45312185 maruti-suzuki-project-report

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. I’d also like to express my
sincere gratitude towards Mr. V.K. Arora (Asstt. General Manager, Plant
Maintenance) ,Mr. S. Prabhakar (Sr. Manager, Plant Maintenance) & Mr. Manoj
Attri (Engineer, Plant Maintenance)for their guidance & help which enabled me to get
the required data & information required to finish my assignments Their inspiring
suggestions and timely guidance enabled me to perceive the various aspects of the
projects in a new light.
I would also like to thank all senior members and workers of Plant Maintenance for
having guided and encouraged me throughout the duration of the project. In all I found a
congenial work environment in MSIL and the completion of the projects will mark a new
beginning for me in the coming days.

PROJECT REPORT
ON
 Study of vehicle manufacturing processes from raw material
to finish vehicles.
 Study of Vehicle Tracking System (VTS) & equipment interface.
 Auto closing system (Concept,design & fabrication)
of floor service pit to improve safety of human.
SUBMITTED BY
-------------------
4TH
YEAR ELECTRICAL ENGINEERING
YMCA INSTITUTE OF ENGINEERING
FARIDABAD

Maruti Suzuki is one of India's leading automobile manufacturers and the market leader
in the car segment, both in terms of volume of vehicles sold and revenue earned. Until
recently, 18.28% of the company was owned by the Indian government, and 54.2% by
Suzuki of Japan. The Indian government held an initial public offering of 25% of the
company in June 2003. As of May 10, 2007, Govt. of India sold its complete share to
Indian financial institutions. With this, Govt. of India no longer has stake in Maruti
Udyog.
Maruti Udyog Limited (MUL) was established in February 1981, though the actual
production commenced in 1983 with the Maruti 800, based on the Suzuki Alto kei car
which at the time was the only modern car available in India, its' only competitors- the
Hindustan Ambassador and Premier Padmini were both around 25 years out of date at
that point. Through 2004, Maruti has produced over 5 Million vehicles. Maruti are sold in
India and various several other countries, depending upon export orders. Cars similar to
Maruti (but not manufactured by Maruti Udyog) are sold by Suzuki and manufactured in
Pakistan and other South Asian countries.
The company annually exports more than 50,000 cars and has an extremely large
domestic market in India selling over 730,000 cars annually. Maruti 800, till 2004, was
the India's largest selling compact car ever since it was launched in 1983. More than a
million units of this car have been sold worldwide so far. Currently, Maruti Alto tops the
sales charts and Maruti Swift is the largest selling in A2 segment.
Due to the large number of Maruti 800s sold in the Indian market, the term "Maruti" is
commonly used to refer to this compact car model. Till recently the term "Maruti", in
popular Indian culture, was associated to the Maruti 800 model.

Maruti Suzuki India Limited, a subsidiary of Suzuki Motor Corporation of Japan, has
been the leader of the Indian car market for over two decades.
It’s manufacturing facilities are located at two facilities Gurgaon and Manesar south of
New Delhi. Maruti’s Gurgaon facility has an installed capacity of 350,000 units per
annum. The Manesar facilities, launched in February 2007 comprise a vehicle assembly
plant with a capacity of 100,000 units per year and a Diesel Engine plant with an annual
capacity of 100,000 engines and transmissions. Manesar and Gurgaon facilities have a
combined capability to produce over 700,000 units annually.
More than half the cars sold in India are Maruti cars. The company is a subsidiary of
Suzuki Motor Corporation, Japan, which owns 54.2 per cent of Maruti. The rest is owned
by the public and financial institutions. It is listed on the Bombay Stock Exchange and
National Stock Exchange in India.
During 2007-08, Maruti Suzuki sold 764,842 cars, of which 53,024 were exported. In all,
over six million Maruti cars are on Indian roads since the first car was rolled out on
December 14, 1983.
Maruti Suzuki offers 12 models, Maruti 800, Omni, Alto, Versa, Gypsy, A Star, Wagon
R, Zen Estilo, Swift, Swift Dzire, SX4, Grand Vitara. Swift, Swift dzire, A star and SX4
are maufactured in Manesar, Grand Vitara is imported from Japan as a completely built
unit (CBU), remaining all models are manufactured in Maruti Suzuki's Gurgaon Plant.
Suzuki Motor Corporation, the parent company, is a global leader in mini and compact
cars for three decades. Suzuki’s technical superiority lies in its ability to pack power and
performance into a compact, lightweight engine that is clean and fuel efficient.

Maruti is clearly an “employer of choice” for automotive engineers and young managers
from across the country. Nearly 75,000 people are employed directly by Maruti and its
partners.
The company vouches for customer satisfaction. For its sincere efforts it has been rated
(by customers)first in customer satisfaction among all car makers in India for nine years
in a row in annual survey by J D Power Asia Pacific.
Maruti Suzuki was born as a government company, with Suzuki as a minor partner to
make a people's car for middle class India. Over the years, the product range has
widened, ownership has changed hands and the customer has evolved. What remains
unchanged, then and now, is Maruti’s mission to motorize India.
BACKGROUND OF THE INDIAN AUTO INDUSTRY
Although the Indian car industry was established in the late forties, there was little
growth or technical progress, as passenger cars were given very low priority in the
scheme of Centralized Economic Planning. In the 1980s, the car industry was
undergoing technological stagnation and was characterized by low production volumes,
high cost and low productivity. The consumer had very little choice and the market was
selling just around 30,000 cars per year.
There was a clear need to provide a cost effective, reliable and quality car to the
customers. Maruti Suzuki India Limited was incorporated in such a scenario as a fully
owned Government Company on February 24, 1981 with a resolve to bring about
expansion and technological modernization, of the automobile sector. Thus MSIL, when
started was entrusted with the task of achieving the following policy objectives:

