ASSIGNMENT

Manufacturing Process ME-245Manufacturing Process ME-245

SUZUKI ALTOSUZUKI ALTO

Submitted to Sir Ejaz Yaqub

Ahmad Hanan 090802BEME – IV – B

Manufacturer:

Product:

ALTO

Introduction: The Suzuki Alto is a small car designed by Suzuki. Its selling points

include low price and good fuel economy. The model was introduced in 1979 and has been built in many countries worldwide. It is a Japanese designed car which has satisfied customers all over the globe with unmatched performance. It is a Suzuki enterprise and belongs to Kei car class of cars which is a Japanese category of small vehicles. Suzuki Alto is famous all over the world as a low-price economic car with excellent services. Generally Suzuki Alto is powered by 1.1 liter straight 4 engine, 16 valve unit. It manages a reliable mileage of 62bhp and sometimes an extra mileage of 9 bhp. The top speed of the car is generally 150km/hr. A turbocharged model of

Suzuki is called Alto RS—X. The fuel that is advised to use in Suzuki Alto is unleaded petrol.  In spite of being a small car, the Suzuki Alto is known to give great mileages. The fuel consumption is calculated on the basis of 100km/liter and for urban roads it is 43.5 liters. The fuel consumption for the extra urban roads is 70.6 liter and on an average basis the consumption is 57.6 liters. It is safe to drive a Suzuki Alto because the car is well equipped with twin airbags and side impact beams. All the controls are simple to use and the instruments clear and uncluttered. Driving a Suzuki Alto is almost like a child’s play now. The only disadvantage of the car is the small size and its cramped interiors. At 119g/km, the Alto’s CO2 emissions are some of the lowest around while its fuel consumption is similarly impressive. A combined fuel figure of 57.6mpg is very good going for a petrol-engine city car. The Alto, despite its humble beginnings, is still a very significant model for Suzuki, a company that has built its reputation on affordable cars. As the importers are open to new options they are giving much stress on the third world market. Suzuki has now opened more than 50 factories throughout the world, each one dedicated to achieving stringent Japanese quality standards. There are many joint ventures like the Alto programmed which Suzuki shares with the Pakistan government.

Specifications

Alto 1000 cc ( Smart Choice - Futuristic Look )Alto has bright, roomy, comfortable cabin which keeps body relaxed and has a strong and lighter body shell resulting in smooth drive due to reduction of unpleasant noise harshness and vibration. It has tiny turning radius and compact body make parking a breeze.

Dimensions and Weights

Overall Length (mm) 3395Overall Width (mm) 1475Overall Height (mm) 1460Wheel Base (mm) 2360Tread Front 1295(mm) Rear 1290(mm)Min turning Radius (m) 4.2No of Doors 4Kerb Weight (kg) 720 kg

Capacities

Seating Capacity (person) 5Fuel Tank Capacity (liter) 37 L Gas cylinder for CNG (liter) 55 L 

Fuel Economy

Mileage Highway (100km/liter) 70.6 litersMileage City (100km/liter) 43.5 litersMileage Overall (100km/liter) 57.6 liters

Engine

Displacement cc 970Engin Power (PS@rpm) 54.31[55.06] @ 5,500Torque (Nm@rpm) 83.4 [8.4] @ 2,500Compression Ratio 9.5 : 1 No of Cylinders (cylinder) 4Cylinder Configuration: In-lineMax. Output (ps / rpm)  55/5,500Max. Torque (kg-m / rpm) 8.5/2,500Fuel Type: Petrol & CNG

Transmission

Transmission Type ManualGears/Speeds 5-speed aGear Ratio 1st 3.416

2nd 1.8943rd 1.2804th 0.9145th 0.757Reverse 3.583Final 4.388

Suspensions

Front Suspension McPherson strutRear Suspension Isolated Trailing Link

Brakes

Front Brakes DiscRear Brakes Drum

Steering

Steering Type Rack and pMinimum Turning Radius (meter) 4.2 m

Wheels and Tires

Wheel Type SteelWheel Size 13-inchTyres 145 / 80 R 12

Features:

Air Conditioner: YesDial type Air Conditioner Controller : YesPower Windows: No AM/FM Stereo Cassette Player : YesPower Steering: No Anti-Lock Braking System: No Air-Bags (Driver | Passenger): NoLeather Seats: No CD Player: No Power Door Locks: NoTraction Control: No Air-Bags (Driver | Passenger): NoImmobilizer: No Digital Twin Trip Merers : YesWhite Meter Panel: YesCup Holders: Yes Key/Lights-off Reminder : YesFolding Rear-Seat: No Rear Luggage Shelf: YesRear Wash Wiper: No Assistant Grips (3): YesAlloy Wheels: No Tubeless Tires: YesMulti-reflector Crystal headlamps: YesGreen-tinted Glass: YesColoured bumper front & rear: YesSmoked Rear Combination Lamps: Yes

