Acknoeledgement: Maruti Suzuki India Limited

MARUTI SUZUKI INDIA LIMITED
ACKNOELEDGEMENT
I take this opportunity to express my sincere thanks and deep gratitude to all those people who
extended their whole hearted co-operation and have helped me in completing this project
successfully.
First of all, I would like to thank Mr. S. K Bhatia, Dy. Manager (HRD), for giving me an
opportunity to do my training in this prestigious organization. I’d also like to express my sincere
gratitude towards Mr. V.K. Arora (Asstt. General Manager, Plant Maintenance) ,Mr. S.
Prabhakar (Sr. Manager, Plant Maintenance) & Mr. Manoj Attri (Engineer, Plant
Maintenance)for their guidance & help which enabled me to get the required data & information
required to finish my assignments Their inspiring suggestions and timely guidance enabled me to
perceive the various aspects of the projects in a new light.
I would also like to thank all senior members and workers of Plant Maintenance for having
guided and encouraged me throughout the duration of the project. In all I found a congenial work
environment in MSIL and the completion of the projects will mark a new beginning for me in the
coming days.
PROJECT REPORT
ON
 Study of vehicle manufacturing processes from raw material

to finish vehicles.
 Study of Vehicle Tracking System (VTS) & equipment interface.
 Auto closing system (Concept, design & fabrication)

of floor service pit to improve safety of human.
SUBMITTED BY
SHAMSHER SINGH
-------------------
TH
4 YEAR MECHANICAL ENGINEERING
SIX MONTH TRAINING
SRI SAI INSTITUTE OF ENGINEERING & TECHNOLOGY

BADHANI (PATHANKOT)
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 of May 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 Alto kei car which at the time was
the only modern car available in India, its' only competitors- the Hindustan Ambassador and
Premier Padmini were both around 25 years out of date at that point.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 other South Asian countries.
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", in popular
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.
It’s manufacturing facilities are located at two facilities Gurgaon and Manesar south of New
Delhi. Maruti’s 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 and National 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. Suzuki’s 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.
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
Maruti’s mission to motorize India.
BACKGROUND OF THE INDIAN AUTO INDUSTRY
Although the Indian car industry was established in the late forties, there was little growth or
technical progress, as passenger cars were given very low priority in the scheme of Centralized
Economic Planning. In the 1980s, the car industry was undergoing technological stagnation and
was characterized by low production volumes, high cost and low productivity. The consumer had
very little choice and the market was selling just around 30,000 cars per year.
There was a clear need to provide a cost effective, reliable and quality car to the customers.
Maruti Suzuki India Limited was incorporated in such a scenario as a fully owned Government
Company on February 24, 1981 with a resolve to bring about expansion and technological
modernization, of the automobile sector. Thus MSIL, when started was entrusted with the task of
achieving the following policy objectives:
 Modernization of Indian Automobile Industry.

 Production of Vehicles in large volumes, which was necessary for economic growth.
 Production of Fuel-efficient vehicles to conserve scarce resources.
Choice of product and collaborator
 To achieve the above objectives, one of the foremost tasks before. Maruti Suzuki India
Limited was to determine the most suitable product mix and to select the most suitable
foreign partner who would be willing to accept MSIL ‘s requirements in terms of product
mix, technology transfer, and equality participation and had the
 required technological expertise and experience in producing high quality, reliable and
fuel efficient vehicles.
After extensive discussion with several major European and Japanese car manufacturers, MUL
chose Suzuki Motor Corporation (SMC) further increased its equity holding to 50% in the year
1992, converting . Maruti Suzuki India Limited, into a Non-Government Company with a total
Equity base of Rs. 1322.92 million.
BACKGROUND OF SMC
SUZUKI was founded in 1909 as Suzuki Loom Manufacturing Company. It started

manufacturing motorcycles in 1952 and has become a world leader in the manufacture of two-
wheelers .SUZUKI started producing cars from 1955.Today it is Japan’s largest manufacturers of
small , fuel-efficient cars. At present the company’s name is SUZUKI MOTOR
CORPORATION.
SUZUKI AND MARUTI’S WORLD-CLASS MANUFACTURING

