ACKNOWLEDGEMENT

Industrial training is an indispensable part of any curriculum. It provides

the students with an opportunity to gain experience on the practical
application of our knowledge.

I express my gratitude to all the people at Maruti Suzuki India Limited who
helped me during the past six weeks. The exposure and experience
gained at Maruti has been unique.

I would like to thank Mr. Vinay Agarwal. (DPM MP-GKB) for giving me
this opportunity to work in their departments and guiding me through the
projects for his constant guidance and support.

I would also like to express my sincere gratitude to Mr. Sanjay Kumar,

Training In charge their able guidance and keen interest in my training.

LOVE KUMAR YADAV

DCRUST MURTHAL

DCRUST, Murthal
Page 1
 ABSTRACT

In order to get faster result over a particular period, maximum utilization of is very much
required. So if the proper utilization of time will be done then the maximum efficiency will
be produced with in the industry. My topic STUDY OF MP-KB ENGINE LINE
ASSEMBLY at Maruti is very much related with above fact.

There are many reasons for wanting to know the amount of time a particular task should
take to be completed. It may simply be for reasons of curiosity. But realistically, it is for
any of three reasons: (1) to accomplish planning, (2) determine performance and
(3) establish costs.

In this project I have studied the engine line assembly for KB series engine, along with
the complete plant layout. The study of the plant and its assembly line have been
concluded calculated the total time that the each worker at each station took to
complete its task in (KB-1) and I also design the layout of KB.2 .I have calculated time
at different station with the help of stop watch and for layout design I visited all the
station of KB-1 to find how many workers are engaged there and note all the workers
working in different sections of KB-1 and know its category(category such block line,
cylinder head line, main line storage line etc.) and finding various details of these
sections and various maintenance related to stations and equipment used, I designed
the layout of KB-2

DCRUST, Murthal
Page 2
CONTENTS:

Introduction to MSIL

Organisational structure of MSIL

Production overview

Milestones reached by MSIL

How a car is made in reality

Different shops in MSIL

Project report on Engine Assembly

Observations made

Conclusion

DCRUST, Murthal
Page 3
 COMPANYS VISION:

TERMS OF PRODUCTION VOLUME, COSTS AND PROFITS. WE

MUST NOT ONLY MAINTAIN LETO BECOME AN
INTERNATIONALLY COMPETETIVE COMPANY IN ADERSHIP IN
INDIA BUT SHOULD ASPIRE TO BE AMONGST THE GLOBAL
PLAYERS. THE CULTURE, THINKING AND ACTIONS HAVE ALL TO
BE CONSISTENT WITH THIS VISION

DCRUST, Murthal
Page 4
 INTRODUCTION

An aerial view of the MSIL, Gurgaon.

DCRUST, Murthal
Page 5
 PLANT LAYOUT OF
MARUTI SUZUKI INDIA LIMITED

DCRUST, Murthal
Page 6
 MARUTI SUZUKI INDIA LIMITED

ABOUT MARUTI SUZUKI INDIA LIMITED

THE START OF A NEW ERA:

Maruti Suzuki India Limited (MSIL) was established in Feb 1981 through an Act of
Parliament, to meet the growing demand of a personal mode of transport caused by the lack
of an efficient public transport system.

Suzuki Motor Company was chosen from seven prospective partners worldwide. This was
done not only due to their undisputed leadership in small cars but also due to their
commitment to actively bring to MSIL contemporary technology and Japanese management
practices (which had catapulted Japan over USA to the status of the top auto manufacturing
country in the world).

A license and a Joint Venture agreement were signed between Govt. of India and Suzuki
Motor Company (now Suzuki Motor Corporation of Japan) in Oct 1982.

The objectives of MSIL then were:

1. Modernization of the Indian Automobile Industry.

2. Production of fuel-efficient vehicles to conserve scarce resources.

3. Production of large number of motor vehicles, which was necessary for economic
growth.

THE REVOLUTION:
Maruti created history by going into production in a record time of 13 months. On 14
December 1983, the then Prime Minister of India, Mrs. Indira Gandhi, handed over the keys
of the first car to Mr. Harpal Singh of Delhi. Volume targets were routinely exceeded, and in
March 1994, Maruti became the first Indian company to produce over one million vehicles.
Maruti is one of the most successful automobile joint ventures, and has made profits every
year since inception till 2000-01. In 2000-01, although Maruti generated operating profits on
an income of Rs. 92.5 billion, high depreciation on new model launches resulted in a book
loss. Maruti revolutionized the way Indians looked at cars. "No other car company so
completely dominates its home market" - (The Economist). Despite there being more
than 10 companies now in the passenger car market, Maruti holds about 54.5% of the total

DCRUST, Murthal
Page 7
market share. MSIL is also the first and only car company in the world to lead its home
market in terms of both market share and in the JD Power Customer Satisfaction study.

TRANSFER OF TECHNOLOGY:
Every 26 seconds a vehicle rolls out of the Maruti plant. It is therefore imperative that the
transfer of contemporary technology from its partner SUZUKI is a smooth process. Great
stresses are laid on training and motivating the people who man and maintain the equipment,
since the best equipment alone cant guarantee high quality and productivity. From the
beginning it was a conscious decision to send people to SUZUKI Motor Corporation for on
the job training for line technician supervisors and engineers. These help them to imbibe the
culture in a way that merely transferring technology through documents can never replicate.
At present 20% of its workforce has been trained under this program.

ETHOS OF MARUTI:
Employees are Marutis greatest strength and asset. It is this underlying philosophy that has
moulded its workforce into a team with common goals and objectives. The employee-
management relationship is therefore characterized by:
Customer obsession
Fast, flexible and first mover
Innovation and creativity
Networking and partnership
Openness and learning
Participative management
Team work and kaizen
Communication and information sharing
Open office culture for easy accessibility
To implement this philosophy, Maruti has taken several measures like a flat organizational
structure. There are only three levels of responsibilities ranging from the Board of Directors,
Division to Head of departments. Other visible features of this philosophy are an open office,
common uniforms at all levels, and a common canteen to all.
The structure ensures better communication and speedy decision making process. It also
creates an environment that builds trust, transparency and a sense of belonging amongst
employees.