 Modernization of Indian Automobile Industry.
 Production of Vehicles in large volumes, which was necessary for economic
growth.
 Production of Fuel-efficient vehicles to conserve scarce resources.
Choice of product and collaborator
 To achieve the above objectives, one of the foremost tasks before. Maruti Suzuki
India Limited was to determine the most suitable product mix and to select the
most suitable foreign partner who would be willing to accept MSIL ‘s
requirements in terms of product mix, technology transfer, and equality
participation and had the
 required technological expertise and experience in producing high quality, reliable
and fuel efficient vehicles.
After extensive discussion with several major European and Japanese car
manufacturers, MUL chose Suzuki Motor Corporation (SMC) further increased its equity
holding to 50% in the year 1992, converting . Maruti Suzuki India Limited, into a Non-
Government Company with a total Equity base of Rs. 1322.92 million.
BACKGROUND OF SMC
SUZUKI was founded in 1909 as Suzuki Loom Manufacturing Company. It started
manufacturing motorcycles in 1952 and has become a world leader in the manufacture
of two-wheelers .SUZUKI started producing cars from 1955.Today it is Japan’s largest
manufacturers of small , fuel-efficient cars. At present the company’s name is SUZUKI
MOTOR CORPORATION.

SUZUKI AND MARUTI’S WORLD-CLASS MANUFACTURING
FACILITIES AT MANESAR
On February 06,2007 Mr. Bhupendera Singh Hooda , Chief Minister of Haryana
inaugurated three world-class manufacturing facilities set up by SMC and Maruti Suzuki
India Limited.
The facilities inaugurated were as follows:
 MSIL’s fourth car Assembly plant.
 A diesel engine and transmission plant, set up under a joint venture of SMC and
MSILcalled Suzuki Power train India Limited (SPIL)
 SMC’s two-wheeler plant in Gurgaon, Suzuki Motorcycle India Private Limited
(SMIPL).
INTRODUCTIONTO MARUTISUZUKI INDIA LIMITED
 A License and a Joint Venture Agreement was signed with Suzuki
Motor Company of Japan, in OCT. 1982
 Market leader with over 54% Share in Domestic Car Market
Exporting cars to over 70 countries around the world including most
advance Western European Markets.
 Maruti has revolutionized the Indian Automobile and Component
Industry and has set standards in quality of products and service.
MARUTI INSTALLED CAPACITY

 PLANT 1 200,000 units
 PALNT 3 150,000 units
COMPANY MISSION
 A leader in the Indian Automobile Industry.
 Creating Customer Delight and Shareholders wealth.
 A pride of India!
LEADERSHIP
 By Market share and brand equity
 By operational practices
 By people strategy
CUSTOMER DELIGHT
 Values for money

 Quality
 Service
SHARE HOLDERS WEALTH
 High Profitability & Image
A PRIDE OF INDIA
 As a corporate citizen
 Products
 People
 Practices
 Customers
VALUES
 Customer Obsession
 Fast, Flexible, First Mover
 Innovation and creativity

 Networking and partnership
 Openness and learning
QUALITY POLICY
To increase consumer satisfaction through continuous improvement of products and
services, this is achieved by following PDCA functions and levels of Maruti
Organizations.
QUALITY TOOLS
PLAN
DO
CHECKACT
QUALITY
POLICY

 5 S
 4 M
 3 M
 3 G
 3 K
What is 5S?
SEIRI – PROPER SELECTION
SEITION – ARRANGEMENT
SEISO – CLEANING
SEIKETSO – CLEANLINESS
SHITSUKE – DISCIPLINE
What is 4M?
The factory is essentially a mix of man, materials, machines and methods. These should
move continuously and effectively to produce a quality product at low cost. The most
essential work in quality control is to thoroughly investigate regarding the problems
concerning quality, decide suitable counter measures and carry out improvements
accordingly.
 MAN
 MACHINE
 MATERIAL
 METHODS

What is 3M?
In Japanese Language 3M is:
MURI – INCONVENIENCE
MUDA – WASTAGE
MURA – INCONSISTENCY
What is 3G?
In Japanese Language 3G is:
GENCHI – GO TO ACTUAL PLACE
GENBUTSU – SEE THE ACTUAL THING
GENJITSU – TAKE APPROPRIATE ACTION

INTRODUCTION TO VARIOUS MODELS
PRODUCT RANGE
MODELS SPECIFICATIONS YEAR OF LAUNCH
MARUTI 800 (FIRST
MODEL)
796CC, HATCHBACK DECEMBER 1983
OMNI 796CC, MUV NOVEMBER 1984
GYPSY 992CC, 4WD DECEMBER 1985
MARUTI 800 (MODIFIED) 796CC, HATCHBACK APRIL 1986
MARUTI 1000 996CC, SEDAN OCTOBER 1990
ZEN 996CC, HATCHBACK OCTOBER 1993
ESTEEM 1.3L LX 1296CC, SEDAN NOVEMBER 994
ESTEEM 1.3L VX 1296CC, SEDAN NOVEMBER1995
ESTEEM 1.3L AX 1296CC, SEDAN JUNE 1996
ZEN AX (AUTOMATIC) 996CC, HATCHBACK OCTOBER 1996
GYPSY KING 1296CC, 4WD NOVEMBER1996
OMNI (E) 796CC, MUV DECEMBER 1996
GYPSY (E) 1296CC, 4WD DECEMBER 1996
MARUTI 800 (NEW
MODEL)
796CC, HATCHBACK SEPTEMBER 997
ESTEEM 98 1296CC, SEDAN OCTOBER 1997
NEW OMNI & OMNI-E 796CC, MUV FEBRUARY 1998
ZEN VX & ZEN VX 996CC, HATCHBACK JULY 1998