FACILITIES AT MANESAR
On February 06,2007 Mr. Bhupendera Singh Hooda , Chief Minister of Haryana inaugurated
three world-class manufacturing facilities set up by SMC and Maruti Suzuki India Limited.
The facilities inaugurated were as follows:
 MSIL’s fourth car Assembly plant.
 A diesel engine and transmission plant, set up under a joint venture of SMC and MSILcalled
Suzuki Power train India Limited (SPIL)
 SMC’s two-wheeler plant in Gurgaon, Suzuki Motorcycle India Private Limited (SMIPL).
INTRODUCTION TO MARUTI SUZUKI INDIA LIMITED
 A License and a Joint Venture Agreement was signed with Suzuki

Motor Company of Japan, in OCT. 1982
 Market leader with over 54% Share in Domestic Car Market

Exporting cars to over 70 countries around the world including most
advance Western European Markets.
 Maruti has revolutionized the Indian Automobile and Component

Industry and has set standards in quality of products and service.
MARUTI INSTALLED CAPACITY
 PLANT 1 200,000 units
 PALNT 3 150,000 units

COMPANY MISSION
 A leader in the Indian Automobile Industry.
 Creating Customer Delight and Shareholders wealth.
 A pride of India!
LEADERSHIP
 By Market share and brand equity
 By operational practices
 By people strategy
CUSTOMER DELIGHT
 Values for money
 Quality
 Service
SHARE HOLDERS WEALTH

 High Profitability & Image
A PRIDE OF INDIA
 As a corporate citizen
 Products
 People
 Practices
 Customers
VALUES
 Customer Obsession
 Fast, Flexible, First Mover
 Innovation and creativity
 Networking and partnership
 Openness and learning

QUALITY POLICY
To increase consumer satisfaction through continuous improvement of products and services,

this is achieved by following PDCA functions and levels of Maruti Organizations.
PLAN
DO
QUALITY
POLICY
ACT CHECK
QUALITY TOOLS
 5S
 4M
 3M
 3G
 3K
What is 5S?
SEIRI – PROPER SELECTION
SEITION – ARRANGEMENT
SEISO – CLEANING
SEIKETSO – CLEANLINESS
SHITSUKE – DISCIPLINE
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 accordingly.
 MAN
 MACHINE
 MATERIAL
 METHODS
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

INTRODUCTION TO VARIOUS MODELS
PRODUCT RANGE
MODELS SPECIFICATIONS YEAR OF LAUNCH

MARUTI 800 (FIRST
796CC, HATCHBACK DECEMBER 1983
MODEL)
OMNI 796CC, MUV NOVEMBER 1984
GYPSY 992CC, 4WD DECEMBER 1985
MARUTI 800 (MODIFIED) 796CC, HATCHBACK APRIL 1986
MARUTI 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 (NEW
796CC, HATCHBACK SEPTEMBER 997
MODEL)
ESTEEM 98 1296CC, SEDAN OCTOBER 1997
NEW OMNI & OMNI-E 796CC, MUV FEBRUARY 1998
ZEN VX & ZEN VX JULY 1998
996CC, HATCHBACK
AUTOMATIC
ZEN D 1200CC, HATCHBACK AUGUST 1998
MARUTI 800 EX 796CC, HATCHBACK JANUARY 1999
ZEN LX 996CC, HATCHBACK JANUARY 1999
ZEN CLASSIC 996CC, HATCHBACK AUGUST 1999

ZEN VXI 996CC, HATCHBACK OCTOBER 1999
OMNI XL 796CC, MUV OCTOBER 1999
BALENO 1586CC, SEDAN DECEMBER 1999
WAGON R 1096CC, HATCHBACK JANUARY 2000
1586CC, HATCHBACK
ALTURA MARCH 2000
(BALENO)
ALTO LX, LXI 796CC, HATCHBACK SEPTEMBER 000
VERSA 1296CC, MUV DECEMBER 2001
SWIFT 1296CC, HATCHBACK MAY 2005
ZEN ESTILO 1096CC, HATCHBACK DECEMBER 2006
SWIFT DIESEL 1296CC, HATCHBACK FEBRUARY 2007
SWIFT DIESEL
FEBRUARY 2007
GRAND VITARA MARCH 2007
SX4
1.600CC MAY 2007
SWIFT DZIRE MARCH 2008
A- STAR NOVEMBER 2008
RITZ MAY 2009
ORGANISATIONAL STRUCTURE
Maruti has believed, since the very beginning that it is its employees who could make it into an
organization with a difference .Accordingly, as against the traditional hierarchical