DCRUST, Murthal
Page 8
SHAREHOLDING:
Maruti Suzuki India Limited was set up as a deemed public limited company in 1981 by an
Act of Parliament. MSIL was classified in the Public Sector as long as the equity of
Government of India remained over 51%. A License and Joint Venture Agreement was
signed in 1982, with Suzuki Motor Corporation (SMC) acquiring 26% of the equity. SMC
increased its equity to 40% in 1989. In 1992, Maruti ceased to be a government company, as
SMC's equity holding went up to 50%.
In 2002, SMC's share went up to 54.2%, making MSIL a subsidiary of SMC. The Govt. of
India held 46.6%, and employees trust holds the balance 0.2%.
As of Sept 2006, Suzuki holds 54.21% shares, Govt. of India hold 10.27%, rest of the shares
are distributed between the public, insurance companies, FIIs, Mutual funds etc.

VISION OF MARUTI:
To be The leader in the Indian automobile industry
Creating customer delight and shareholders wealth
Be A pride of India

DCRUST, Murthal
Page 9
 MARUTI SUZUKI INDIA CULTURE

Building a distinctive organizational culture is one of the most challenging tasks faced
by any company. By organizational culture, is meant an organizational philosophy,
which guides the actions and behavioral pattern of the members. It also defines
implicitly how the external agents perceive the organization. Hence the necessity of a
work culture which, while appealing to those within, also satisfies the expectations of
those outside the organizational environment. There is no use for a work ethic that
creates highly efficient pseudo-robots out of the employees. Such an approach might
look like giving dividend in the short term but will definitely lead to stagnation and
frustration in the long term.
A harmony between the work culture and organizational objectives is hence very
essential. It is the duty of every employee to work towards sustaining the MARUTI
CULTURE, which is built over the years.

5 S OF MSIL
SEIRI - PROPER SELECTION
SEITON - ARRANGEMENT
SEISO - CLEANING
SEIKETSU - CLEANLINESS
SHITSUKE - DISCIPLINE

3M OF MSIL
In factory various problems occur which hamper production and adversely affect the
quality of products. Most of these problems occur due to 3M: -
MURI - INCONVENIENCE
MUDA - WASTAGE
MURA - INCONSISTENCY

DCRUST, Murthal
Page 10
3G OF MSIL
3G means, In case of an abnormality, all concerned members should actually go to the
place where the problem has occurred, see the actual thing and take Realistic action to
solve the problem. In the Japanese language this point is compiled in 3 words: -

GENCHI - ACTUAL PLACE

GENBUTSU - ACTUAL THING
GENJITSU - ACTUALLY

3K OF MSIL

KIMERAARETA KOTO GA: What has been decided

KIHON DORI: As per the standard
KICHIN TO MAMORU: Must be followed

COMMUNICATION CHANNELS

As a part of open culture, all managers strive to facilitate both top-down as well as
bottom-up communications. At all levels, throughout the company employees can
communicate on any business, organizational or personal concern, without having to
cross many channels. The organizational structure has deliberately been kept very flat
to facilitate communication.

DCRUST, Murthal
Page 11
ORGANISATIONAL STRUCTURE AT MSIL

MSIL is a functional organization. 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, which are headed by Department
Managers who report to the respective divisional managers. Designations in the
Company are based on the functional responsibility in terms of the Company's
philosophy of de linking designations and functional responsibility 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 further
divided into Departments.
For example: -
In Marketing & Sales Division, the departments are Exports, Marketing, Sales Planning,
Sales & Dispatch, RO-East, - West, - South, - North-I, North-II & MSS-N. In Information
Services Division, the departments are Marketing & Sales Information, Production
Management Information, Materials Management information & Resource Management
Information.
Maruti Suzuki India Limited has a total of 3354 employees (not including trainees or
Japanese experts).

DCRUST, Murthal
Page 12
SYSTEM OF DESIGNATION
There will be a dual set of designations. Internally, only the designations linked to
functional responsibility will be used. For external dealings a different set of
designations may be followed.
The following system of designations would be practiced without any exception within
the Company. For the purposes of defining explicit responsibility centers,
The Company has been divided into three layers of management.
Division
Department
Section
An official of the Company, who will be designated as Divisional Manager, Department
Manager, Section Manager respectively would head each of these responsibility
centers. Remaining employees of the Company will have no specific designation and
would simply use the name of the Division/Department/Section to which they belong, to
identify their location in the Company.
The MD would make appointment to positions of Divisional Managers and Department
Managers only. The Divisional Managers would appoint section Managers.

DCRUST, Murthal
Page 13
Designation Flowchart

M a n a g in g D ir e c t o r
(M D )

J o in t M a n a g in g D ir e c t o r
(J M D )

D ir e c t o r

D iv s io n a l M a n a g e r ( D V M ) / C G M

D e p u t y D iv s io n a l M a n a g e r ( D D V M ) / G M

D e p a rtm e n t M a n a g e r (D P M )/D G M /A G M

M anager

D e p u ty M a n a g e r

S e n io r E x e c u t iv e / A s s t . M a n a g e r

E x e c u t iv e

S u p e r v is o r

DCRUST, Murthal T e c h n ic ia n
Page 14
OVERVIEW OF PRODUCTION AT MARUTI

The plants were setup with an initial collective capacity of 5 lakh cars per year. But over
the years as the demand has increased Maruti has risen to the task and responded
tremendously to the market. By introducing automation at various levels, streamlining
and refinement of material handling systems and operator motivation and incentives,
Maruti is now churning out close to 10 lakh vehicles from the plants that were planned
only for 5 lakh.

