1

TO ENSURE ZERO INCIDENTS, STUDY OF SAFETY

SENSORS IN GURUGRAM VEHICLE PLANT OF MARUTI
SUZUKI INDIA LIMITED AND STUDY OF GENERAL CAR
SERVICE PROCEDURE IN CM AUTO SALES PVT. LTD.

An Internship Project Report

Submitted by

ARUPAM THAKUR
14BTD5020421 (8th Sem.)

in partial fulfillment for the award of the degree

of
B. TECH. (MECHANICAL ENGINEERING)

RAJIV GANDHI GOVERNMENT ENGINEERING COLLEGE

KANGRA AT NAGROTA BAGWAN (H.P.)
Affiliated to

H.P. TECHNICAL UNIVERSITY, HAMIRPUR (H.P.)

MAY 2019
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Rajiv Gandhi
Government Engineering College Kangra at
Nagrota Bagwan (H.P)
CERTIFICATE
We hereby certify that the work which is being presented in the final internship/project
report entitled “STUDY OF GENERAL CAR SERVICE PROCEDURE AND GENERAL
CAR COMPONENTS AND THEIR WORKING” in partial fulfillment of the
requirements for the award of the B. Tech. and submitted to the Department of Mechanical
Engineering of Rajiv Gandhi Govt. Engg. College Kangra at Nagrota Bagwan is an
authentic record of our own work carried out during a period from January 2019 to May
2019 under the supervision of Mr. Vikram Sharma and MR. ABHINAY KUMAR.

The matter presented in this report has not been published earlier and has never been
submitted by us for the award of any other degree elsewhere.

Arupam Thakur
14BTD5020421
8th Semester
Mechanical Engineering

This is to certify that the above statement made by the candidates is correct to the best of
our knowledge.
Supervisors:

Mr. Vikram Sharma Mr. Abhiney Kumar

Workshop Manager Assistant Professor

Workshop Mechanical Department

Mr. Mohit Dhiman

HEAD OF THE DEPARTMENT
Mechanical Department
R.G.G.E.C Nagrota Bagwan.
 3

Rajiv Gandhi
Government Engineering College Kangra at
Nagrota Bagwan (H.P.)

CERTIFICATE

We hereby certify that the work which is being presented in the final internship/project
report entitled “STUDY OF DIFFERENT SHOPS,STUSY OF SENSORS OF SFETY,
TO ENSURE ZERO INCIDENTS IN GURUGRAM VEHICLE PLANT OF
MARUTI SUZUKI INDIA LIMITED” in partial fulfillment of the requirements for the
award of the B. Tech. and submitted to the Department of Mechanical Engineering of Rajiv
Gandhi Govt. Engg. College Kangra at Nagrota Bagwan is an authentic record of our own
work carried out during a period from January 2019 to May 2019 under the supervision of
Mr. Rameshwar Dass and MR. ABHINAY KUMAR.

The matter presented in this report has not been published earlier and has never been
submitted by us for the award of any other degree elsewhere.

Arupam Thakur
14BTD5020421
8th Semester
Mechanical Engineering
R.G.G.E.C Nagrota Bagwan

This is to certify that the above statement made by the candidates is correct to the best of
our knowledge.
Supervisors:

Mr. Rameshwar Dass Mr. Abhiney Kumar

Dptt. Manager Assistant Professor
PC-GV, MSIL Mechanical Department

Mr. Mohit Dhiman

HEAD OF THE DEPARTMENT
Mechanical Department
R.G.G.E.C Nagrota Bagwan
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ABSTRACT

This project report aims a bringing out the just of the work done by me as a part of 4 month

industrial training schedule at MARUTI SUZUKI INDIA LIMITED GURUGRAM

AND IN CM AUTO SALES PRIVATE LIMITED MARUTI SUZUKI INDIA

LIMITED. The project report is divided into suitable section and sub-section that bring out

the procedure and day by day work breakdown of my daily routine of the training schedule.

The various sections of the report are introductory part, different shops of workshop and

general procedure of car service. The project during the training is study about different

cars and their service procedure.

The various sections of the report are introductory part, different shops in plants and audit

of safety countermeasures in PC-GV department. The project during the training is study

different shops in plants and audit of safety countermeasures in PC-GV department. Audit

of countermeasures is done to ensure there is no further incident take place, which fulfill

the policy of Maruti Suzuki India Limited i.e. “zero accident, zero defects”.
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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 and at CM Auto
Sales Private Limited who helped me during my training. The exposure and experience
gained at Maruti has been unique.