System of management, which causes unnecessary delays in decision-making, we have built up a
flat organization with a family type of atmosphere at our place of work.
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 that are
headed by Department Managers who report to the respective Divisional Managers. Designations
in the company are based on the functional responsibility and not levels as in terms of the
company’s philosophy designations and functional responsibility are de-linked 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 furthering divided into
Departments and headed by Departmental Managers who is assisted by Supervisory Executives.
The hierarchy diagram of MSIL

DIVISIONS AND DEPARTMENTS
Corporate Services Division
 Legal & Secretarial Department

 Corporate Communication Cell

 Protocol
 Strategic Initiative Group
 Recruitment & Management Compensation
Human Resource Division
 Employee Relations Department

 Establishment & Time Office
 Factory Administration Department
 Organizational Development Department
Production Division
 Plant- 1
 Plant- 2
 Plant- 3
 Plant- 6 at Manesar
Production Engineering
 Production Engineering Division

 Production Service Division
Engineering Directorate
 QAIN Division
 Service Division
 Service- 1-5
 MSS(D)
 Parts Inspection Division
 Engineering Division
Supply Chain division
 Supply Chain- 1,2,3 Division

 Shipping & transport Department
 Imports Department
 Consumables Department
Information Technology Division
 Application Group1 (AG1)

 Information Technology Strategies(ITS)
 IT Operation and Services(ITOS)
Marketing & Sales Secretariat
 Marketing Strategy & Development

 Marketing
 Sales
 Exports
 Web-IT, E-Commerce
Spare Parts Division
 Spare Parts Procurement

 Warehousing & Dispatch

 Spare Parts Sales
 Accessories
Vigilance Division
 Security Wing
 Vigilance Wing
Finance Division
 Budget, Cost & Accounts Department Income Accounting
The total project costs, priority, completion time and personnel’s required were estimated. Initial
plans were drawn up as to how the project would proceed to its final implementation, while
running the existing system so that company’s information needs were not affected.
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
 Vehicle Inspection (VI)

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 :-
Steel coil Blank Panel
1. Currently Press Shop is producing sheet metal components for 8 running models of
Maruti Suzuki and one model of GM India - Tavera
2. The Blanking and stamping shop processes 10000 metric ton of steel / month i.e. 400
tons a day
Machine :
 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 Ton
transfer
press
Pressed panels
come out from
this side
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.
Upper die Lower die

Steel Coils
 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 as foreign
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
 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 to form
large mass of blanks
 These stacks of blanks are further sent to press machines for forming into shape of
body panels
Stack of blanks
Panel
Blanks are supplied to press lines for pressing. Blanks are converted to body panels by this
process. Panels are stored in pallets which are supplied to Weld Shops for making White
Bodies.
Panels re
stacked in
pallet
trolleys
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.

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.

 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.

PROCESS THROUGH PICTURES:

PB ON(WHITE BODY) PRE TREATEMENT
ELECTRO DEPOSITION PROCESS
DRY SANDING I SOL SEALING LINE PVC COATING
IC OVEN IC COATING
DRY SANDING II
TC OVEN TC COATING
FINAL INSPECTION TO ASSEMBLY SHO