DCRUST, Murthal
Page 15
 MILESTONES REACHED BY MARUTI

2015
Maruti Suzuki launches NEXA
Opens its booking for premiere crossover Scross
Completes 10 successful years of swift.
2014
Maruti Suzuki launches CIAZ
Maruti Suzuki donates 2,00,00,000 to prime ministers national relief fund.
Maruti Suzukis manesar facility crosses 25 lakh milestone.
2013
Maruti Suzuki contribution for victims of uttrakhand tragedy
Swift and etriga bag india design mark ; good design award 2013
2012
Maruti Suzuki introduces all new alto800
Maruti Suzuki declares lockout at manesar plant
Unveils first life utility vehicle ERTIGA
2011
Maruti Suzuki board approves land purchase for new facility in Gujarat
Maruti Suzuki roll out its 1,00,00,000th car
Mr R C Bhargava, Chairman, Maruti Suzuki, India felicitated by Emperor Akihito
of japan.
2010
Maruti Suzuki becomes the first advertiser in India to win the prestigious global MMA
Award
DCRUST, Murthal
Page 16
 Maruti Suzuki swift awarded the frost and Sullivan 2010
Maruti Suzuki to establish new plant at manesar

2009
Utarakhand cm dedicates Maruti Suzuki IDTR to citizens
Maruti Suzuki launches new sx4
Haryana allots 700acres to Maruti Suzuki RND at Rohtak

2008
Maruti Suzuki moves A-star for Europe on auto wagons
Maruti Suzuki completes 25 years
2007
Launch of SX4
2006
WagonR Lx & Lxi LPG new car plant and the diesel engine facility commenced
operations during 2006-2007 at Manesar, Haryana
2005
The fiftieth lakh car rolls out in April, 2005
2004
Alto becomes India's new best-selling car
LPG variant of 'Omni Cargo'
Versa 5-seater, a new variant
Baleno LXi, a new variant
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
2003
New Suzuki Grand Vitara XL-7
Enters into partnership with State Bank of India
DCRUST, Murthal
Page 17
 Production of 4 millionth vehicle. Listed on BSE and NSE after a public issue
oversubscribed 10 times
2002
WagonR Pride
Esteem Diesel. All other variants upgraded
Maruti Insurance. Two new subsidiaries started: Maruti Insurance Distributor
Services and Maruti Insurance Brokers Limited
Alto Spin LXi, with electronic power steering
Special edition of Maruti 800, Indias first colour-coordinated car
Maruti Finance in Mumbai with 10 finance companies
2001
Zen LXi
Maruti True Value launched in Bangalore and Delhi
Maruti Versa, Indias first luxury MPV
Alto Vxi
2000
First car company in India to launch a Call Center
New Alto
Altura, a luxury estate car
1999
Maruti 800 EX (796cc, hatchback car)
Zen VXi (993cc, hatchback car with power steering)
Omni XL ( 796cc, MUV, high roof)
Baleno (1600cc, 3 Box Car)
Wagon R
1998
Zen D (1527 cc diesel, hatchback car)

DCRUST, Murthal
Page 18
 New (Omni & Omni E) (796cc, MUV)
Launch of website as part of CRM initiatives

1997

1998 Esteem (1299cc, 3 box car) LX, VX and AX

New Maruti 800 (796cc,hatchback Car) Standard and Deluxe
Produced the 2 millionth vehicle since the commencement of production

1996

Gypsy King (1298cc, 4WD, off road vehicle)

Zen Automatic (993cc, hatchback car)
Launch of 24-hour emergency on-road vehicle service
1995

With the launch of second plant, installed capacity reached 200,000 units
1994

Esteem1.3L (1298cc, 3 box car)LX

Produced the 1 millionth vehicle since the commencement of production
1993

Zen(993cc, hatchback Car), which was later exported in Europe and elsewhere
as the Alto
1991

Reaches cumsilative indigenisation of 65 percent for all vehicles produced

1990

Maruti 1000(970cc, 3 box), Indias first contemporary sedan

1988

Installed capacity increased to 100,000 units

1987
DCRUST, Murthal
Page 19
 Exported first lot of 500 cars to Hungary

1986

Maruti 800 ( New Model-796cc, hatchback Car)

Produced 100,000 vehicles (cumsilative production)

1985

Launch of Maruti Gypsy (970cc, 4WD off-road vehicle)

1984

Omni, a 796cc MUV

Installed capacity reached 40,000 units

1983

Maruti 800, a 796 cc hatchback, Indias first affordable car.

Production was started under JVA
1982

License and JV agreement signed between Maruti Suzuki India Ltd. and SMC of
Japan
1981

Maruti Suzuki India Ltd was incorporated under the provisions of the Indian
Companies Act, 1956.

DCRUST, Murthal
Page 20
 HOW IS A CAR MADE

The making of a car starts from the press shop, where the raw material is obtained in
the form of cold- rolled sheets. From the press shop, the parts are send to the weld
shop, where they are welded to make the frame of the car. From the weld shop, these
frames are transferred via conveyors to the paint shop, where these are coated and
glazed. From the paint shop, these are send to the assembly shop, where through a
conveyor system, various parts are fitted at various canopies or stations. The machine
shop and the Engine assembly shops are located close to the respective assemblies,
and the car engine and
Other transmission parts are also fitted in the assembly shop itself. Then, the V.I dept.
conducts various tests to ensure that no defects remain before the car is dispatched via
trucks to various parts of the country.

DCRUST, Murthal
Page 21
The flow chart for a typical car body weld line looks as follows:

DCRUST, Murthal
Page 22
The basic layout of a paint shop is as follows:

From weld shop

DCRUST, Murthal
Page 23
The features of an assembly shop is shown as follows :

Trim line: The car body moves over the conveyor on mounts, as shown below:

DCRUST, Murthal
Page 24
Chassis Line: Here, the car is loaded on overhead jigs as shown below:

Final Line: Here, as both the engine and wheels have been fitted, the car once again
moves over the conveyor belt.

