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 REPORTON

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 ENGINEERINGFARIDABAD


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Hindustan Ambassador and Premier Padmini were both around 25 years out of date at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.

http://en.wikipedia.org/wiki/Government_of_India

http://en.wikipedia.org/wiki/Maruti_Alto

http://en.wikipedia.org/wiki/Maruti_800

http://en.wikipedia.org/wiki/South_Asia

http://en.wikipedia.org/wiki/Pakistan

http://en.wikipedia.org/wiki/Premier_Padmini

http://en.wikipedia.org/wiki/Hindustan_Ambassador

http://en.wikipedia.org/wiki/Kei_car

http://en.wikipedia.org/wiki/Suzuki_Alto

http://en.wikipedia.org/wiki/2007

http://en.wikipedia.org/wiki/May_10

http://en.wikipedia.org/wiki/Initial_public_offering

http://en.wikipedia.org/wiki/Japan

http://en.wikipedia.org/wiki/Suzuki


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.

http://en.wikipedia.org/wiki/1983

http://en.wikipedia.org/wiki/December_14


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).

INTRODUCTION TO MARUTI SUZUKI 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.

PLANDO

CHECKACT

QUALITY POLICY


QUALITY TOOLS

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

AUTOMATIC996CC, HATCHBACK

JULY 1998

ZEN D1200CC,

HATCHBACKAUGUST 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 R1096CC,

HATCHBACKJANUARY 2000

ALTURA

1586CC,

HATCHBACK

(BALENO)

MARCH 2000

ALTO LX, LXI 796CC, HATCHBACK SEPTEMBER 000

VERSA 1296CC, MUV DECEMBER 2001

SWIFT1296CC,

HATCHBACKMAY 2005

ZEN ESTILO1096CC,

HATCHBACKDECEMBER 2006

SWIFT DIESEL1296CC,

HATCHBACKFEBRUARY 2007

SWIFT DIESELFEBRUARY 2007

GRAND VITARA MARCH 2007


SX41.600CC 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

Machine :

Steel coilSteel coil BlankBlank PanelPanel


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

Steel Coils

46.2

56.9

4

50.1

2

105

29.6

13.0 21

.0

77.8

6

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 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

Panel

Stack of blanks


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

Tyre sensors

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


CIRCUIT DIAGRAM

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


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.

Process control Management

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 Throughput Management

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 Based Management

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 ManagementImprove Safety & Equipment Utilization

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.


Equipment Tracking 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.

Equipment Utilization

"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

VTS OBJECTIVES


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

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

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


SERVER CONFIGRATION

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


PLC-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


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

The LED goes off as soon as the operator picks up the correct component

Green light glows on correct part


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.

maruti suzuki project report

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