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
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.
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.
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)
c. Ritz (Diesel)
Project
Safety system on floor pit to provide protection against fall inside it
Air cylinder Pit cover
Tyre sensors
Area
sensors
Project Description
 Open pit 4x2 square meter & 2 meter deep is provided inside the working area for repairing
under the vehicles.
 The pit is open from top , side safety railings can not be provided as vehicles are to be
brought on it by starting & there were some incidents of working operators falling inside &
getting serious injuries.
 Manual covers were being used to cover it but due to absence of any fool proof system many
times pit remains open from top.
Objective
 To provide fool proof safe cover over pit which can be automatically operated when vehicle
is brought over it & as soon as vehicle is taken off from it the cover should automatically
close.
 Pit should not be closed when operator is standing inside pit & waiting for next vehicle to
come
 Auto closing to have clearance from Safety department & no extra material to be procured
from outside, only in-house material available inside the Maintenance department to be used
Methedology adopted
 Initial study was done on site to check the safety risk, it was found that the pit can not be
reallocated to other area & it is required to carry on the repairs.
 Manual cover is not used to closed the pit as it is very heavy & slips when somebody walks
on it.
 Idea of providing a horizontal gate over pit with guided rails came, in this a gate was
fabricated as per opening’s size & rollers were provided on corners & rails were provided to
guide rollers to traverse smoothly.

 The system worked well & with a push of hand the cover could be closed & opened. But the
problem of this system was nobody closed it after use & it is kept in open condition many
times & in open condition the risk of falling inside pit was still persisting.
 More study was done to provide automatic system on door so that it can open & closed
automatically as per requirements.
 It was thought that a pneumatic cylinder should be provided to slide the gate over pit which
will be operated by providing sensing system .

CASE NO-1 : 4 sensors were provided on top of pit where front tyres are positioned . Sensors
will sense the presence of vehicle on pit & will send signal to control panel to open the air valve
solenoid which will operate the gate by activating the air cylinder towards open position.
After the gate opened the operator could do the repair work from beneath the vehicle.
After the job is finished the car is driven off the pit. The issue of closing back the door
automatically remained.
CASE NO-2 : When vehicle is driven off the pit the door remains open & risk of falling inside
pit remains there, in this case the de-activation of sensors S1 & S2 is linked to auto closing of pit
The problem of automatically closing & opening the pit door was solved by activating & de-
activating the sensors S1 & S2.

SAFETY CONCERN : In case someone is standing between the closing door & does not
notice the movement of closing the door he can be trapped in between the door & pit wall &
serious accident can happen.
New idea of closing the door in between in case some one or some object comes between at the
time of closing the door by pneumatic pressure.
CASE NO-3 : At the time of closing of door if someone or some object comes in between the
door 2 area sensors (S3) provided at both sides of pit which will sense the presence of human or
object & will stop the door suddenly & get it reversed to its home (OPEN) position. With this
system no one will be trapped between moving door & pit wall
CASE NO-4 : At the time of closing the door if nothing is inside the pit & both area sensors
are clear of any obstruction the door will be closed safely & nobody will fall inside the pit
CIRCUIT DIAGRAM
DOUBLE ACTING CYLINDER
5/2 DOUBLE
PILOT SOLENOID
VALVE
3/2 SPRING
RETURN PUSH 3/2 SPRING
BUTTON RETURN PUSH
BUTTON
F R L
COMPRESSOR
The safety project implemented by the team is working in MSIL Gurgaon plant in Assembly
Shop-3 since 1st week of December’2009.

It was a great learning experience by working in a team. Mr. Manoj Attri (Engineer MP2) & his
team has helped me in completing the project in time.
They provided me with every help from arranging the material & getting the structures
fabricated.
 Without the ability to locate and track units as they make their way through manufacturing,
testing and repair processes, managers lack the ability to achieve optimum performance for
their business and are forced to rely on outdated, inaccurate data and labor-intensive
processes.
 The most powerful tool for any manager is accurate, real-time information about the location
and status of the work-in-process.
 The Vehicle Tracking and Management System (VTMS), provides real-time information to
track, measure and manage vehicles anywhere within a facility, both indoors and outdoors.
 Vehicle Tracking and Management System is a ground-breaking step in automating vehicle
tracking and management in today's vehicle assembly, delivery chain and fleet operations and
is the first solution to provide real-time information to today’s manufacturing management
community.
 Vehicle Tracking and Management System allows a vehicle manufacturer, delivery chain or
fleet operation to know in real-time or historically exactly where the vehicle is located or has
been.
 Off-line processes are frequently a forgotten segment of lean manufacturing and Vehicle
Tracking and Management System is one of the world’s first systems to drive efficiency and
optimization in this area.