AUTOMATIC
ZEN D
1200CC,
HATCHBACK
AUGUST 1998
MARUTI 800 EX 796CC, HATCHBACK JANUARY 1999
ZEN LX 996CC, HATCHBACK JANUARY 1999
ZEN CLASSIC 996CC, HATCHBACK AUGUST 1999
ZEN VXI 996CC, HATCHBACK OCTOBER 1999
OMNI XL 796CC, MUV OCTOBER 1999
BALENO 1586CC, SEDAN DECEMBER 1999
WAGON R
1096CC,
HATCHBACK
JANUARY 2000
ALTURA
1586CC,
HATCHBACK
(BALENO)
MARCH 2000
ALTO LX, LXI 796CC, HATCHBACK SEPTEMBER 000
VERSA 1296CC, MUV DECEMBER 2001
SWIFT
1296CC,
HATCHBACK
MAY 2005
ZEN ESTILO
1096CC,
HATCHBACK
DECEMBER 2006
SWIFT DIESEL
1296CC,
HATCHBACK
FEBRUARY 2007
SWIFT DIESEL FEBRUARY 2007
GRAND VITARA MARCH 2007
SX4 1.600CC MAY 2007
SWIFT DZIRE MARCH 2008
A- STAR NOVEMBER 2008
RITZ MAY 2009

ORGANISATIONAL STRUCTURE
Maruti has believed, since the very beginning that it is its employees who could make it
into an organization with a difference .Accordingly, as against the traditional hierarchical
System of management, which causes unnecessary delays in decision-making, we have
built up a flat organization with a family type of atmosphere at our place of work.
The company is divided into different divisions according to the various functional areas.
A Divisional Manager heads each Division. Divisions are further divided into
Departments that are headed by Department Managers who report to the respective
Divisional Managers. Designations in the company are based on the functional
responsibility and not levels as in terms of the company’s philosophy designations and
functional responsibility are de-linked from the salary levels.
The total operations of the Company are divided into Divisions like Marketing & Sales,
Spares, Engineering, Q.A. & Services, Production, Production Engineering, Materials,
Information Services, Finance, Personnel & Administration, etc. Each division is
furthering divided into Departments and headed by Departmental Managers who is
assisted by Supervisory Executives.

The hierarchy diagram of MSIL

DIVISIONS AND DEPARTMENTS
Corporate Services Division
 Legal & Secretarial Department
 Corporate Communication Cell
 Protocol
 Strategic Initiative Group
 Recruitment & Management Compensation
Human Resource Division
 Employee Relations Department
 Establishment & Time Office
 Factory Administration Department
 Organizational Development Department
Production Division
 Plant- 1
 Plant- 2
 Plant- 3
 Plant- 6 at Manesar
Production Engineering

 Production Engineering Division
 Production Service Division
Engineering Directorate
 QAIN Division
 Service Division
 Service- 1-5
 MSS(D)
 Parts Inspection Division
 Engineering Division
Supply Chain division
 Supply Chain- 1,2,3 Division
 Shipping & transport Department
 Imports Department
 Consumables Department
Information Technology Division
 Application Group1 (AG1)
 Information Technology Strategies(ITS)
 IT Operation and Services(ITOS)
Marketing & Sales Secretariat

 Marketing Strategy & Development
 Marketing
 Sales
 Exports
 Web-IT, E-Commerce
Spare Parts Division
 Spare Parts Procurement
 Warehousing & Dispatch
 Spare Parts Sales
 Accessories
Vigilance Division
 Security Wing
 Vigilance Wing
Finance Division
 Budget, Cost & Accounts Department Income Accounting
The total project costs, priority, completion time and personnel’s required 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 company’s information
needs were not affected.

Production Division of Maruti Suzuki India Limited
Production Division in Maruti Suzuki India Limited has been renamed as
Production Business Vertical (PBV) after inclusion of Projects, Production
Engineering, Vehicle Inspection & Supplier Quality Assurance divisions in it.
Major components of PBV
 Press Shop and Blanking Line
 Weld Shop (1,2 & 3)
 Paint Shop (1,2,& 3)
 Engine Assembly (1,2,& 3)
 Assembly Shop (1,2,& 3)
 Machine Shop (1,2,& 3)
 Materials – X (1,2,& 3)
 Plant maintenance
 KB Casting
 KB Engine
 KB Machine Shop
 Production facility at Manesar Plant
 SQA (Supplier Quality Assurance)

 Production Engineering & Projects
 Vehicle Inspection (VI)
Milestones
1981
 Maruti Udyog Ltd. was incorporated.
1982
 Stepped into a JV with SMC of Japan.
1983
 Maruti 800, a 796 cc hatchback, India's first affordable car
was produced.
1984
 Installed capacity reached 40,000 units. Omni, a 796 cc MUV
was in production.
1985
 Launch of Maruti Gypsy (970cc, 4WD off-road vehicle).
1986
 Produced 100,000 vehicles (cumulative production).
1987
 Exported first lot of 500 cars to Hungary.
1988
 Installed capacity increased to 100,000 units.
1992
 SMC increases its stake to 50 per cent.
1994
 Produced the 1 millionth vehicle since the commencement of
production.
1995
 Second plant launched, the installed capacity reached
200,000 units.
1996
 Launch of 24-hour emergency on-road vehicle service.
1997
 Produced the 2 millionth vehicle since the commencement of
production.
1998
 Launch of website as part of CRM initiatives.
1999
 Launch of Maruti - Suzuki innovative traffic beat in Delhi and
Chennai as social initiatives.

2000
 IDTR (Institute of Driving Training and Research) launched
jointly with Delhi government to promote safe driving habits.
2001
 Launch of customer information centers in Hyderabad,
Bangalore, and Chennai.
2002
 SMC increases its stake to 54.2 per cent.
 Launch of Maruti Finance with 10 finance companies in
Mumbai.
 Start of Maruti True value in Mumbai.
2003
 Production of 4 millionth vehicle.
Listed on BSE and NSE after a public issue oversubscribed 10
times.
2004
 Maruti closed the financial year 2003-04 with an annual sale
of 472122 units, the highest ever since the company began
operations 20 years ago.
2005.
 The fiftieth lakh car rolls out in April, 2005.
2006.
 Maruti tops jd power csi survey for record seventh time in a
row
2007
 Govt of India awarded O SUZUKI with coveted padma bhusan
 Board of directors give approval to new name MUL to become
maruti Suzuki India limited.
2008.
 M-800 crosses 25 lakh mark
 MSIL celebrates SILVER JUBILEE
 MSIL launches national road safety program.
2009
 Capacity to manufacture expanded from 800,000 to a million
units(Gurgaon plus Manesar) annually
 All India engineering export promotion council(EEPC) award.
 MSIL achieved highest sales ever in Dec’2009

