Professional Documents
Culture Documents
Maruti Suzuki
manesar
Submitted by
Ayush Khatana
14MEU014
B. Tech (2014-2018)
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. Sanjay Yadav. For giving me this opportunity to
work in their departments and guiding me through the projects for his
constant guidance and support.
AYUSH KHATANA
NCU GURGAON
Introduction to MSIL
Production overview
Conclusion
INTRODUCTION
PLANT LAYOUT OF
VISION OF MARUTI:
To be The leader in the Indian automobile industry
Creating customer delight and shareholders wealth
Be A pride of India
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
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: -
3K OF MSIL
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).
The flow chart for a typical car body weld line looks as follows:
Trim line: The car body moves over the conveyor on mounts, as shown below:
Final Line: Here, as both the engine and wheels have been fitted, the car once again
moves over the conveyor belt.
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: 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.
2. WELD SHOP
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.
3. PAINT SHOP
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
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.
ASSEMBLY SHOP -B
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
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
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-
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, Motoman 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.
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 2
Five liters of petrol is filled in the vehicle. A/C vaccum 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.
VEHICLE INSPECTION - I
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
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
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 tyre 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.
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.
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 checksheet. The appearance check
points are I.D plate, emblems, bumper, doors, fuel lid, front hood, routing and clamping,
seats, interiors, seat belts, weather strips, tyres 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.
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
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.
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
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.
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
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 Cemedine(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.
1. All the possessions of an enterprise that is, what it owns are called its assets. Frequently
the value of the stocks of goods and/or materials held in its Store is as great as if not greater
than the total value of all its other possessions e.g. land and/or buildings, plant, machinery,
motor vehicles, equipment, etc., and, of course, money and investments added together!
2. The items and/or materials in the Store cost money; if, through bad Stores Management, there
are too many held in the Store or if the wrong items or materials are being held, money will be
tied up money which might be required to buy other, needed items and/or materials or to pay
the many expenses involved in running the enterprise.
3. Conversely, if poor stores management has led to shortages of needed items and materials,
there will be hold-ups and interruptions in production, or losses of production and/or losses of
sales to customers and, indeed, losses of the customers themselves, and losses of profits which
can in turn lead to job losses and in extreme cases to the collapse of the enterprise.
4. If items in the Store are lost, stolen or damaged in any way, the enterprise loses money.
5. And it costs money to run the Store on building maintenance and/or rent, on salaries of
stores personnel, on containers and equipment, on heating or cooling, on lighting and power, etc.
and the enterprise must receive a return from its expenditure, in terms of efficiency,
particularly as its Stores is nonproductive.
The 5 weeks Industrial Training is indeed the most important part of our curriculum at the
I have done my industrial training in the ASSEMBLY SHOP-B of MARUTI SUZUKI INDIA
LIMITED. In my training I have learned store management . Store management 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 my Mentor at Maruti and all staff members of assembly shop -B who have encouraged and