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Final Report Maruti
Final Report Maruti
Report
Session 2010-2014
NIT Jalandhar
Maruti Suzuki
ACKNOWLEDGEMENT
I acknowledge my gratitude to my mentor , Mr. Vikram Wadhawan (ASSY-3, L12) Gurgaon plant. The supervision and support that he gave truly help the progression
and smoothness of the internship program. The co-operation is much indeed appreciated.
My grateful thanks also go to Mr. Sunil Gupta (ASSY-3, DPM) Gurgaon plant. A
big contribution and hard worked from both of you during the six week is very great
indeed. All projects during the program would be nothing without the enthusiasm and
imagination from both of you. Besides, this internship program makes me realized the
value of working together as a team and as a new experience in working environment,
which challenges us every minute. Not forget, great appreciation go to the rest of MSIL
staffs that help me from time to time during the project.
My grateful thanks also go to Dr. R.K.Garg ,Head of the Training & Placement and Dr.
Subhash Chander, HOD Mechanical for giving me chance to be part of MSIL for the industrial
training.
Last but not least I would like to thank my friend Plash Monga who worked
together as an intern at Maruti Suzuki India Limited for the wise ideas and help
throughout the project that encouraged, supported and helped me in completing this
program successfully.
Vishal Badyal
10109090
NIT Jalandhar
10109090
NIT Jalandhar
Maruti Suzuki
TABLE OF CONTENTS
1. Introduction about the company
1.1.
1.2.
1.3.
1.4.
1.5.
1.6.
1.7.
Historical background
Shareholding
Marutis quality policy
Quality system
Employee quality measures
Performance of MSIL
Exports
Press shop
Weld shop
Paint shop
Engine assembly shop
Assembly shop
Machine shop
Vehicle inspection
Vehicle flow in MSIL
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Maruti Suzuki
INTRODUCTION
1.1 HISTORICAL BACKGROUND
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 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 MUL 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.
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, a
landmark yet to be achieved by any other car company in India. Maruti is the highest
volume car manufacturer in Asia, outside Japan and Korea, having produced over 3.5 million
vehicles by December 2001. 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 is on track for profits in 2001-02, with a profit of
Rs 300 million in the first half. In this period, sales have increased by 5.3%, against an
industry decline of 6.1%.
Maruti revolutionized the way Indians looked at cars. "No other car company so completely
dominates its home market" - (The Economist). Despite there being 11 companies now in
the passenger car market, Maruti holds about 60% of the total market share. MUL 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 (JD Power Asia Pacific 2000 India
Customer Satisfaction studies).
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1.2 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 holds 46.6%, and employees trust holds the balance 0.2%.
In 2005, SMC's share went up to about 74%, making MSIL a subsidiary of SMC. The Govt.
of India holds about 26%, and employees trust holding the balance.
NIT Jalandhar
Maruti Suzuki
Marts emphasis is on total quality has meant that today it is in a position to guide vendors
and dealers in establishing and consolidating their individual quality systems. This
commitment to quality has ensured a consistently satisfying product and world class sales and
after sales services.
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1200000
1000000
800000
Exports
600000
Domestic
Total
400000
200000
0
1999-00
2000-01
2001-02
2002-03
2003-04
2004-05
5.36 lac vehicles in the domestic and export markets during 2004-05. This resulted in gross
sales revenue of Rs. 113,538 million (Net of Excise), a growth of 19.7 per cent over 200304. For the year 2004-05, company achieved its highest ever sales volume of 487,402
units against 420,947 in 2003-04 in the domestic sector. In volume terms, passenger car
sales accounted for over 77.3 per cent of the Indian passenger vehicles market and
grew by 17.8 per cent from 696,153 units in 2003-04 to 819,918 units in 200405.
1.7 EXPORTS
In 2004-05, company exported 48,899 vehicles to 50 countries.
of 4.5 per cent in the export sale compared to 2003-04.
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Maruti has entered some unconventional markets like Angola, Benin, Djibouti, Ethiopia,
Morocco, Uganda, Chile, Costa Rica and El Salvador. The Middle-East region has also
opened up and is showing good potential for growth. Some markets in this region where
Maruti is are Saudi Arabia, Kuwait, Bahrain, Qatar and UAE. The markets outside of Europe
that have large quantities, in the current year, are Algeria, Saudi Arabia, Silence and
Bangladesh.
Europe is the largest destination of Marutis exports where it is selling over 70% of its
exported quantity, and the top ten destination of the cumulative exports have been
Netherlands, Italy, Germany, Chile, U.K., Hungary, Nepal, Greece, France and Poland in that
order.
MUL continues to be the market leader. During 2004-05, in the passenger car
market, had a market share of 50.9 per cent as compared to 51.41 per
cent in 2003-04.
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III. PLANT 3 - 150,000 units
Maruti Suzuki
QUALITY TOOLS
I.
5S
II. 4 M
III. 3 M
IV. 3 G
V. 3 K
What is 5S?