PRESS SHOP
The press shop can be regarded as the starting point of the car manufacturing process.
Centrally located between weld 1, weld 2 and weld 3 supplies components to all the
three plants. The press shop has a batch production system whereas the plants have a
line production system. The press shop maintains an inventory of at least two days. The
weld shop as per the requirements picks the finished body parts from the press shop.
These may be divided as A, B and C. ‘A’ components are large outer components as for
example roof, door panels etc. These components are manufactured in the press shop
at Maruti due to design secrecy and huge investment requirements. ‘B’ and ‘C’
components are manufactured by joint ventures or bought from vendors.
Process flow of Press Shop activity :-
1. Currently Press Shop is producing sheet metal components for 8 running
models of Maruti Suzuki and one model of GM India - Tavera
2. The Blanking and stamping shop processes 10000 metric ton of steel / month
i.e. 400 tons a day
SStteeeell ccooiill BBllaannkk PPaanneell

Machine :
 Five Transfer Press ( 4000 ton , 3500 ton , 2400 ton -1 2400 ton -2 ,
2000 ton in terms of total capacity i.e. draw+trim+pierce+bend+restrike ) &
1 Tandem line( 1500 ton draw capacity )
 Two Coil processing lines ( ROSL – Shear line & Blanking line ) SPM
of 60
 Capacity of 55,000 strokes / day from 400 tons of steel coils
4000 Ton
transfer
press
Pressed panels
come out from
this side

Upper die
Press Machine : Mass production presses are continuous flow transfer presses. Set
of 4 to 5 dies are mounted on single press & complete panel comes out from press after
going through stamping, trimming & piercing.
 189 die sets (including 15 die sets of GMI) – 1 die set has avg 4 upper +
lower dies
SMED : “Single Minute Exchange of Dies” new concept being adopted . This concept
helps in changing of die set up within single digit minute (below 9 minutes) This helps us
in improving machine utilization & operating efficiency. Since press machines are very
high cost investment & any idle time lost due to die exchange will be a cost to company.
Lower die

Yield improvement (Ratio of output panel to input coil in weight) is Best amongst
the SMC group Companies. ( Presently at 63.2% )
Modifications to improve yield are continuously done & till Oct-09 Press Shop has saved
Rs. 7.786 millions of material in current year
Yield is improved by
1. Reducing the blank size
2. Utilization of scrap for making smaller sheet metal parts
46.2
56.94
50.12
105
29.6
13.0
21.0
77.86
0
20
40
60
80
100
120
Apr 09 May 09 Jun 09 Jul 09 Aug 09 Sep 09 Oct 09 Nov 09 Dec 09 Jan 10 Feb 10 Mar 10 Target
(09-10)
LACS
Yield Improvement

Steel Coils
 Steel coil is raw material used to make body sheet metal parts. These are
CRS coils made of mild steel having thickness from 0.65 mm to 0.8 mm &
weight from 1 ton to 4 tons.
 Steel coils are received in bulk quantities from indigenous as well as
foreign suppliers in the ratio of 60 to 40 & stored at a centralized storage &
supplied to blank cutting areas as per plan
 Steel coils are fed to Blanking & ROSL lines by overhead EOT cranes.
Sheet is first de-coiled , cleaned, oiled & fed to cutting or shearing areas of
blanking or ROSL lines.

Blank
 Coils are fed to blanking line & continuous supply of sheet to cutting dies
result in shaping of coils to plan blanks.
 Blanks are cut by stamping or shearing process & are stacked one by one to
form large mass of blanks
 These stacks of blanks are further sent to press machines for forming into
shape of body panels
Stack of blanks

Panel
Blanks are supplied to press lines for pressing. Blanks are converted to body panels
by this process. Panels are stored in pallets which are supplied to Weld Shops for
making White Bodies.
Panels re
stacked in
pallet
trolleys

WELD SHOP
The body panels produced in the press shop and the other small components are joined
here to give the “white body” or “shell”. In a typical car body 1400 different components
are welded together. The weld shops have the following facilities.
 Welding jigs
 Spot welding guns
 Kawasaki welding robots
 Hemming machines
 Punching machines
PROCESS OUTLINE: The shop has different lines for different models, each of, which
is further divided into three parts:
UNDER BODY: Here different underbody panels are welded together. These comprise
of rear underbody, central underbody, front engine room panel. These underbodies are
put on the conveyor and welded together to give the underbody.
MAIN BODY: As the body moves on, the conveyor roof and side body panels (prepared
on the sub lines) are welded to it to give the main body. The chassis number is punched
on the cowl top and it is welded to the front engine room panel.
WHITE BODY: The doors, hood and back door are attached on the main body with the
help of bolts and screws to make it a “white body”. The body is checked for dent, burr
and spatter and these defects are repaired. After inspection and repairs the body is
called WBOK. It is sent to the paint shop thereafter.

PAINT SHOP
In the paint shop following processes are carried out: -
There are five plants/units that provide a uniform painting over the white body coming
from the weld shop. In paint shop all the models are painted on the same line. The five
units are: -
 Pre-treatment (PT): The body is thoroughly washed to remove the dirt and oil
scales. Then the body is treated with ZnPO4 (phosphating) to prevent corroding
of the body.

 ED coat: This is done by electric deposition method, at 240V-DC supply. After
applying the ED coat the body is baked in oven.
 Sol-sealer and under coat: Here the left in the body (due to welding) are filled
with sol-sealer to provide water proofing. Under coat is done on the surface
above wheels to prevent damage of body in that portion.
 Intermediate coat: This is done by spray-painting method using 10 Kawasaki
Robots. After applying the coat, the body is dried in the oven. Painting done is
basically an intermediate coating to provide base for the final coat.
 Top coat: This is done by spray-painting method using 20 Kawasaki Robots. For
metallic coating, double coats are applied and aluminum flakes are provided to
shine the metallic paints.
After inspection and touch up, the PBOK, i.e. the paint body ok is sent to the assembly
shop.
In paint shop II, only ZEN and ALTO are painted. Paint used is Nerolac. There are 4
coatings of paint.
1] Phosphate coating
2] ED coating
3] IC coating
4] TOP coating
Inside portion of vehicle is painted manually and outside is by Robots.

