This document summarizes information about Maruti Suzuki India Limited, an automobile company based in Delhi. It discusses Maruti Suzuki's green manufacturing initiatives like using natural gas in plants and recycling over 12 lacs cubic meters of water annually. It also describes Maruti Suzuki's use of lean manufacturing techniques like the Maruti Production System and Kaizen for continuous improvement, which have helped reduce vehicle lead times from 57 to 13 days in 10 years. Kaizen is applied through employee KPAs and automation to ensure quality control and drive improvements within 30 days.

1. Knowledge Management
Submitted to :
Prof. Supratik Ghatak
Submitted By:
Minervi Gupta
B-16

2. • Founded in 1981, headquartered in Delhi
• Entered into joint venture with Suzuki motor company
• Most trusted and accepted automobile company
• Plants located at Gurgaon and Manesar Industrial town
• Around 1400 dealers across India
MARUTI SUZUKI INDIA LIMITED

3. STANDARD PROCEDURES APPLIED
• Green Manufacturing
• Maruti Production System / Lean Manufacturing
• Kaizen

4. GREEN MANUFACTURING
• All power plants use natural gas
• Green Procurement Promotion System (Green Supplies)
• Zero waste outside factory premises
• Registered with Clean Development Management project
• Approx. 12 lacs cubic meters water recycled and reused
• Gurgaon Plant has 25% green area – Advanced K-series engine used

5. Initiatives Undertaken include:
• One gram one component to reduce material consumption
• Energy Conservation – waste heat recovery boilers and steam turbine
generators in Gurgaon plant
• Zero discharge Status in terms of water wastage
• Reduced e-waste and hazardous waste generation

6. MARUTI PRODUCTION SYSTEM – LEAN
MANUFACTURING
• Mistake- proofing followed in both plants
• Started programme called Maruti centre for Excellence (MACE)
• Lean manufacturing applied on 720 products
• Done by collaborating with vendors especially with local vendors for
70-80% components
• Yield improvement program
• Primary raw material –steel coils and paint
• Lead time reduced from 57 days to 13 days in just 10 years

7. KAIZEN
• Maruti Suzuki India Limited (MSIL) applies Kaizen which helps in 'zero-
compromise' quality culture
• Every employee is given Kaizen numbers in Key Performance Areas (KPAs)
• Applies Kaizen using automated robotics
• Kaizen applied to Manesar plant because of Capacity contraints
• Benefits:
1. Quality control
2. Improvements made within 30 Days
3. 12 hours for 1 car

8. Thank you