 In a Vehicle Tracking System solution, an RFID tracking tag is placed in each vehicle
typically before the vehicle enters the off-line processing areas., the solution delivers real-
time tracking information of the vehicle.
 In addition, beyond the ability to locate a vehicle on demand, the tracking data can be used to
monitor such things as adherence to process, process cycle time, and dwell time analysis for
off-line areas.
 Vehicle Tracking and Management System provides for accurate planning, execution and
monitoring of performance — making it the ultimate support tool for improving processes
and creating efficiency in off-line manufacturing areas.
Vehicle Tracking and Management Core System

Components:
Vehicle Event Management
The VTS Vehicle Event Management feature automates vehicle status changes, reduces labor
intensive barcode scanning, and triggers transactions with zero human intervention.
Process control Management

Conditions like Special Comments etc can be broadcasted using check sheet or any
printers.Comments can be made for recheck,evaluation purposes for Trial Vehicle, Spare Vehicle
etc.Through VTS the position of any vehicle in the assembly line can be easily traced out using
the mimic.Vehicles can be viewed on the basis of Chassis,PSN,Vehicle Model Etc.
Vehicle Throughput Management

The VTS Vehicle Throughput Management feature automates and
optimizes the vehicle throughput, by creating a process map for every
vehicle, knowing the current inventory location, deducing the "process
step" or "containment area" capacity and the FIFO ordering of vehicles,
the throughput management engine actively manages and optimizes the
vehicle movement. Vehicle Tracking System communicates this
information with users via desktop computers, Windows Mobile
Terminal Wi-Fi devices, Production Control Boards, and Video Terminal
Kiosks.
Vehicle Exception Based Management

The VTS Exception Based Management feature provides a goal setting
capability and delivers real-time exception-based information to the user
community. Therefore maximizing issue resolution time, increasing
options and reducing costs. The exception management rules engine
allows users to see exceptions for a vehicle, as well as, for a "process
step".
BENEFITS:
 Increase vehicle throughput
 Improve order to delivery
 Reduce dwell time
 Increase labour productivity

 Minimize work-in-process inventory
 Improve inventory accuracy

 Reduce operation costs
 Increase vehicle utilizations in fleet hours .
Equipment Tracking and Management

Improve Safety & Equipment Utilization
 In any manufacturing environment, safety is paramount. Material handling equipment can be
extremely dangerous if not used by an authorized individual that has been properly trained.
 The Equipment Tracking and Management System solution provides a secure method of
vehicle access and authorization, and can prevent the equipment from starting or moving
without proper authorization.
 In addition, Equipment Tracking and Management System provides vital information directly
from the equipment itself, including Run-Time, Idle-Time, Battery Consumption, Lift
Sensing and Impact Sensing.
 By utilizing this data, and closely monitoring the precise run-time and utilization of the
equipment, Equipment Tracking and Management System can significantly reduce the total
operating costs through proper "right-sizing" of the equipment fleet, by total quantity and by
equipment type.
Equipment Tracking and Management System helps address the following real-
time material handling equipment requirements:
Access Control
 Reduces injuries by ensuring that only approved users can operate the equipment by using
a contact button or proximity card.
 Eliminates government fines associated with access controls.
 Decreases abuse or misuse by linking incidents to specific operators.
Preventive Maintenance
 Maximizes equipment life through routine maintenance based on actual engine runtime
hours.
 Increases operator productivity with improved up-time of equipment.
 Reduces costs and increases useful life by performing usage based preventive
maintenance.
Equipment Utilization
 "Right-size" fleet by tracking actual utilization.
 Increases useful life of equipment with better accountability and management.
 Reduces headcount through increased productivity.
BENEFITS
 Increase productivity
 Improve equipment utilization
 Reduce injuries
 Maximize equipment life
 Reduce labour
 Better efficiency
VTS OBJECTIVES
 High System availability and real time response.

