Suzuki's core philosophy is to provide value-packed products by developing them from the customer's point of view. This allows Suzuki to meet customer needs and have well-received products worldwide. The document then discusses the roles of the utility, maintenance, and various production departments like paint shop, welding, and press shop. It describes the key equipment used like generators, boilers, conveyors, injection molding machines, robots, and presses.

1. Presented by :
Saurabh Pathak
110106249
ME-D

2. MISSION & VISION
The core philosophy of SUZUKI is to provide "VALUE-PACKED PRODUCTS". Since the founding of
SUZUKI Motor Corporation, the Organization's endeavour has always been to provide "VALUE-PACKED
PRODUCTS" as one of the manufacturing philosophies.
SUZUKI believes that "VALUE-PACKED PRODUCTS" come from the effort to carry out Product
development from customer's point of view. This policy has been in effect since Company's
inception and has helped the Organization to meet customer's needs.
As a result, SUZUKI's Products have become well received throughout the World. SUZUKI is fully
committed to create Products that meet customer's demand by utilizing its dynamic, long-nurtured
technological advantage coupled with its fresh and active human resources.
•Develop products of superior value by focusing on the customers
•Establish a refreshing and innovative company through teamwork
•Strive for individual excellence through continuous improvement

3. INRODUCTION
• Initial training was in utility
• Learnt about role & function of Utility
• Learnt about their equipments like Diesel Genset, Gas Genset, Compressors, Dryers,
Boilers etc.
• Next phase of training was in Maintenance
• Learnt about role & function of Maintenance
• Learnt about different machines & equipment in different shopes
• Later I was deputed for paint shop, where I took detailed training
• Lets start from Utility

4. Role & Function of Utility
Utility is a department in an organization that maintains infrastructure. It handles
power supply of our company (electrical & mechanical), & provide new connections.
Diesel Genset & Gas Genset
• We have 3 DGs of 1500 KVA & 1 DG of 500 KVA. Make : Cummins
•It runs on high speed diesel
• 1 Gas Genset of 2500 KVA. Make : Caterpillar
• It runs on Compressed Natural Gas

5. We have 4 type of check for them :
A Check : It is a daily check. Here battery gravity level is check with hydrometer, dyno
voltage check, Air filter indicator, coolant is check & maintained. Leakages is also
checked
B Check : It is done in 300 hours or 6 month, whichever is earlier.
In this lube oil is changed. Oil filter, by pass filter & air filter is checked
& maintained. Filter paper is changed
C Check : Rarely done now in industry. Done in 1500 hours. Complete A & B check is
done.
D Check : It is done in 6000 hours. B Check is done. Fuel injector are sent for repairing,
Head & HSD pump are check & repaired

6. Boiler :
• We use Fire Tube type of Boiler
• We have 2 Boiler of Make Shellmax
• DM water is used for steam generation, raw water is avoided to prevent scaling
• Generally 1 boiler is runned, during peak times 2 can be runned
• Currently we are use CNG for steam generation

7. Maintenance Department :
It maintains all type of equipments available in Production Department. It handles there
breakdown & practices preventive procedures to prevent any breakdown. Now lets discuss
different equipments , starting from paint shop.
PAINT SHOP
• It has total 5 lines
• They are plastic line 1 for scooter plastic parts.
• Plastic Line 2 for motorcycle plastic parts
• Tank Line for fuel tank of motorcycle.
• Frame Line 1 for frame & other metallic parts of scooter
• frame line 2 for frame & other metallic parts of motorcycle

8. Conveyor :
• We have Over Head type of conveyor in paint shop, abbreviated as OH conveyor
• There are single conveyor for plastic line 1, plastic line 2 & tank line
• There are 3 conveyor each for frame line 1 & frame line 2, which run in synchro mode
• 3 Conveyor are used since different conveyor speed & type is required for different purposes
• We use 2 type of overhead conveyor, power & free conveyor, & fixed conveyor.
• Power & free conveyor are fast conveyor that carry & leave the job with the help of stopper &
dog