PRE TREATMENT:
Before sending vehicle to painting process pretreatment is done to
ED PAINTING:
ED is electro deposition. Vehicle is dipped in the ED solution. In this around 300V is
passed to make paint to be attached. ED is 17% of paint rest is water and some
additives (EDD, M).
Hot water rinse Spray degreasing Dip de
WR I
WR VIWR VWR IV
WR III WR IISURFACE CONTROL
PHOSPHATING WR VII
DI WATER MISTED PROCESS
WBS

PROCESS:
The whole solution of ED acts as electrolytic solution. Vehicle before coming to ED dip,
it undergoes pre treatment. In that phosphating is done, in which Zn phosphate is made
to attach vehicle body which help in electro deposition, in this, vehicle acts as cathode
and paint as positive ions. When current is passed paint will be attracted by vehicle till
its thickness will be covered. ED is very accurate to apply. This is about whole process.
Rinsing is done after to remove excessive color. In rinsing industrial water is used which
will not be left go waste. That will be filtered and used again.
ULTRA FILTRATION:
Ultra filtration is the process in which all the rinse pipes and dip tanks will be filtered and
cleaned, by this way water is recycled. Here Osmosis process is used to filter water.
ED DIP
WR I WR II
WR IV WR III RINSING BY DIPPING
OVENWR V DI WATER

IC painting:
IC is intermediate coating in which 3 colors are used. They are white, blue and red.
Outside portion of vehicle is painted by robots and inside is done manually. Paint
thickness is taken care, after that vehicle is sent to IC oven. Oven temperature is 198+/-
5’C.
TOP COAT Painting:
Top coating is done after checking in Dry sanding II. There are 2 sub coatings Base coat
and Clear coat. Here 11 colors are used; 8 metallic and 3 solid. Only metallic colors are
coated with clear coating. Here also outside portion of vehicle is painted by robots and
inside is done manually.
Next vehicle will move to final inspection and will be sent to assembly.
DRY SANDING
 Following repairs are done:
1. Roof sanding
2. Side repair if any.
 Following checking is done:
1. Dosing mark
2. Sanding mark

SOL SEALING LINE:
 Sealer appearance is given the preference.
 3 types of guns are used.
1. Pencil gun
2. Flat gun
3. Blind gun
4. Moti gun
 In this line followings are checked;
1. Powder dust
2. Extra sealer
3. Pin hole in lamp area
4. Sealer appearance

PROCESS THROUGH PICTURES:
PB ON(WHITE BODY) PRE TREATEMENT
ELECTRO DEPOSITION PROCESS
DRY SANDING I SOL SEALING LINE PVC COATING
IC OVEN IC COATING
DRY SANDING II

TC OVEN TC COATING
FINAL INSPECTION TO ASSEMBLY SHO

ASSEMBLY SHOP
In the assembly shop the body is loaded on an overhead conveyor. As the conveyor
moves the body, fitments are made at various stations. There are three Assembly
Shops named ASSY-1, ASSY-2 and ASSY-3. Plant 2 and Plant 3 have similar setup but
in Plant-1 there are separate assembly lines for separate models. The assembly shop
has a continuous production system. The assembly line can be subdivided into the
followings: -
(a) Trim line
The vehicle proceeds through a series of Trim workstations where team members begin
by installing weather stripping, moldings and pads. Then they put in wiring, vents and
lights. After an instrument panel, windows, steering column and bumper supports are
added, it starts to look less like a shell and more like a car.
(b) Chassis Line
This is where many safety-related items are installed. Things like brake lines, torque,
gas tanks and power steering are double-checked. The engine is installed, along with
the starter and alternator. Then come suspension and exhaust systems. Then wheel is
mounted with the help of wheel nut fastening machine.

(c) Final Line
From there the vehicle enters Final 1, which covers many interior items such as the
console, seats, carpet, glove box and steering wheel. This is also where bumpers, tires
and the battery are added, as well as finishing touches like covers and vents. Then,
Coolant, Brake oil, Power steering oil are filled and also the A/C gas are charged.
Features
Different assembly shop layouts are followed to reduce material handling operations &
to facilitate material flow between workstations.
a) Straight-line layout – Car & omni line (Assy shop-1): Simplest layout in which
material enters at 1 end & leaves at the other end.
b) U shape layout – Assy shop 2 & 3: Receiving & shipping ends of line are at
same end of plant, due to material handling considerations (same forklift for both
needs) or external needs.
c) S shape layout – Esteem line (AS-1): Serpentine layout to fit longer assy line in
square shop.
Separate door Assy line: - Doors are taken out from the vehicle at the first station of the
trim line. Doors fitted in the final line make working easier.

OTHER SHOPS/DEPARTMENTS
MACHINE SHOP
The machine shop is the source of all major components for the engine assembly shop.
The un-machined crankshaft and camshaft forgings, transmission case cylinder head
and cylinder block castings are brought in the form of raw materials from the vendors.
The cylinder heads and transmission case are aluminum castings while crankshaft and
camshaft are steel forgings.
It has the following lines:
(a) Transmission case line
(b) Cylinder head line
(c) Cylinder block line
(d) Crankshaft line
(e) Camshaft line.
ENGINE ASSEMBLY
There are four types of engines which are assembled in the Engine Plant
1. FC Engine – Engine with cast iron block
a. M-800
b. Omni
c. Alto
d. Wagon-R
e. Zen Estillo