 Enable mixed production in various shops as per VBS.
 Interfacing with Shop Equipment.
 Automatic component selection system(Pika-Pika).
 Material Flow Sequence Supply.
 Engine-Assembly Planning.
 Eliminate human error creeping in system at manual data entry.
 Modular and Scalable.
MAIN FEATURES
The Vehicle Tracking System or VTS was developed in house by the cross functional team of IT,
PE and Production of Maruti Suzuki India Limited to reduce the company’s response time to
market demand, and to handle the complexities of producing vehicles across multiple variants
 VTS acts as a middle layer between the Host (Business) computer

and the Shop floor terminals and devices.
 Facilitate real-time communication for data transfer between
computer system and PLC.
 Pika-Pika for Component selection
 Sub System and Equipment Interfacing

 Broadcasting vehicle sequence at various control points to different

areas
 Tracking point Achievements
 Special Case Handling
 Progress Management
VTS IMPLEMENTATION
 VTS acts as a intermediary between the database server and the various shop floor terminals
and devices.
 It facilitates real time communication for transferring data between the computer system and
the PLC system which in turn provides data to the robots and to the equipments that enables
them to pick up the right component and also to broadcast the requisite information to the
printer.
 Thus providing data to the technicians. The technicians use this data for the assembly of the
vehicles and finally VTS aids the implementation of the production plan sequence on the
shop floor.
 The production plan contains all the requisite information in terms of the path to be followed
by each vehicle through the manufacturing plant the vehicle code, its color, the country code,
and chassis number. It also specifies the start and end point for each process.
 The VTS facilitates this complex planning using which a vehicle under production can be
routed in a flexible manner across various shops and lines in the most effective manner.
 The VTS enables the engine from multiple locations to be tracked as manufacturing process
progresses.
AREAS COVERED
 Weld Shop – 1, 2 & 3 (WB- ON & WB-OK)
 PAINT SHOP – 1, 2 & 3 (PB ON & PB OK )
 ASSEMBLY SHOP –1, 2 & 3 (AB ON & AB OK)
 ENGINE SHOP – 1, 2 ,3 & AL Shop
 VI1, VI2 & VI3 (FC ON & FC OK Points)
VEHICLE TRACKING
The manufacturing plant in Gurgaon has

 3-weldshops,
 3-paint shop,
 3-assembly shops and
 4-engine shops.
In the above fig,each model is specified with different color and the path followed by each is
represented by the arrows joining different shops
SERVER CONFIGRATION
VTS IN ASSEMBLY SHOP
AREAS COVERED
 Equipment activation – All equipment are connected through LAN with VTS & as
soon as triggering mechanism will get signal of presence of a particular model it will pass on
the signal to PLC of the equipment & the equipment will come in that mode automatically.
Vehicle Tracking from 1st control point to last control point (WB ON to FC OK)
 WIP (Work – IN – Process) between two control point
(For example if we want to see No. of vehicles in WIP in Paint Shop then we have to give
command to system for PB ON to PB OK & No of vehicles will be under Paint Shop WIP)
 Shop Sequencing – In multi model mix production overprized lines what sequence of
models is in line will be known in advance & that sequence can be printed by line printers
which can be displayed for operator to see what model of vehicle is approaching in next few
hours to him.
In the Assembly Shop, VTS tracks vehicle at two points

 Starts at AB-ON or assembly body ON and
 Ends at AB-OK or assembly body OK.
At the AB-ON point, the data is transferred to the PLC and the vehicle sequence is broadcast at
various control points to different areas.
Let us take a closer look on some of the areas points at which such broadcasts take place:
 The Main Fundoshi Printer — this contains the details of components, and this information
helps the operators to fix the right components in the correct vehicles.
 The Door Mini Fundoshi Printers — these printouts are stuck to the doors. Based on this
information, the doors are assembled.
 The Process Check Sheet — this document is used to check the completion of the processes
at various checkpoints along the assembly line.