In Japanese Language 5S is:
SEIRI PROPER SELECTION
SEITION ARRANGEMENT
SEISO CLEANING
SEIKETSO CLEANLINESS
SHITSUKE DISCIPLINE
What is 3M?
In Japanese Language 3M is:
MURI INCONVENIENCE
MUDA WASTAGE
MURA INCONSISTENCY
What is 3G?
In Japanese Language 3G is:
GENCHI GO TO ACTUAL PLACE
GENBUTSU SEE THE ACTUAL THING
GENJITSU TAKE APPROPRIATE ACTION
What is 4M?
The factory is essentially a mix of man, materials, machines and methods. These should
move continuously and effectively to produce a quality product at low cost. The most
essential work in quality control is to thoroughly investigate regarding the problems
concerning quality, decide suitable counter measures and carry out improvements
8 | Summer Training Report 2013
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accordingly.
Maruti Suzuki
Man
Machine
Material
Methods
What is 3K?
In Japanese Language 3k is:
KIMERARETA KOTO GO WHAT HAS BEEN DECIDED
KICHIN TO MAMORU MUST BE FOLLOWED
KIHON DORI NI AS PER STANDARDS
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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:
Uncoiling
Cleaning
Leveling
Measuring
Shearing/ cutting
Piling/ stacking
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The shop has different lines for different models, each of, which is further divided into three
parts
2.3.1 Pre-treatment
The body is thoroughly washed to remove the dirt and oil scales.
2.3.2 ED coat
This is done by electric deposition method. After applying the ED coat the body is baked in
oven.
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This is done by spray painting method. After applying the coat, the body is dried in the
oven.
The PBOK, i.e. the paint body ok is sent to the assembly shop.
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A sub assembly integrating the throttle body, inlet and exhaust manifold and fuel injectors
cater to this line.
Main
1.
2.
3.
4.
5.
6.
parts:
Inlet and exhaust valves
Cotter valves
Retainer springs
Rocker arm assembly
Throttle body
Inlet and exhaust manifold
Main
1.
2.
3.
parts are:
Clutch release shaft
Gear box assembly
Transmission oil pan
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3. 4 A.C Compressors
4. Water pump
5. Air filter
Maruti Suzuki
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1. Process design/development and equipment planning for new engine components to be
machined in machine shop.
2. Procurement, installation and commissioning of new machining lines / Modification of
existing machining lines for new variants
3. Indigenization of machines for reduction in project cost
4. Development (Indigenization) of raw material for machine shop
5. Designing of Jigs, Fixtures and procurement of wear parts, inspection gauges
6. Development / Indigenization of cutting tools, holders and wear parts.
7. Preparation of standards related to Machine shop.
8. Support to shops for trouble shooting in operation and quality related problems
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NIT Jalandhar
Maruti Suzuki
CASTING
PRESS
SHOP
ENGINE
ASSY.
WELD
SHOP
M/C
SHOP
PAINT
SHOP
ASSY.
SHOP
VEHICLE
INSPECTION
STORAGE
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3.2 OBJECTIVES
To prepare a Repairman training module and so as to be displayed at the plant at
various locations in assembly line for the enlightenment of in-line operators and
repairmen which in turn would help reducing the defects and increasing the direct pass
thus increasing the production and reducing the production cost of the company.
10109090
NIT Jalandhar
Maruti Suzuki
extensively so as to get acquainted with the procedure followed at the respective
substations in the assembly line by the in-line operators and the repairmen at repairing
bays. After doing extensive study in line and at repairing area we were supposed to
make the repairman module for the repair area and assembly line area.
1st challenging task was to interview each and every operator about various important
points that should be kept in mind while performing the operation which are not
mentioned in MOS. Then the suggestions of each operator were duly noted. Then the
next task was to sum up almost similar points as one point. Then they were grouped
together under many subgroups. Then the points were verified by supervisors for their
genuinity and were further modified if required.
After being sub grouped we were supposed to take a photo to be used as visual aid
for understanding the point in a better way. The repercussion if not followed is also
mentioned alongside the Dos and Donts. Finally the above collected data were sorted
out and was documented in a proper way in Microsoft Excel sheet.
The Excel sheet which was prepared was sent to the Vendor shop to be printed out in
a flex and board to be displayed in various locations in assembly line and repairing
area.
Following are the Module prepared in Excel sheet and presented in the report as the
image of the sheet.
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checked
steering
module
and the
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After the each excel sheet was prepared and completed, the data was sent to vendor so as to be
printed in flex and board. The sample image sent by the vender is given in fig 1.
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Maruti Suzuki
Finally the module was printed in A0 size board and displayed for centralized
information flow in the assembly line. The image of the board installed in the assembly
line-3 after completion of project is provided below in fig 2.
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NIT Jalandhar
Maruti Suzuki
CONCLUSION
Finally concluding the project I want to state that Maruti Suzuki India Limited has
provided me an opportunity to study and gain knowledge in vehicle production. During
the process of the project I came to learn the various effective techniques to avoid
defects in production line and the various ways of repairing a vehicle. But out of all
those the support and brotherhood given by the Marutians will always be memorable.
REFERENCES:
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