I would like to thank Mr. Vikram Sharma, Mr. Rameshwar DASS, Mr Vipin Sahu and
Mr Rajesh 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.Abhinay Kumar, Training

Incharge, their able guidance and keen interest in my training.
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Table of Contents
ABSTRACT ........................................................................................................................... 4

ACKNOWLEDGEMENT ............................................................................................................. 5

Table of Contents ................................................................................................................... 6

List Of Tables ....................................................................................................................... 11

List Of Figure ....................................................................................................................... 12

Abbreviations ....................................................................................................................... 13

PART-1 OF TRAINING .................................................................................................... 14

1. About Company Profile ............................................................................................. 15

2. About CM Auto Sale Private Limited ....................................................................... 16

3. WORKSHOP & SHOWROOM ................................................................................ 17

3.1. Workshop ............................................................................................................... 17

3.2. Showroom .............................................................................................................. 18

4. Tools Equipment For And A Garage, Service Station And Specaialist Repairshop
&Powertools ......................................................................................................................... 19

4.1. Hand tools: ................................................................................................................. 19

4.2. Service station equipment .......................................................................................... 22

4.3. Special equipment for engine repair: ......................................................................... 22

4.4. Special equipment for compression engines .............................................................. 23

4.5. Power tools: ............................................................................................................... 23

5. Working in workshop ................................................................................................ 24

5.1. Body shop .................................................................................................................. 25

5.2. Paint shop ................................................................................................................... 25

5.3. Service shop ............................................................................................................... 26

6. WORKING IN DURING SERVICES IN WORKSHOP.......................................... 28

6.1. Replacement of the oil filter cartridge ....................................................................... 28

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6.2. Air filter ..................................................................................................................... 28

6.3. A/C filter .................................................................................................................... 28

6.4. Engine oil ................................................................................................................... 29

6.5. Clutch plate ................................................................................................................ 29

6.6. Brake .......................................................................................................................... 30

6.7. Brake pad ................................................................................................................... 31

6.8. Wheel alignment & balancing ................................................................................... 32

6.9. Final Inspection.......................................................................................................... 32

7. CONCLUSION ......................................................................................................... 33

PART -2 OF TRAINING ................................................................................................... 34

8. About Company Profile ............................................................................................. 35

9. History ....................................................................................................................... 36

10. Manufacturing facilities ............................................................................................. 37

11. Products and services ................................................................................................ 38

11.1. Current models ................................................................................................... 38

11.2. Discontinued models .......................................................................................... 40

11.3. Sales and service network .................................................................................. 42

11.4. NEXA ................................................................................................................. 42

11.5. Maruti Insurance ................................................................................................ 43

11.6. Maruti Finance ................................................................................................... 43

11.7. Maruti TrueValue ............................................................................................... 43

11.8. Maruti Accessories ............................................................................................. 43

11.9. Maruti Driving School ....................................................................................... 44

12. DIFFERENT SHOPS IN MARUTI SUZUKI INDIA LIMITED IN GURUGRAM45

12.1. PRESS SHOP ..................................................................................................... 46

12.1.1. Raw material: .............................................................................................. 46

12.1.2. Blanking line: ............................................................................................... 46

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12.1.3. Stamping line: ............................................................................................. 46

12.2. WELD SHOP ........................................................................................................ 47

12.2.1. UNDER BODY: .................................................................................................... 47

12.2.2. MAIN BODY: ................................................................................................ 47

12.2.3. WHITE BODY: .............................................................................................. 47

13. PAINT SHOP............................................................................................................ 49

14. Machine Shop ........................................................................................................ 52

15. Engine Assembly .................................................................................................... 52

16. Assembly Shop ....................................................................................................... 53

16.1. TRIM LINE .................................................................................................... 53

16.2. CHASSIS ........................................................................................................ 54

16.3. FINAL ............................................................................................................ 55

17. VEHICLE INSPECTION - I ......................................................................................... 56

17.1. Toe-In Test ..................................................................................................... 56

17.2. SLIP TESTER ................................................................................................ 57

17.3. HEAD LAMP TESTER ................................................................................. 57

17.4. Appearance Test ............................................................................................. 57

17.5. Brake Tester .................................................................................................... 59

17.6. Engine Room .................................................................................................. 59

17.7. Pit Inspection .................................................................................................. 59

17.8. Shower Tester ................................................................................................. 59

17.9. Road Test ........................................................................................................ 59

17.10. Final Check ..................................................................................................... 60

Project: To Ensure Zero Incident.......................................................................................... 61

18. PC-GV (plant control in gurugram vehicle) .............................................................. 62

19. Safety ......................................................................................................................... 62