 Engine Storage Out — engines are put on the Engine Docking Line according to the AB-
ON sequence, which is broadcast to the printer at the time of AB-ON. At the Engine-Body
marriage point, the Engine Number is matched against the Chassis Number by scanning the
barcode sticker.
Various other sequence printers are used for different sub-assembly lines:
 Tyre sub-assembly;
 Instrument panel sub-assembly;
 Windshield sub-assembly;
 Door sub-assembly;
 Door latch sub-assembly; and
 ID plate
At certain points, PC Monitor applications are also used to broadcast the sequence.
The marriage of the engine with the vehicle is done at the EG Storage-Out point — this is
integrated with the VTS to avoid the possibility of wrong engine marriage.
The process ends with the AB-OK sequence.
Key features
 Tracking points: AB-ON , AB-OK.
 PBS Out sequence check at AB-ON

 Broadcasting of AB-ON sequence at different Sub Assemblies (Ex:- Instrument Panel,
Engine Storage Out etc..)
 Component selection using Pika-Pika.
 Sequence display through GOT’ s and PC-Monitor (Ex:- Glass/Door,radiator,Tyre etc)
 Interfaced with Equipments:LLC filling,Break-oil,AC charging etc
 Air bag Registration for export vehicles.
 Interfaces with machines: ID Plate, Vin No marking machines.
 Engine Storage Out (Engine & Vehicle)
SCHEMATIC LAYOUT
List of equipment connected through VTS

 Pikka-Pikka
 Id plate m/c
 AC gas charging machine
 Gasoline filling machine
 Coolant filling machine
 Brake oil filling machine
 Engine oil filling machine
Equipment interfacing
 VTS interacts with the equipments in assembly shop through line PLC’s .
 VTS gives the input to the PLC’s as per current vehicle model
 PLC controls the equipment and automatically gives the desired
commands as per vehicle model
PLC-EQUIPMENT INTERFACING
 As soon as the vehicle comes in position it hits the limit switch which is connected to the
line PLC
 The line PLC then interacts with the server to collect the information about the vehicle
(which in this case is amount of engine & break oil)
 The PLC then passes this information to the fuel filling machine for the particular vehicle
 The information is also displayed in the GOT
PIKKA-PIKKA SYSTEM
 The selection of components in the main areas is carried out through the VTS using Pika-
Pika.
 This is a LED-based system.
 A LED glows on the bin from which the operator is supposed to pick the component, thereby
guiding the operator to pick up the correct component.
 As soon as he picks the component, the LED turns off.
 However, if the operator puts his hand into the wrong Bin, a warning signal is generated.
Fool proofing for component selection through

PIKKA-PIKKA
Green light
glows on
correct part
 VTS provides Fool-proofing by means of Pika-Pika.
 The information pertaining to the vehicles in line is passed by the VTS to the line PLC which
in turn controls the pika-pika.
 Pikka-pikka system has series of rows & columns of the component for the particular vehicle
model,thereby guiding the operator to pick up the correct component
 On the vehicle arrival,Pika-Pika indicates the user which component is to be selected as per
the vehicle model.
 A LED glows above the particular column having components for the coming vehicle model
 The LED goes off as soon as the operator picks up the correct component
 However a warning signal is generated if wrong component is selected by the operator
 Thus through the pika-pika ,the VTS fool proofs the component selection process.
VTS IN ENGINE SHOP
RFID TRACKING
 To control the production and
quality in the highly automated
Engine assembly line, Radio
Frequency Identification (or
RFID) technology is used.
 To communicate with the RFID
tag and to pass on the production
plan information, a Production
Management system (PMS) is required.
 The system acts as an interface between the host computer and the production floor and is
used to transfer production plan information, dressing data to plant devices
and tags and obtaining production process data, traceability data and quality data from the tag.
 The system then stores the data to the host computer for storing analyzing and for future
useThe data related to testing is handled by the test management system or TMS which in
turn interacts with the PMS.