2. Aluminum Engine – Engine with aluminum block
a. Gypsy
b. SX4
c. Swift (Petrol)
d. Dezire (Petrol)
3. KB Engine (New series of engines with aluminum block)
a. A-Star
b. Ritz
4. Diesel Engine
a. Swift (Diesel)
b. Dezire (Diesel)
c. Ritz (Diesel)

Project
Safety system on floor pit to provide protection against fall
inside it
Tyresensors
Area
sensors
Air cylinder Pit cover

Project Description
 Open pit 4x2 square meter & 2 meter deep is provided inside the working area for
repairing under the vehicles.
 The pit is open from top , side safety railings can not be provided as vehicles are to
be brought on it by starting & there were some incidents of working operators falling
inside & getting serious injuries.
 Manual covers were being used to cover it but due to absence of any fool proof
system many times pit remains open from top.
Objective
 To provide fool proof safe cover over pit which can be automatically operated when
vehicle is brought over it & as soon as vehicle is taken off from it the cover should
automatically close.
 Pit should not be closed when operator is standing inside pit & waiting for next
vehicle to come
 Auto closing to have clearance from Safety department & no extra material to be
procured from outside, only in-house material available inside the Maintenance
department to be used

Methedology adopted
 Initial study was done on site to check the safety risk, it was found that the pit can
not be reallocated to other area & it is required to carry on the repairs.
 Manual cover is not used to closed the pit as it is very heavy & slips when somebody
walks on it.
 Idea of providing a horizontal gate over pit with guided rails came, in this a gate was
fabricated as per opening’s size & rollers were provided on corners & rails were
provided to guide rollers to traverse smoothly.
 The system worked well & with a push of hand the cover could be closed & opened.
But the problem of this system was nobody closed it after use & it is kept in open

condition many times & in open condition the risk of falling inside pit was still
persisting.
 More study was done to provide automatic system on door so that it can open &
closed automatically as per requirements.
 It was thought that a pneumatic cylinder should be provided to slide the gate over pit
which will be operated by providing sensing system .

CASE NO-1 : 4 sensors were provided on top of pit where front tyres are positioned .
Sensors will sense the presence of vehicle on pit & will send signal to control panel to
open the air valve solenoid which will operate the gate by activating the air cylinder
towards open position.
After the gate opened the operator could do the repair work from beneath the vehicle.

After the job is finished the car is driven off the pit. The issue of closing back the door
automatically remained.
CASE NO-2 : When 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 S1 & S2 is linked to
auto closing of pit
The problem of automatically closing & opening the pit door was solved by activating &
de-activating the sensors S1 & S2.

SAFETY CONCERN: In case someone is standing between the closing door &
does not notice the movement of closing the door he can be trapped in between the
door & pit wall & serious accident can happen.
New idea of closing the door in between in case some one or some object comes
between at the time of closing the door by pneumatic pressure.
CASE NO-3 : At the time of closing of door if someone or some object comes in
between the door 2 area sensors (S3) provided at both sides of pit which will sense the
presence of human or object & will stop the door suddenly & get it reversed to its home
(OPEN) position. With this system no one will be trapped between moving door & pit
wall

CASE NO-4 : At the time of closing the door if nothing is inside the pit & both area
sensors are clear of any obstruction the door will be closed safely & nobody will fall
inside the pit
DOUBLE ACTING CYLINDER
5/2 DOUBLE
PILOT SOLENOID
VALVE
3/2 SPRING
RETURN PUSH
BUTTON
3/2 SPRING
RETURN PUSH
BUTTON
F R L
COMPRESSOR

CIRCUIT DIAGRAM
The safety project implemented by the team is working in MSIL Gurgaon plant in
Assembly Shop-3 since 1st week of December’2009.
It was a great learning experience by working in a team. Mr. Manoj Attri (Engineer MP2)
& his team has helped me in completing the project in time.
They provided me with every help from arranging the material & getting the structures
fabricated.

 Without the ability to locate and track units as they make their way through
manufacturing, testing and repair processes, managers lack the ability to achieve
optimum performance for their business and are forced to rely on outdated,
inaccurate data and labor-intensive processes.
 The most powerful tool for any manager is accurate, real-time information about the
location and status of the work-in-process.
 The Vehicle Tracking and Management System (VTMS), provides real-time
information to track, measure and manage vehicles anywhere within a facility, both
indoors and outdoors.
 Vehicle Tracking and Management System is a ground-breaking step in automating
vehicle tracking and management in today's vehicle assembly, delivery chain and
fleet operations and is the first solution to provide real-time information to today’s
manufacturing management community.
 Vehicle Tracking and Management System allows a vehicle manufacturer, delivery
chain or fleet operation to know in real-time or historically exactly where the vehicle
is located or has been.
 Off-line processes are frequently a forgotten segment of lean manufacturing and
Vehicle Tracking and Management System is one of the world’s first systems to drive
efficiency and optimization in this area.

 In a Vehicle Tracking System solution, an RFID tracking tag is placed in each
vehicle typically before the vehicle enters the off-line processing areas., the solution
delivers real-time tracking information of the vehicle.
 In addition, beyond the ability to locate a vehicle on demand, the tracking data can
be used to monitor such things as adherence to process, process cycle time, and
dwell time analysis for off-line areas.
 Vehicle Tracking and Management System provides for accurate planning, execution
and monitoring of performance — making it the ultimate support tool for improving
processes and creating efficiency in off-line manufacturing areas.
Vehicle Tracking and Management Core
System Components:
Vehicle Event Management
The VTS Vehicle Event Management feature automates vehicle status changes,
reduces labor intensive barcode scanning, and triggers transactions with zero human
intervention.
ProcesscontrolManagement
Conditions like Special Comments etc can be broadcasted using check sheet or any
printers.Comments can be made for recheck,evaluation purposes for Trial Vehicle,
Spare Vehicle etc.Through VTS the position of any vehicle in the assembly line can be
easily traced out using the mimic.Vehicles can be viewed on the basis of
Chassis,PSN,Vehicle Model Etc.