Central Locking: No Remote Boot/Fuel-Lid: Yes Steering Adjustment: No Tachometer: No Cigarette Lighter : YesGearshift Lever Console: YesSun visor (Both sides):YesRoom lamp (3-position): YesSeat Upholstery: New FabricReclining & sliding front seats: YesFront Door Pockets: YesFuel Lid Opener: YesMolded Full Trimming (Doors,Roof & Pillars): YesFront Fog Lights: No Rear Defroster: No Defogger (Rear): Yes Leather Seats: No Power Seats: No Cassette Player: Yes Sun-Roof | Moon-Roof: NoMuffler End pice: YesFull Wheel Cover: YesFront seatbelts: YesChildproof rear door lock: YesSide Impact Door Beams (All Doors) : Yes

Engine Piston Manufacturing Process

In Suzuki Alto , Pistons used in Engine are made by Hengshui Juneng Machinery Fittings Co., Ltd. s one of the leading manufacturers & exporters of pistons, piston rings, piston pins and cylinders . This company is Chinese origin.

Vehicle: Suzuki Alto Engine Type: F8B Bore: 68.5mmOE NO.: 12110-78402Brand Name: CYPEngine: F8BDia: 68.5mmPiston Pin:16X53.50Piston Ring: 1.5+1.5+2.8mmEngine Type: GasolineMaterial: Alluminum AlloyMOQ: 2000PCS

Manufacturing Process: A piston starts from a 3 meter Aluminum rod. Aluminum is ideal because it is light weight and rust resisting metal. And its easy to cut metal. A rotary saw slices the rod into small pieces (called slugs) the length of which can be changed by adjusting the feeder machine to push the rod at different intervals. The factory recycles the excess Aluminum chips. The punch press and die are pre-heated to 426 Celsius. The temperature requires to forged the slug . The slugs brought to a same temperature in an oven. Then Punch applies 2000 tons of pressure to forming into the initial shape of the piston. Then dip this forged slug into water for checking the defects. To make forging easier pre-lube the slugs before heating them, that’s why the slugs flames up when struck by the press. It only takes 2 seconds for the press to do its job, but the forgings are so hot that they need at least one hour to cool before the next step. Workers heat the forging twice more, the first time at very high heat to strengthen the metal, the second time at lower heat to stabilize it . Now insert each slug into the lathe to give forging a correct shape for the car that handles it later , then dig small holes through

drill that allow oil to flow through to lubricate the piston when it is used . Another machine then cuts three grooves, 2 for compression ring and another for oil control ring. These rings help the piston in regulating oil consumption, supporting heat transfer from the piston to the cylinder wall and enable it to provide an air tight seal. Then drills another hole (quiet bigger then the previous one) for the wrist pin that will attach the piston to a connecting rod. A milling machine then shaves off up to few centimeters from 2 sides of the piston to reduce to over all weight. Another milling machine cuts away the part what they called a dome. In this way they will clear other parts moving around the cylinder. The piston much be in just the right shape and size because they have the busiest job in a car, some of them moves up and down 6000 times when the engine is running. Next a lathe shaves the hair width amount of metal from outside, this cut enables the piston expands slightly when the heat build up inside the cylinder. Then a drill made two intersecting drain holes at some angle to enhance the lubrication of the wrist pin. Another machine engraves model and production data, then a worker removes sharp edger by a fine tool. Then use belt sander for further smoothen the surface, sharp edges can damage cylinder walls. Remember one thing, always use lubricant throughout the machining process otherwise piston could damage. Once the cutting is complete high pressure jet sprays the piston with hot de-ionized water, this cleaning removes all traces of lubricant. After that, blow hot air with air gun , now Pistons are ready for your Suzuki Alto.

Market Potential

Official sales data from the Pakistan Automobile Manufacturers Association indicate that the Toyota Corolla is still by far the best-selling car in the country this month with 3,397 sales and 21.6% share. It is also leader year-to-date at 12,103 units and 27.7%.

The Suzuki Mehran stays 2nd at 2,654 sales and a strong 16.9% share, or 17.1% year-to-date, compared to 15.6% in 2010. Excellent performance of the Suzuki Alto, climbing onto the podium in March at 1,957 sales and 12.5%. It is #5 year-to-date at 8.3% share.

The Suzuki Bolan follows in 4th, and the Honda City has a great year so far with 3,006 sales and 6.9% year-to-date, one percentage point above its 2010 share.

Full Top 10 Ranking Table below.

Pakistan March 2011:

Price: In Pakistan Price of Alto VXR Including Sales Tax w.e.f. May 01, 2011 is Rs.

693,000 , and for VXR CNG Rs. 748,000. Add Rs. 5000/- for the Metallic Color