9. Injection Moulding :
• Injection Moulding machines are used for making plastic parts of scooter & motorcycle .
• Acrylo Butadiene Styrene in the form of a paste is injected through nozzle into a die which
gives shape to our final product
• ABS is crushed in granulator & heated in moulding heater, which are 5 in number.
• These machines have star sieki make robot which are used to take out the part from jig
• We are using injection moulding machines of make Mitsubishi & L&T
• Main parts of machine are nozzle, clamp unit, granulator, die, heat exchanger , pump,
screw cylinder

10. TOSHIBA INJECTION MOULDING
MACHINE

11. Weld Shop :
• Initially there were 5 lines in weld shop
• GE line, GT/GS line, UP/UZ line, swing arm line & tank line, now GT/GS line is shifted to new
place
• These line consist MIG welding machines, Robots, Welding Jigs, Revise Jigs, Belt Grinder,
Washing Machine, Spot Welding Machine, Seam Welding Machine, Leakage Testing Machine,
Boring Machine etc.

12. Robots :
• We are using 6 axis type of robots with 1 extended axis for fixture rotation
• Robots are of Make Fanuc & Motoman
• Robots have automatic curtains made of acrolyic with photo sensor for job
• Generally electrical breakdown comes in robots such as supply problem
• Sometimes mechanical problem such as curtains not working also comes

13. Welding & Revise Jigs :
• They are used for holding frames during welding & rechecking respectively. They have
pneumatic cylinders, with different type of pneumatic valves & pipes.
• Pneumatic cylinders are of 2 types. Single acting &Double acting, we are mostly using
double acting.
• Common problems that come in jigs are of leakage & jamming of cylinder & pipes
•Leakages are mainly due to burst pipe, damage fittings & damaged O rings

14. Washing Machine :
• Used for washing fuel tanks of motorcycle
• Consists of single chamber, subdivided into 2 parts, hence 2 tanks can be washed at the
same time
• First washing of the tank place with hot solution coming from clean tank
• Then purging of the tank take place with compressed air coming from spray nozzles
• After purging, compressed air is blown through air blow nozzles
• During cycle trolley is continuously reciprocated for effective washing
• A mist separator is present on top of machine for reject fume generated during process
• After washing contaminated solution is collected in dirty tank through sieve filter
• Then the solution is pumped by transfer pump to clean tank passing

15. Bend Machines :
• Hydraulic Machines used to bend frame pipes
• Make : YLM
• CNC based machine where bending can be done at any angle by changing the program but
maximum bending angle is limited to ensure correct operation
• Mandrel can be used both ways
• Oil cooler system & Oil filter system provided for hydraulic oil
• Bending can be done in manual, semi manual & fully auto mode
• Air & Oil are injected through mandrel to bend piece while bending
• Servo motor are used for accurate bending angle
• Other important parts are pressure die, clamp, collet, mandrel etc.

16. Press Shop :
• We are using 2 presses.
• 1 is 500 tonne mechanical press & other is 50 tonne hydraulic press
• Both make is ISGEC
• 500 tonne press is used for production purpose while 50 tonne is used for die
maintenance purpose
• Its main parts are slide, bolster plate, Main motor, slide adjustment motor, Cushion
cylinder, snubber, flywheel, clutch, counter balance cylinder
• For 50 tonne press we have 1 main cylinder & 2 pull back cylinder, bolster is of fix type
• Main motor uses a working pressure of 165kg/cm²

17. Sew Power Press :
• We use 63 tonne power press of make Singhal Power Press Pvt. Ltd.
• It has motorized lubrication pump for main bearing, connecting rod bearing & ram
• Fly wheel lubrication & back shaft lubrication is done by grease gun
• Reciprocated motion of slide can be adjusted for maximum & minimum stroke
• V belt is used for power transmission
• Pneumatic clutch is used
• Other parts are Balancers, safety valve, Solenoid Valve for Pneumatic clutch, FRL unit, NRV
etc.