19.1. HEINRICH LAW: .................................................................................................. 63

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19.2. Policies for safety ............................................................................................... 63

19.2.1 KYT: ................................................................................................................. 63

19.2.2. HHT: ............................................................................................................ 63

19.2.3. Robo Safety: ................................................................................................ 63

19.2.4. LOTO: .......................................................................................................... 63

19.2.5. MARU: ......................................................................................................... 63

19.2.6. ROKO-TOKO ................................................................................................ 63

19.2.7. WIS: ............................................................................................................. 63

19.2.8. POKO-YOKE: ................................................................................................ 63

19.2.9. 5S ................................................................................................................ 63

19.2.10. 3G ................................................................................................................ 64

19.2.11. 3K ................................................................................................................ 64

19.2.12. 3M ............................................................................................................... 64

19.2.13. Quality Policy ............................................................................................. 64

19.3. Steps to ensure safety: ....................................................................................... 65

19.4. PPE: Personal Protective Equipment ................................................................. 66

20. Project-1: Audit for different countermeasures regarding safety in gurugram vehicle
plant……………………. .......................................... ……………….……………………..69

20.2. Display Of "Please Do Not Touch The Glass" On The Doors ....................... 70

20.3. Audit for Goggle And Plier Condition In Engine Sub-Assembly .................. 75

20.4. Slope Angle Of Ramp .................................................................................... 76

20.5. TOGGLE CLAMP PAINTED RED COLOUR ............................................. 77

20.6. Monitoring Of Toe-in Tester .......................................................................... 78

20.7. Monitoring Of Position Of Parking Cable ...................................................... 80

20.8. Audit For Working Table In Dismantle Area ................................................. 81

20.9. Audit In Dismantle Area................................................................................. 82

20.10. Mirrors In Break Tester Area ......................................................................... 83

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20.11. Distance Of Trollry Guide From Gangway .................................................... 84

20.12. Arm cover uses by worker in IP torquing operation. ..................................... 85

20.13. height of toogle clamp not in reachable area of worker ................................. 85

20.14. Helmet Stand Near Toilet ............................................................................... 86

20.15. gangway in press shop .................................................................................... 87

20.16. height of toogle clamp not in reachable area of worker ................................. 87

20.17. door handel bar and push/pull indication check ............................................. 88

20.18. audit of no person while car is moving........................................................... 89

21. Project 2: study of sensors of safety .......................................................................... 90

21.2. Sensor at end of line ........................................................................................... 90

21.3. Fool Proofing: Poka-Yoke ................................................................................. 90

21.3.2. PIKA PIKA ................................................................................................. 91

22. CONCLUSION ......................................................................................................... 93

23. REFERENCES .......................................................................................................... 94

List of references .............................................................................................................. 94