DCRUST, Murthal
Page 25
DIFFERENT SHOPS IN MARUTI SUZUKI INDIA LIMITED

1. 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. The press
shop can be explained under following headings:

(a) Raw material

(b) Blanking line
(c) Stamping line

(a) Raw material: The raw material is in the form of cold rolled steel coils. It is specified
in terms of steel grade and width of coil required. The coils weigh about 15000 kg.

(b) Blanking line: There are two blanking lines; ROSL (Rotary Oscillatory shear line)
for rectangular shapes and the others employing die cutting for irregular shapes.

(c) Stamping line: there are six presses of capacity varying from 1500 Ton to 4000
Ton, out of which five are transfer presses and one is semi-automatic press. The die
can be changed to obtain different body components.

DCRUST, Murthal
Page 26
2. 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.

DCRUST, Murthal
Page 27
3. 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: -
(a) 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.
(b) ED coat: This is done by electric deposition method, at 240V-dc supply. After
applying the ED coat the body is baked in oven.
(c) Sol-sealer and under coat: Here the left in the body (due to welding) are filled with
sol-sealer to provide waterproofing. Under coat is done on the surface above wheels
to prevent damage of body in that portion.
(d) 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.
(e) Topcoat: This is done by spray-painting method using 20 Kawasaki Robots. For
metallic coating, double coats are applied and aluminium 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.

DCRUST, Murthal
Page 28
MACHINE SHOP
The machine shop is the source of all major components for the Engine Assy. Shop.
The unmachined crankshaft and camshaft forgings, transmission case, cylinder head
and cylinder block castings are brought in as raw material from vendors. The cylinder
Head and transmission case are aluminum castings while crankshaft and camshaft are
steel forgings.
It has the following lines
Transmission Case Line
Cylinder Head Line
Cylinder Block Line
Crankshaft Line
Camshaft Line

ENGINE ASSEMBLY
Engine assembly 3 is currently used to assemble the 1061cc engine for WagonR, F8D
engine (5-speed transmission, 796cc MPFI) for Car800 and Alto. Engine assembly is
Divided into 3 main Sub-Assemblies, one Main Line and a Firing Test. The sub-
assemblies are:
Cylinder Block Line
Cylinder Head Line
Transmission Line

The cylinder block, cylinder head, transmission case, camshaft and crankshaft are
received here from the machine shop.

DCRUST, Murthal
Page 29
ASSEMBLY SHOP -I
There are 3 assembly shops in MSIL which produce on an average 1750 cars daily.
The assembly shop receives PB-OK i.e. paint body OK from the paint shop. Here the
body is loaded on an overhead conveyor. As the conveyor moves the body, fitments are
made at various stations.
Assembly I mainly produces MARUTI 800 (Domestic & Export Mainly), ZEN ESTILO
(Domestic& Export), OMNI(Passenger & Cargo), A-STAR,RITZ & WAGON R(new
model).
The Whole process of assembling undergoes through different number of stations.
There are about 375 employees in two shifts. The Assembly shop can be further
subdivided as following
Trim
Chassis
Final

TRIM LINE
Trim can be further subdivided as following:

Trim 1
This is the beginning of the assembly line conveyor. Here amongst the first tasks done
is attaching the hydraulic supporters for the boot. The assembly line check sheet is put
inside the body. Door is removed here and sent to final line .The various fitments made
here are door/floor grommets, electric wiring, and door trims parking brake cable, inner
and outer door openers, model stickers and emblems, roof silencer and cabin lamp.
Steering gear case is put inside to be fixed later.

Trim 2
DCRUST, Murthal
Page 30
It starts with Rear combination light fitment. Other operations done here are vacuum
booster/ brake master cylinder fitment, seat belts, fuse box, wiper sprayer and motor,
accelerator, clutch, brake pedals, door glasses and a/c panel fitment. Trim 2 ends with
the fitment of the instrument panel, which is received from an instrument panel sub-
assembly. This sub assembly involves the fitting of the speedometer console, ashtray
and stereo system. .

Trim 3
The fittings done here are rear inside cover for boot, back door glass and windshield,
quarter glasses and connecting pipe between fuel lid and fuel tank. Steering gear is
mounted. For cemendine application on the windshield, Moto man robots are employed.
Here a process check is done

CHASSIS
The chassis receives a trim up body. Here underbody fitments are made, hence body is
loaded on overhead jigs. Chassis is subdivided as following:

Chassis 1
Various fitments made here are rear shock absorbers, brake pipes, front coil spring with
knuckle, steering wheel, tie rods, rear suspension, fuel pipes, fuel tank and rear brake
drum. There is a knuckle sub assembly that feeds the line with knuckles for the front
suspension system. Process check is done at the end of Chassis 1.

Chassis 2
The fitments made here the exhaust system (silencer and catalytic converter), engine
cum transmission case assembly, gearshift rod, front and rear bumpers, stabilizer bars
and tyres. The tie rod and drive shafts are connected to the knuckle to complete the
front suspension system and ID plate fixation. A process check is done at the end of
chassis 2.

DCRUST, Murthal
Page 31
FINAL
Since all the fitments have been made, the body is referred as vehicle from now
onwards. The vehicle is loaded on the final conveyor. Final area is further subdivided
as: -

Final 1
The fitments made here are Spare wheel cover, scuff, seats, roof trim and carpet, boot
carpet, battery and air cleaner. Clutch cable and parking brake connections are made.
Brakes are evacuated and brake oil is filled. Coolant is also filled.

Final 2
Five liters of petrol is filled in the vehicle. A/C vacuum and charging is also done here,
the refrigerant used here is R134a (400 gm. +- 50).Door Assembly is also done here.

