that help an equipment operator avoid mistake.
• It’s purpose to eliminate product defects by preventing or
drawing attention to human error as the occur.
• There are three type of poke yoke in mass production
• Contact method
• Fixed value
• Motion step
13. Painting shop
• Paint shop has consist main this step in
painting
Loading
Hot water
wash
Surface
activation
Phosphatizing
Water Dry
Oven
Tag Rag
Primer , base
& top coat
Paint Baking
Oven
Unloading