Vehicle ThroughputManagement
The VTS Vehicle Throughput Management feature automates and
optimizes the vehicle throughput, by creating a process map for
every vehicle, knowing the current inventory location, deducing
the "process step" or "containment area" capacity and the FIFO
ordering of vehicles, the throughput management engine actively
manages and optimizes the vehicle movement. Vehicle Tracking
System communicates this information with users via desktop
computers, Windows Mobile Terminal Wi-Fi devices, Production
Control Boards, and Video Terminal Kiosks.
Vehicle Exception BasedManagement
The VTS Exception Based Management feature provides a goal
setting capability and delivers real-time exception-based
information to the user community. Therefore maximizing issue
resolution time, increasing options and reducing costs. The
exception management rules engine allows users to see
exceptions for a vehicle, as well as, for a "process step".
BENEFITS:
 Increase vehicle throughput
 Improve order to delivery
 Reduce dwell time

 Increase labour productivity
 Minimize work-in-process inventory
 Improve inventory accuracy
 Reduce operation costs
 Increase vehicle utilizations in fleet hours .
Equipment Tracking and Management
Improve Safety & EquipmentUtilization
 In any manufacturing environment, safety is paramount. Material handling equipment
can be extremely dangerous if not used by an authorized individual that has been
properly trained.
 The Equipment Tracking and Management System solution provides a secure
method of vehicle access and authorization, and can prevent the equipment from
starting or moving without proper authorization.
 In addition, Equipment Tracking and Management System provides vital information
directly from the equipment itself, including Run-Time, Idle-Time, Battery
Consumption, Lift Sensing and Impact Sensing.
 By utilizing this data, and closely monitoring the precise run-time and utilization of
the equipment, Equipment Tracking and Management System can significantly
reduce the total operating costs through proper "right-sizing" of the equipment fleet,
by total quantity and by equipment type.

EquipmentTracking and Management System helps address the following
real-time material handling equipment requirements:
Access Control
 Reduces injuries by ensuring that only approved users can operate the
equipment by using a contact button or proximity card.
 Eliminates government fines associated with access controls.
 Decreases abuse or misuse by linking incidents to specific operators.
Preventive Maintenance
 Maximizes equipment life through routine maintenance based on actual engine
runtime hours.
 Increases operator productivity with improved up-time of equipment.
 Reduces costs and increases useful life by performing usage based preventive
maintenance.
EquipmentUtilization
 "Right-size" fleet by tracking actual utilization.
 Increases useful life of equipment with better accountability and management.
 Reduces headcount through increased productivity.
BENEFITS
 Increase productivity
 Improve equipment utilization
 Reduce injuries
 Maximize equipment life
 Reduce labour
 Better efficiency

 High System availability and real time response.
 Enable mixed production in various shops as per VBS.
 Interfacing with Shop Equipment.
 Automatic component selection system(Pika-Pika).
 Material Flow Sequence Supply.
 Engine-Assembly Planning.
 Eliminate human error creeping in system at manual data entry.
 Modular and Scalable.
The Vehicle Tracking System or VTS was developed in house by the cross functional
team of IT, PE and Production of Maruti Suzuki India Limited to reduce the company’s
response time to market demand, and to handle the complexities of producing vehicles
across multiple variants
 VTS acts as a middle layer between the Host (Business)
computer and the Shop floor terminals and devices.
 Facilitate real-time communication for data transfer between
computer system and PLC.
 Pika-Pika for Component selection
 Sub System and Equipment Interfacing
VTS OBJECTIVES
MAIN FEATURES

 Broadcasting vehicle sequence at various control points to
different areas
 Tracking point Achievements
 Special Case Handling
 Progress Management
VTS IMPLEMENTATION
 VTS acts as a intermediary between the database server and the various shop floor
terminals and devices.
 It facilitates real time communication for transferring data between the computer
system and the PLC system which in turn provides data to the robots and to the
equipments that enables them to pick up the right component and also to broadcast
the requisite information to the printer.
 Thus providing data to the technicians. The technicians use this data for the
assembly of the vehicles and finally VTS aids the implementation of the production
plan sequence on the shop floor.
 The production plan contains all the requisite information in terms of the path to be
followed by each vehicle through the manufacturing plant the vehicle code, its color,
the country code, and chassis number. It also specifies the start and end point for
each process.
 The VTS facilitates this complex planning using which a vehicle under production
can be routed in a flexible manner across various shops and lines in the most
effective manner.
 The VTS enables the engine from multiple locations to be tracked as manufacturing
process progresses.

AREAS COVERED
 Weld Shop – 1, 2 & 3 (WB- ON & WB-OK)
 PAINT SHOP – 1, 2 & 3 (PB ON & PB OK )
 ASSEMBLY SHOP –1, 2 & 3 (AB ON & AB OK)
 ENGINE SHOP – 1, 2 ,3 & AL Shop
 VI1, VI2 & VI3 (FC ON & FC OK Points)
VEHICLE TRACKING

SERVER CONFIGRATION
The manufacturing plant in Gurgaon has
 3-weldshops,
 3-paint shop,
 3-assembly shops and
 4-engine shops.
In the above fig,each model is specified with different color and the path followed by each is
represented by the arrows joining different shops

VTS IN ASSEMBLY SHOP
AREAS COVERED
 Equipment activation – All equipment are connected through LAN with
VTS & as soon as triggering mechanism will get signal of presence of a particular
model it will pass on the signal to PLC of the equipment & the equipment will come in
that mode automatically. Vehicle Tracking from 1st control point to last control point
(WB ON to FC OK)
 WIP (Work – IN – Process) between 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 OK & No of vehicles will be under Paint Shop
WIP)
 Shop Sequencing – In multi model mix production overprized lines what
sequence of models is in line will be known in advance & that sequence can be
printed by line printers which can be displayed for operator to see what model of
vehicle is approaching in next few hours to him.
In the Assembly Shop, VTS tracks vehicle at two points
 Starts at AB-ON or assembly body ON and
 Ends at AB-OK or assembly body OK.
At the AB-ON point, the data is transferred to the PLC and the vehicle sequence is
broadcast at various control points to different areas.