Final 3
There is a process check at the end of this line. The vehicle is said to be AB-OK now. It
is handed over to the vehicle inspection department.

DCRUST, Murthal
Page 32
 VEHICLE INSPECTION - I

The VEHICLE INSPECTION II having the following stations:

Toe-in test
Slip tester
Head lamp test
Appearance test
Drum test
Brake test
Engine room and Pit inspection
Shower test
Road test
Final check

General Procedure
In VI a vehicle is checked at checkpoints in the above mentioned order. At each
checkpoint different parameters are checked. Each vehicle is issued a check-sheet in
which the operator at the check points marks down the defects if any, otherwise he
marks an OK stamp. After the road test if the vehicle has no defects marked in the
check sheet it goes to the final check conveyor belt where it is again checked for overall
appearance. If a vehicle has any defect then it is sent to the following repair areas
depending on the type of defect:

Assembly repair
Weld repair
Paint repair
Engine Assembly repair

DCRUST, Murthal
Page 33
After repairs the vehicle is then sent to the final check conveyor where the repair work is
checked and if satisfactory then the vehicle is given final clearance.

Toe-In Test
This is the first inspection point for a vehicle once it comes off the assembly line
conveyor. Before the vehicle is accepted for this test it is checked for external damages,
feel of the brakes and floor carpet. The objectives of doing the toe-in test are as follows:

Minimum tire wear

Steering position OK
Minimum side slip

Toe-In refers to the alignment of the wheels. It is not possible to have a wheel alignment
such that the wheels are perfectly straight (ideally this leads to minimum tire wear). The
wheels are either pointing slightly inwards (toe-in) or outwards (toe-out). Also when a
car is in motion then the wheels tend to align outwards so vehicles are generally set
with a toe-in condition. Statistical analysis and experiments has given a value of toe-in 2
and toe-out 1 for front wheels in Car800, WagonR and Baleno. Baleno has rear wheel
allowance of toe-in 3.5 and toe-out 0.5.

Another point checked here is the steering position. Correct steering position refers to
that setting of the steering wheel that would allow the car to move in a straight line and
which is the natural position of the wheel i.e. the driver isnt holding the steering wheel.
Figure no. 5 shows the toe-in tester machine.

DCRUST, Murthal
Page 34
SLIP TESTER
This machine checks vehicle slipping after the toe in adjustment. The machine is
calibrated for 2 unit toe-in and 1 unit toe-out. If the vehicle slipping falls in between the
calibration limits, the vehicle is OK in slipping otherwise NOT OK.

HEAD LAMP TESTER

Often the car driver faces the problem, the headlight beam adjustment. Because of the
maladjustment the light beam falls on unwanted objects. At the headlamp tester, a
yellow cross represents the position of the headlamp whereas the point where it should
ideally be is shown as green rectangle. The operator manning the test tries to get the
yellow cross inside the green rectangle by adjusting screws for horizontal and vertical
alignment of the lamp.
Apart from checking the headlamp, turning radius and other things are also checked at
this checkpoint.

Appearance Test
This test involves evaluating a vehicle on a large number of parameters ranging mainly
from external appearance of the vehicle to the internal trim fittings to checking for
coolant level and braking fluid level. The vehicle is loaded on a conveyor. The vehicle is
visually inspected for weld, paint and assembly defects and the same are marked on
the diagrammatic representation given on the check sheet. The appearance check
points are I.D plate, emblems, bumper, doors, fuel lid, front hood, routing and clamping,
seats, interiors, seat belts, weather strips, tires and glasses.
Various paint defects are paint peel off, scratches, paint miss, overflow, orange peel,
shade mismatch, pin holes sealer application and sanding marks. Various weld defects
are level difference, dents, door gap and fouling.

DCRUST, Murthal
Page 35
The vehicle is driven in all the gears and the various parameters checked are as
follows:
Steering wheel : position/vibration
Clutch : free play 20-30 mm/noise/engagement/disengagement
Accelerator Pedal: free play 2-7 mm/operation
Gear shifting: hard/noise/slippage
Speedometer: needle vibration/error/reading at 40 km/h
Horn: volume/tone
Wiper/washer (front/rear): auto stop position/wiping/spraying position
Warning lamps and indications: parking brake/battery changing/oil
pressure/hazard lamp/turn signal/pilot lamp/room lamp/panel light/pre heat/brake
oil indication.
Rear view mirror: blurred image/ distortion
Fuel/Temperature gauge: function
Lamps: Parking, head lamp high/low, side turn signal, cabin lamp/door switch/fog
lamp, brake light, hazard lamp, reverse light
Blower: Operation of switch at different speeds, air direction control, fresh/re-
circulating air control, fins
Heater: functioning, switch operation
A/C: functioning, switch operation
Choke: operation/ function
Abnormal noise of any kind from wheels/body/engine should not be there.

Brake Tester
The front and rear brake forces are measured here. Here the brake pedal is checked
for hardness, sponginess, play and noise. Parking brake force is also checked here.
The vehicle is moved onto the drums, vehicle brakes are employed and the
corresponding resistance force is measured with the help of computerized machine.

DCRUST, Murthal
Page 36
The measured force is displayed on the screen and must lie between the values
prescribed by the company.

Engine Room
Here the engine is inspected for various kinds of defects such as tappet noise, clutch
lever play (Car800), exhaust emissions as per the standards laid down, idling rpm with
and without A/C switched on. In case of MPI cars, a DLC (Data Link Connector) cable
is used to detect the working of Electronic Control Module and various sensors. The
DLC cable is connected to a computer which shows not ok if there is any malfunctioning
in the engine. The defects are noted on the check sheet to be repaired in assembly or
engine assembly.