 At these stations the magnetic RFID Tag communicates with the tracking system known as
PMS system via the Tag Controller to exchange and verify the data. Additionally, the RFID
tags also exchange data with other equipment and machines on the assembly line in the same
way, using the Tag Controller. The Tag contains the data related to the engine kept on the
palate.
 The RFID Tag will start receiving data from set up station — for example, type of engine,
engine number, master data, etc. As the pallet goes along the line and different operations are
performed on the engine by various machines, the RFID Tag continues collecting data from
machines recording the operation done, its status, etc. When the pallet reaches the release
station, the entire data in the RFID Tag is transferred to the PMS and after updating, it is
flushed from the Tag. Now the tag is ready for the next engine loading.
VTS IN VEHICLE INSPECTION(VI)

In the Vehicle Inspection Shop, tracking is done at two points:
 FC-ON and
 FC-OK.
 After FC-OK, an FC-OK confirmation Sticker is attached to rear window of the vehicle, and
then the vehicles are transferred to the dispatch area.
 In the vehicle inspection shop, the VTS is integrated with the TECH-1 system which carries
out the emission check and the air bag check.
 Without the TECH-1 check FC-OK of the vehicle cannot be done.
 This ensures that the vehicle has been passed through all the necessary checks.
On the Quality Front, the VTS interacts with the quality gate system to provide faults tolerance.
All defects details are tracked through the VTS to ensure that no vehicle gets FC-OK clearance
without rectifying the defects.
Hence, VTS is a system that offers real time data to facilitate quick decision. It carries out real
time monitoring to detect errors and quality issues well in time; it broadcasts messages that
facilitate in-line correct evection at the shop floor.

Acknoeledgement: Maruti Suzuki India Limited

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MARUTI SUZUKI INDIA LIMITED

 Study of vehicle manufacturing processes from raw material

 Study of Vehicle Tracking System (VTS) & equipment interface.

 Auto closing system (Concept, design & fabrication)

SIX MONTH TRAINING

SRI SAI INSTITUTE OF ENGINEERING & TECHNOLOGY

BACKGROUND OF THE INDIAN AUTO INDUSTRY

 Modernization of Indian Automobile Industry.

Choice of product and collaborator

SUZUKI was founded in 1909 as Suzuki Loom Manufacturing Company. It started

SUZUKI AND MARUTI’S WORLD-CLASS MANUFACTURING

The facilities inaugurated were as follows:

 MSIL’s fourth car Assembly plant.

INTRODUCTION TO MARUTI SUZUKI INDIA LIMITED

 A License and a Joint Venture Agreement was signed with Suzuki

 Market leader with over 54% Share in Domestic Car Market

 Maruti has revolutionized the Indian Automobile and Component

MARUTI INSTALLED CAPACITY

 PLANT 1 200,000 units

 PLANT 2 150,000 units

 PALNT 3 150,000 units

 PLANT 4 100,000 units

 A leader in the Indian Automobile Industry.

 Creating Customer Delight and Shareholders wealth.

 By Market share and brand equity

 Values for money

SHARE HOLDERS WEALTH

 High Profitability & Image

 Fast, Flexible, First Mover

 Innovation and creativity

 Networking and partnership

 Openness and learning

To increase consumer satisfaction through continuous improvement of products and services,

SEIRI – PROPER SELECTION

In Japanese Language 3M is:

In Japanese Language 3G is:

GENCHI – GO TO ACTUAL PLACE

GENBUTSU – SEE THE ACTUAL THING

GENJITSU – TAKE APPROPRIATE ACTION

INTRODUCTION TO VARIOUS MODELS

MODELS SPECIFICATIONS YEAR OF LAUNCH

ZEN CLASSIC 996CC, HATCHBACK AUGUST 1999

A- STAR NOVEMBER 2008

RITZ MAY 2009

organization with a difference .Accordingly, as against the traditional hierarchical

System of management, which causes unnecessary delays in decision-making, we have built up a

flat organization with a family type of atmosphere at our place of work.

Engineering, Q.A. & Services, Production, Production Engineering, Materials, Information

Departments and headed by Departmental Managers who is assisted by Supervisory Executives.

The hierarchy diagram of MSIL

DIVISIONS AND DEPARTMENTS

Corporate Services Division

 Legal & Secretarial Department

 Corporate Communication Cell

Human Resource Division

 Employee Relations Department

 Production Engineering Division