Let us take a closer look on some of the areas points at which such broadcasts take
place:
 The Main Fundoshi Printer — this contains the details of components, and this
information helps the operators to fix the right components in the correct vehicles.
 The Door Mini Fundoshi Printers — these printouts are stuck to the doors. Based
on this information, the doors are assembled.
 The Process Check Sheet — this document is used to check the completion of the
processes at various checkpoints along the assembly line.
 Engine Storage Out — engines are put on the Engine Docking Line according to
the AB-ON sequence, which is broadcast to the printer at the time of AB-ON. At the
Engine-Body marriage point, the Engine Number is matched against the Chassis
Number by scanning the barcode sticker.
Various other sequence printers are used for different sub-assembly lines:
 Tyre sub-assembly;
 Instrument panel sub-assembly;
 Windshield sub-assembly;
 Door sub-assembly;
 Door latch sub-assembly; and
 ID plate
At certain points, PC Monitor applications are also used to broadcast the sequence.
The marriage of the engine with the vehicle is done at the EG Storage-Out point — this
is integrated with the VTS to avoid the possibility of wrong engine marriage.
The process ends with the AB-OK sequence.

Key features
 Tracking points: AB-ON , AB-OK.
 PBS Out sequence check at AB-ON
 Broadcasting of AB-ON sequence at different Sub Assemblies (Ex:- Instrument
Panel, Engine Storage Out etc..)
 Component selection using Pika-Pika.
 Sequence display through GOT’ s and PC-Monitor (Ex:- Glass/Door,radiator,Tyre
etc)
 Interfaced with Equipments:LLC filling,Break-oil,AC charging etc
 Air bag Registration for export vehicles.
 Interfaces with machines: ID Plate, Vin No marking machines.
 Engine Storage Out (Engine & Vehicle)

SCHEMATIC LAYOUT
List of equipment connected through VTS
 Pikka-Pikka
 Id plate m/c
 AC gas charging machine
 Gasoline filling machine
 Coolant filling machine
 Brake oil filling machine
 Engine oil filling machine

Equipment interfacing
 VTS interacts with the equipments in assembly shop through line
PLC’s.
 VTS gives the input to the PLC’s as per current vehicle model
 PLC controls the equipment and automatically gives the desired
commands as per vehicle model

PLC-EQUIPMENT INTERFACING
 As soon as the vehicle comes in position it hits the limit switch which is
connected to the line PLC
 The line PLC then interacts with the server to collect the information about the
vehicle (which in this case is amount of engine & break oil)
 The PLC then passes this information to the fuel filling machine for the particular
vehicle
 The information is also displayed in the GOT

PIKKA-PIKKA SYSTEM
 The selection of components in the main areas is carried out through the VTS using
Pika-Pika.
 This is a LED-based system.
 A LED glows on the bin from which the operator is supposed to pick the component,
thereby guiding the operator to pick up the correct component.
 As soon as he picks the component, the LED turns off.
 However, if the operator puts his hand into the wrong Bin, a warning signal is
generated.

Fool proofing for component selection
through PIKKA-PIKKA
 VTS provides Fool-proofing by means of Pika-Pika.
 The information pertaining to the vehicles in line is passed by the VTS to the line
PLC which in turn controls the pika-pika.
 Pikka-pikka system has series of rows & columns of the component for the particular
vehicle model,thereby guiding the operator to pick up the correct component
 On the vehicle arrival,Pika-Pika indicates the user which component is to be selected
as per the vehicle model.
 A LED glows above the particular column having components for the coming vehicle
model
Green light
glows on
correct part

 The LED goes off as soon as the operator picks up the correct component
 However a warning signal is generated if wrong component is selected by the
operator
 Thus through the pika-pika ,the VTS fool proofs the component selection process.
VTS IN ENGINE SHOP
RFID TRACKING
 To control the production and
quality in the highly
automated Engine assembly
line, Radio Frequency
Identification (or RFID)
technology is used.
 To communicate with the
RFID tag and to pass on the production plan information, a Production Management
system (PMS) is required.
 The system acts as an interface between the host computer and the production floor
and is used to transfer production plan information, dressing data to plant devices
and tags and obtaining production process data, traceability data and quality data from
the tag.

 The system then stores the data to the host computer for storing analyzing and for
future useThe data related to testing is handled by the test management system or
TMS which in turn interacts with the PMS.
 At these stations the magnetic RFID Tag communicates with the tracking system
known as PMS system via the Tag Controller to exchange and verify the data.
Additionally, the RFID tags also exchange data with other equipment and machines
on the assembly line in the same way, using the Tag Controller. The Tag contains
the data related to the engine kept on the palate.
 The RFID Tag will start receiving data from set up station — for example, type of
engine, engine number, master data, etc. As the pallet goes along the line and
different operations are performed on the engine by various machines, the RFID Tag
continues collecting data from machines recording the operation done, its status, etc.
When the pallet reaches the release station, the entire data in the RFID Tag is
transferred to the PMS and after updating, it is flushed from the Tag. Now the tag is
ready for the next engine loading.

VTS IN VEHICLE INSPECTION(VI)
In the Vehicle Inspection Shop, tracking is done at two points:
 FC-ON and
 FC-OK.
 After FC-OK, an FC-OK confirmation Sticker is attached to rear window of the
vehicle, and then the vehicles are transferred to the dispatch area.
 In the vehicle inspection shop, the VTS is integrated with the TECH-1 system which
carries out the emission check and the air bag check.
 Without the TECH-1 check FC-OK of the vehicle cannot be done.
 This ensures that the vehicle has been passed through all the necessary checks.

On the Quality Front, the VTS interacts with the quality gate system to provide faults
tolerance. All defects details are tracked through the VTS to ensure that no vehicle gets
FC-OK clearance without rectifying the defects.
Hence, VTS is a system that offers real time data to facilitate quick decision. It carries
out real time monitoring to detect errors and quality issues well in time; it broadcasts
messages that facilitate in-line correct evection at the shop floor.

45312185 maruti-suzuki-project-report

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