Pit Inspection
The underbody of the vehicle is checked for:
Brake fluid/coolant/fuel/engine oil leakage
Red and yellow paint on nuts, bolts and fuel and brake pipes (the paint indicates that
the nuts and bolts have been properly assembled and checked for torque) Muffler
mounting bolt Rear suspension coil or leaf spring

Shower Tester
The vehicle is moved on the shower tester conveyor belt where it passes through a
series of shower jets aligned at different angles and locations. While passing through,
the vehicle is sealed i.e. all window glasses are rolled up and doors closed. When the
vehicle exits from other side of the shower tester an inspector checks the cabin for
water seepage. If water is found, then the particular leak defect is repaired in the
shower repair section following which the vehicle is sent for the road test.

DCRUST, Murthal
Page 37
Road Test
Road test of a vehicle consists of a track on which the vehicle is run at predetermined
speed. The track is designed so as to check the various aspects of the vehicle such as
braking, acceleration, handling, performance etc. Distance traveled after application of
brakes, reverse braking and steering positioning is also checked. After driving the car at
a fast speed it is made to take a U-turn to try and find for any loose part in the panel.
Other parameters checked in the road test are:
Steering stability: position/play/vibration
Clutch/accelerator pedal: play/noise
Brake: noise/sponginess/brake pulling
Rear view mirror: blurred image/distortion
Gear shifting: gear slip/engagement/hard disengagement/noise
Defogger: functioning
Speedometer: needle vibration
Abnormal noise of any kind from panels, doors, wheels , engine, hood etc is noted
down

Final Check
This is the last of the vehicle inspection checks. After the vehicle has gone through the
other tests and if there are no repairs to be done then it is sent to final check. Here the
overall appearance of the vehicle is checked again.
Scratches, dents, cleanliness and Comedienne (windscreen sealer) leftovers are
checked for. Also secondary defects i.e. defects that may creep in while repairing the
primary defects are also checked for. Inspection stamps for all the previous check
stations are checked to see that there is no inspection miss. Finally the chassis and
engine number on the I.D. plate are verified and the Final Check OK (FCOK) sticker is
put on the car and it is sent to the final check parking area. FC OKed vehicles are later
picked by the Sales and Dispatch drivers.

DCRUST, Murthal
Page 38
 NEED FOR THE PROJECT

The need of the project is to understand the complete working of car plant as well as
management of the different steps and stations to the complete process of car
manufacture at MARUTI SUZUKI

An in-depth view has been taken regarding the department of MP-GKB which is one of
the major Department for manufacture of KB series engine and is associated with the
monitoring and maintenance of the engine plant and its further constant development.

By assigning this department the main goal is to understand and learn the maintenance
task undertaken by the department of MP-GKB and to reduce the losses for the
company as well as take preventive steps to increase the efficiency and output of the
company.

Different stations of the plant KB-1 shall be looked upon and a brief study shall be
conducted relating to the machines and if a breakdown occurs then steps shall be taken
in order to enforce corrective steps

As a whole the study shall build up the knowledge base for student regarding the
management and curriculum employed in industry for the management of a working
station and to improve the knowledge base.

DCRUST, Murthal
Page 39
 Introduction to KB Plant

KB 1 ENGINE ASSEMBLY

The KB plant caters to the needs for the K series engine which is predominantly the
leading innovation of maruti Suzuki. The k series engine is a 998 cc three cylinder
aluminium based engine the is mostly in variants such as A-star, Estillo, and Zen . And
is fast making its appearances in other variants as well due to its better performance
and light weight.

The KB plant is predominantly divided into three parts:

1. KB 1
2. KB 2
3. KB 3
The only difference is in the storage bay and minute differences.

DCRUST, Murthal
Page 40
 LAYOUT OF KB ENGINE ASSEMBLY
The KB engine plant has an installed annual capacity of 240,000 engines.

The in-line plant layout consisting of Casting, Machining and Assembly processes has
high level of automation, effective material handling and inventory reduction techniques
in place, aimed for high operational efficiency. It employs global manufacturing best
practices like cold testing, 100% on line automated checks to ensure global quality.

The various assembly line stations are as follows:

Station no.1: Central block sub assembly

Station no.1b: Central Head assembly

Station no.2:Cylinder Block line 1

Station no.3: Cylinder block line 2

Station no.4:Main line

Station no.5: Storage area

DCRUST, Murthal
Page 41
 DESCRIPTION OF STATIONS AT KB-1
ASSEMBLY:

LINE .1: CYLINDERICAL BLOCK SUB ASSEMBLY

It is one of the primary processes of engine assembly and the primary task is done
here. The engine manufacture process starts with the process of casting where the pre
desidened structured is casted upon by suitable aluminum metal and proper shaping is
done for the casted block to take the appropriate shape.

Once the cylindrical block is casted upon then it reaches the cylindrical block sub
assembly where it moves along the conveyor belt towards various stations where
different workers perform the action designated to that particular stop or station.

The various stations for cylindrical block sub assembly are as follows:

VTS Vehicle tracking system is one of the important steps of the entire
procedure and is not only employed in tracking the progress of the engine part
but always collects anonymous data as to the various stages of engine assembly
time taken at each station and the further other crucial information that might help
in increasing the efficiency of the system
VTS is not only incorporated in the engine architecture but also is established on
other parts of the car such as engine chassis and body components so that
effective monitoring of the system can be done and the process can be kept
tracked.
At the engine stage here the engine no. is patched upon the body of the engine
and is sent up to the next stage.

DCRUST, Murthal
Page 42
 CRANK CAP BOLT OPENING This is a relative simple process that
employees the removal of bolts from the crank cap which have been set up on
the assembly line so that components such as crankshaft can be placed in the
engine body. The process employees the use of servomotor for unfastening of
the bolts.

WASHING SPRAYING After the crank cap is opened up the cylindrical

block enters a jet of water sprayer that eliminated any dust or foreign particles.

