45312185 Maruti Suzuki Project Report (1)

7/27/2019 45312185 Maruti Suzuki Project Report (1)

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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 ofMay 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 Altokei carwhich at the time was the only modern car available in India, its' only competitors- the

Hindustan Ambassadorand Premier Padmini were both around 25 years out of date at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 otherSouth Asiancountries.

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", inpopular 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.
http://en.wikipedia.org/wiki/Government_of_Indiahttp://en.wikipedia.org/wiki/Suzukihttp://en.wikipedia.org/wiki/Japanhttp://en.wikipedia.org/wiki/Initial_public_offeringhttp://en.wikipedia.org/wiki/May_10http://en.wikipedia.org/wiki/2007http://en.wikipedia.org/wiki/2007http://en.wikipedia.org/wiki/Suzuki_Altohttp://en.wikipedia.org/wiki/Kei_carhttp://en.wikipedia.org/wiki/Hindustan_Ambassadorhttp://en.wikipedia.org/wiki/Premier_Padminihttp://en.wikipedia.org/wiki/Pakistanhttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/Maruti_800http://en.wikipedia.org/wiki/Maruti_Altohttp://en.wikipedia.org/wiki/Suzukihttp://en.wikipedia.org/wiki/Japanhttp://en.wikipedia.org/wiki/Initial_public_offeringhttp://en.wikipedia.org/wiki/May_10http://en.wikipedia.org/wiki/2007http://en.wikipedia.org/wiki/Suzuki_Altohttp://en.wikipedia.org/wiki/Kei_carhttp://en.wikipedia.org/wiki/Hindustan_Ambassadorhttp://en.wikipedia.org/wiki/Premier_Padminihttp://en.wikipedia.org/wiki/Pakistanhttp://en.wikipedia.org/wiki/South_Asiahttp://en.wikipedia.org/wiki/Maruti_800http://en.wikipedia.org/wiki/Maruti_Altohttp://en.wikipedia.org/wiki/Government_of_India


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Its manufacturing facilities are located at two facilities Gurgaon and Manesar south of

New Delhi. Marutis 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 andNational 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. Suzukis 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.
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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 Marutis mission to motorize India.

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 1986MARUTI 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 (NEWMODEL)

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


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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 000VERSA 1296CC, MUV DECEMBER 2001

SWIFT1296CC,

HATCHBACKMAY 2005

ZEN ESTILO1096CC,

HATCHBACKDECEMBER 2006

SWIFT DIESEL1296CC,

HATCHBACKFEBRUARY 2007

SWIFT DIESEL

FEBRUARY 2007GRAND VITARA MARCH 2007

SX41.600CC MAY 2007

SWIFT DZIRE MARCH 2008

A- STAR NOVEMBER 2008

RITZ MAY 2009


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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


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Vehicle Inspection (VI)


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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 runningmodels of Maruti Suzuki and one model of GM India - Tavera

2. The Blanking and stamping shop processes 10000 metric ton of steel / monthi.e. 400 tons a day

Machine :

Steel coilSteel coil BlankBlank PanelPanel


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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 Tontransfer

ress

Pressed panelscome out from

this side


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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


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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

Yield Improvement


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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 asforeign 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


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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 toform 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


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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.


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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.


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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.


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PRE TREATMENT:

Before sending vehicle to painting process pretreatment is done to

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


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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).

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.

ED DIPWR I WR II

WR IV WR III RINSING BY DIPPING

OVENWR V DI WATER


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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.

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+/-

5C.

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:


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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


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PROCESS THROUGH PICTURES:PB ON(WHITE BODY) PRE TREATEMENT

ELECTRO DEPOSITION PROCESS

DRY SANDING I SOL SEALING LINE PVC COATING


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IC OVEN IC COATING

DRY SANDING II

TC OVEN TC COATING

FINAL INSPECTION TO ASSEMBLY SHO


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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


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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.


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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.


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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)


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c. Ritz (Diesel)

45312185 Maruti Suzuki Project Report (1)

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