AIR BLOWING The strong jet of air that is blown sends the residual
water and moisture sends away and dries the excess of water from the cylindrical
block and sends is forward for the next process of filtration pump where the water
is filtered for other purposes

ENGINE NUMBER PUNCHING here at this station using power

tools and a proper graphical management system and a visual graphical display
using appropriate camera the engine number is punched on the side line of the
cylinder head

BEARING AND BEARING CHECK- At this stage along the penned

up crank cap bearing are placed so that proper degree of freedom is available for
movement of crankshaft and its associated parts that are placed in the tunnel
side of the cylinder head. The further movement of the shaft is not restricted

The next steps involve the check of bearings because a minor misfault in
placement can cause a huge dispersion of power along the line of crankshaft and
can result in complete breakdown and so such a product would not be approved
by the company standards.

DCRUST, Murthal
Page 43
 LUBRICATION Lubrication provides the appropriate movement and
reduces friction that is essential for free movement of the parts.

TRANSFER TROLLEY It is an automated control transfer unit which

transfers the finished product of first line to the subsequent line reducing the
manpower and useless wastage of energy.

LINE 1B: CYLINDER HEAD ASSEMBLY

DCRUST, Murthal
Page 44
This line is placed parallel to the cylinder block sub assembly and is worked
simultaneously with the other line giving the equal number of cylinder head such as
cylinder block which together come up towards the block line in such a manner that the
production speed remains unaffected.

The cylinder head assembly line is as equal and independent. The feeding of
components is well arranged and supplies of cylinder head are provided with the help of
casting outputs.

RFID TAG INPUT STATION

Various stations along cylinder head assembly are:-

CYLINDER HEAD CONVEYOR This conveyor belt runs along

moving the solid parts of casting shop onwards towards the frontal stations for
further process that needs to be worked upon

DCRUST, Murthal
Page 45
 CHAIN CONVEYOR SOLENOID BAR The solenoid bar helps in
maintain the successive motion of the cylinder head

RFID TAG INPUT This is one of the important step of the whole process
as it is similar to vehicle tracking system rfid is a form of computer readable track
that can give the computer its complete information by simply a laser read from
the bar code readers or the rfid sensors placed along the conveyor

AUTOMATED STORAGE the storage system for cylinder head is

very comprehensive and consists of 6 parallel platforms for the placement of the
cylinder head. the computer reads the rfid tag on the cylinder head and places it
a particular storage location that is systematically monitored by the system and
central control

Each rfid tag is linked to a block head with a particular punched engine serial
number and goes to the block line in its correct time when it is time to join the
corresponding block

DCRUST, Murthal
Page 46
 LINE 2: CYLINDER BLOCK LINE 1

After the cylinder head a cylinder block go through the primary stages of LINE 1 and
LINE 1B the cylinder PR engine block comes to cylinder block line which is also called
as block line.

The block line is the largest set and in order to reduce error and for effective work
stations the block line is divided into two parts that is block line 1 and block line 2 the
major work of fitting all other essential equipments is done in the block line .

The block line encourages the largest man power and workstation which increases the
chances of error so a proper maintenance and guiding system is maintained along the
block line continuous feed of components and supplies enable smooth movement of
parts and engine along the assembly line.

Time at each station is calculated 3 times with the stop watch, so that standard time can
be obtained. Standard time of both cars of line no.4 A-STAR & Ritz at each station is
shown below in the table.

Various stations of block line 1 are:

CON ROD FASTENING After the cylinder block has been sent to the
block line the first step that is incorporated is the con rod fastening as it is
important and delicate step the below shown machinery is used for better and
precise performance.

DCRUST, Murthal
Page 47
Cylinder head fastening machine oil and water pump sea lent machine

CYLINDER HEAD FASTENING This is the next step and is the

place where the cylindrical block from sub assembly line 1 meets the cylinder
head from line 1b

OIL AND WATER PUMP SEALENT This step is a delicate and

important step as no room for error is permissible here. The process is controlled
by a GOT that is a graphically operated terminal that uses touch screen display
and interactive platform

A thin 2 mm layer of sealant is applied across the components which gives them
a hard stick. The only manual work that needs to be done is the collective mixing
of oil and after supplies or raw materials to create the sealant

FLYWHEEL FASTENING At this step after the sealant has been

applied the flywheel or the main energy transferring mechanism wheel is
DCRUST, Murthal
Page 48
 fastened onto the engine component so that effective energy transfer takes place
the fly wheel fastening is also a mechanical process under strict supervision

TRANSFER TROLLEY After the engine has been installed with the
components of the block line 1 the enter on a turn table which rotates the engine
by 180 degree and sends it onto the transfers trolley which sends the engine and
its part to the next line through the transfer trolley which is an automatic transfer
mechanism same as that in line 1

LINE 3: CYLINDER BLOCK LINE 2

DCRUST, Murthal
Page 49
The cylinder block line 2 or the block line 2 is one of the last stages of equipment fitting
or component fastening along the assembly line. The latter lines or the main line of
engine assembly includes testing of the engine so the entire job of engine completion is
done in this step.

No major part installation occurs in this step other than a few minor ones if any major
step is performed then automated system is used accompanied by testing if the part is
found to be faulty then the cycle is repeated till the engine passes the test.

The various stations or steps of cylindrical block line 2 are:

CLUTCH COVER FASTENING- The clutch cover fastening machine

is shown in the picture above and tells us of the process if the process fails then

DCRUST, Murthal
Page 50
 the indicator lights up red sending it back otherwise the green light lights up and
sends the engine to the next stop or station

CRANK PULLEY In this step a pulley with the help of an engine belt is
attached to the crank of the engine here the pulley shall transfer energy to all he
component systems of the engine along the axles of the vehicle and onwards the
other components that require a driving force from the engine.

WATER AND OIL LEAK TEST This is the only test that is included
in the block line because after this step there is no turning back and the engine
cannot be corrected if this test is overcame at a faulty result and still motor
testing is performed . the test is performed as to study the leakage of oil and
water or the dispensing of water into the oil chamber as the reaction in case of a
running engine can be catastrophic so this test is performed beforehand.

OVERHEAD GRAVITY TRANSFER This is an effective way of

transferring the engine from block line 1 to the last line or the main line this is an
effective method because unlike the trolley method this uses overhead chain
pulleys of varying capacity of about 250 kg that transfer the engine from one
station worker to other by simply hooking onto the chain and sliding vehicle being
raised under the effect of gravity alone.

LINE 4: MAIN LINE

DCRUST, Murthal
Page 51
The main line is the last or final line before the engine is ready for shipment or transfer
to the storage area so here the process of testing of the various performance and
compulsory test occurs and only after the engine qualifies these test shall be approved
for use in different categories of vehicles.

The various stations of Main line are:

MOTORING TEST BENCH- Warming benches are utilized to heat the

engine and visually check for fluid leads and emissions checking before
installation of the engine in the assembly process. Other options include detail
checking of Noise, Vibration & Harmonics at different RPM. A Motoring version,
or Cold Test version is also available. This type of test bench enables testing to
be performed without starting the engine. There are four testing benches
available namely mtb 1, mtb 2, mtb 3. Mtb 4. Here simultaneous testing takes
place for benefits such as emission control, quitter operation, torque delivery etc.

SPARK PLUG FITTING- After the successful operation of mtb test and
when the engine is safe to be test fied so the spark plug is installed

INTAKE MANIFOLD AND EXHAUST MANIFOLD- Here the

intake and exhaust manifold for the proper intake of fuel and exhaust of gases
can occur on firing of engine occurs so intake and exhaust manifold are fitted
upom in the engine.

FIRING TEST BENCH Before the engine leaves assembly shop for
final assembly on vehicle; firing benches are used to crank and start the engine.
Firing benches are used for, test for leaks, ensure proper oil pressure, check for
abnormal noise, Clutch and Gear Shifting mechanism, and electrical output from
DCRUST, Murthal
Page 52
 magneto and gain the confidence that the engine meets the quality level before
we put it into service

LEAK TESTING Before the engine is finally shipped off into storage a
final leak testing is conducted to check any sort of loose components or leakage
of fuel or any other liquid or pressure as it could be disastrous..

Motoring test bench

LINE 5: STORAGE AREA

DCRUST, Murthal
Page 53
This is the final place where the engine goes before it is shipped off to be mounted into
a car. The storage facility has been developed keeping in mind the safety and flexibility
using the maximum space available.

Based on the tags and serial numbers the computer arranges and sorts the engine to
designated spots the system is so customized that the transport workers even with
minimal training can load the engines onto the trucks.

Based on the design and capacity KB plant is of three types KB 1, KB 2 and KB 3.

After that the engine is mounted upon the car.

STORAGE BAY

OBSERVATION
PLANT LAYOUT KB-1

DCRUST, Murthal
Page 54
 ENGINE MOUNTING STATION

DCRUST, Murthal
Page 55
At this station an engine is fitted to the car by using an automating
lift. Two operators work on this station below the lift.

The time observed is as follow:

PERSON 1
OPERARIONS TIME(A-STAR) TIME(RITZ)
Total time 69.90sec 75.56sec

PERSON 2
OPERARIONS TIME(A-STAR) TIME(RITZ)
Total time 68.54sec 102.98sec

Definition:
Definition of Line Lay out

Line Layout is the physical arrangement of equipment, facilities & man power within a
line. The Line Layout can be indicated on a floor plan showing the distances between
different features of the line. Optimizing the Layout of a line can improve productivity,
safety and quality of Products. Unnecessary efforts of materials handling can be

DCRUST, Murthal
Page 56
avoided when the Line Layout is optimized. This is valid for:
- Distances Material has to move
- Distances Equipment has to move
- Distances Operators have to move
- Types of Handling Equipments needed
- Energy required to move items against resistance (i.e. gravity)

OBSERVATION
Table Notations:
C-CASUAL P-PERMANENT
T.T-TRAINEE A-APPRENTICE

DCRUST, Murthal
Page 57
 CYLINDER BLOCK SUB ASSEMBLY

Station Category of worker

1L C
2L C
3L C
4L C
5L T.T , R
6L C
7L C

CYLINDER HEAD LINE

Station Category of worker
1R C
2R C
3R C
4R C
5R C
6R C
7R C
RELIEVER-3

BLOCK LINE 1

DCRUST, Murthal
Page 58
 Station Category of worker
24L C
25L C
26L APP.
27L C
28L C
29L C
33L C
34L C

BLOCK LINE 2

Station Category of worker

24R C
25R C
26R APP.
27R C
28R C

MAIN LINE
Station Category of worker
38L C
39L C

DCRUST, Murthal
Page 59
 41L P , APP.
42L APP.
43L C
46L C
47L P
48L P

CONCLUSION

The 6 weeks Industrial Training is indeed the most important part of our curriculum at

the Electrical engineering department At DCRUST, murthal. It provides me an

opportunity to gain experience on the practical application our technical knowledge.

I have done my industrial training in the MP-GKB of MARUTI SUZUKI INDIA LIMITED.

In my training I have leaned 2 topics BRIEF STUDY OF KB ENGINE ASSEMBLY AND

LINE LAY OUT DESIGN. Assembly study is a very useful tool which can be employed

in manufacturing companies like Maruti which have to constantly cater to ever

increasing demand from the market with very small lead times. The overall experience

that I have gained at Maruti helped me a lot in my future. In the end I would like to thank

DCRUST, Murthal
Page 60
my Mentor at Maruti and all staff members of KB-1 who have encouraged and inspired

me to achieve higher goals.

DCRUST, Murthal
Page 61