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List Of Tables
TABLE 1 ................................................................................................................................. 39
TABLE 2 ................................................................................................................................. 42
TABLE 3 ................................................................................................................................. 66
TABLE 4 ................................................................................................................................. 67
TABLE 5 ................................................................................................................................. 68
TABLE 6 ................................................................................................................................. 68
TABLE 7 ................................................................................................................................. 69
TABLE 8 ................................................................................................................................. 74
TABLE 9 ................................................................................................................................. 75
TABLE 10 ............................................................................................................................... 76
TABLE 11 ............................................................................................................................... 77
TABLE 12 ............................................................................................................................... 79
TABLE 13 ............................................................................................................................... 80
TABLE 14 ............................................................................................................................... 81
TABLE 15 ............................................................................................................................... 82
TABLE 16 ............................................................................................................................... 83
TABLE 17 ............................................................................................................................... 84
TABLE 18 ............................................................................................................................... 85
TABLE 19 ............................................................................................................................... 85
TABLE 20 ............................................................................................................................... 86
TABLE 21 ............................................................................................................................... 87
TABLE 22 ............................................................................................................................... 87
TABLE 23 ............................................................................................................................... 88
TABLE 24 ............................................................................................................................... 89
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List Of Figure
FIGURE 1 ............................................................................................................................... 16
FIGURE 2 WORKSHOP AREA ................................................................................................... 17
FIGURE 3 LIFTING M/C IN WORKSHOP .................................................................................... 17
FIGURE 4 ............................................................................................................................... 18
FIGURE 5 SHOWCASE & DEALING ROOM ............................................................................... 18
FIGURE 6 HAND TOOLS .......................................................................................................... 21
FIGURE 7 SERVICE ADVISER ROOM ........................................................................................ 24
FIGURE 8 DAMAGE CAR BODY ............................................................................................... 25
FIGURE 9 DENTING SHOP ....................................................................................................... 25
FIGURE 10 PAINT SHOP .......................................................................................................... 26
FIGURE 11 OPENING OF ENGINE ............................................................................................. 26
FIGURE 12 REPAIRING GEAR BOX .......................................................................................... 26
FIGURE 13 WASHING SHOP .................................................................................................... 27
FIGURE 14 INSERTING NEW AIR FILTER .................................................................................. 28
FIGURE 15 LEFT SIDE NEW A/C FILTER OTHER SIDE POLLUTED A/C FILTER ............................. 29
FIGURE 16 FILLING ENGINE OIL IN ENGINE............................................................................. 29
FIGURE 17 CLUTCH PLATE ..................................................................................................... 30
FIGURE 18 BRAKE WHEEL...................................................................................................... 30
FIGURE 19 DISC BRAKE ASSEMBLY ........................................................................................ 30
FIGURE 20 DISC BRAKE PAD .................................................................................................. 31
FIGURE 21 WHEEL ALIGNMENT ............................................................................................. 32
FIGURE 22 WHEEL BALANCING ............................................................................................. 32
FIGURE 23 CHECKING ALL SPARE PARTS ARE TIGHT OR NOT .................................................. 32
FIGURE 24 ............................................................................................................................. 45
FIGURE 25 ............................................................................................................................. 46
FIGURE 26 ............................................................................................................................. 48
FIGURE 27 ............................................................................................................................. 49
FIGURE 28 ............................................................................................................................. 49
FIGURE 29 ............................................................................................................................. 50
FIGURE 30 ............................................................................................................................. 51
FIGURE 31 ............................................................................................................................. 54
FIGURE 32 ............................................................................................................................. 55
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FIGURE 33 ............................................................................................................................. 62
FIGURE 34 ............................................................................................................................. 63
FIGURE 35 ............................................................................................................................. 64
FIGURE 36 HIERARCHAL CHART FOR PIKA PIKA .................................................................... 91
FIGURE 37 OVER VIEW OF PIKA PIKA INSTALLED ON TRIM LINE ............................................ 92
FIGURE 38 LIMIT SWITCH ...................................................................................................... 92

Abbreviations

PC-GV: plant control – gurugram vehicle

AS: assembly shop

WS: weld shop

PRS: press shop

PS: paint shop

NG: not good

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PART-1 OF TRAINING

In CM Auto Sale Private Limited, Maruti Suzuki India

Limited
 15

1. About Company Profile

Maruti Suzuki India Limited, formerly known as Maruti Udyog Limited, is an automobile
manufacturer in India. It is a 56.21% owned subsidiary of the Japanese car and motorcycle
manufacturer Suzuki Motor Corporation. . 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. As of July 2018, it had a market share of 53% of the Indian passenger car
market.[8] Maruti Suzuki manufactures and sells popular cars such as the Ciaz, Ertiga,
Wagon R, Alto K10, Swift, Celerio, Swift Dzire, Baleno and Baleno RS, Omni, Alto 800,
Eeco, Ignis, S-Cross. The company is headquartered at New Delhi. In May 2015, the
company produced its fifteen millionth vehicles in India, a Swift Dzire.
Maruti’s Gurgaon facility has a major role in India’s automotive history. Since it rolled out
the Maruti 800 in 1983, the company has grown to become the top automaker in India, now
manufacturing one in every two passenger vehicles sold. Its success has encouraged several
other automakers to invest in India’s frugal manufacturing capabilities, making the country
one of the top production bases and markets for passenger vehicles and components.
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2. About CM Auto Sale Private Limited

Authorised Maruti Suzuki dealership with fully equipped service station and
body shop, also deal in true valur cars(sales & purchage of second hand
vehicles) in chandigarh, Ropar, Nangal, Kharar, Anadpursahiband Mohali.
Headquater is situated at Chndigarh.

Figure 1
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3. WORKSHOP & SHOWROOM

3.1. Workshop

I have done my internship in the workshop of Sikka Hyundai. There, I have work under a
mentor who tells me about the organization and the work procedure, quick repairs, how to
solve major-minor problem generally observed in the cars. These are the some pictures of
the workshop where I have done my internship.

Figure 2 Workshop area

Features of workshop
 Equipped with hi tech lift machined for lifting the car to repair top bottom parts
 All the technicians have their own equipment’s and machinery
 They have a very large floor area for working their
 Time to time sweepers clean the workshop to maintain the good working
environment
 All the major & minor faults would be find by manually or through software (G-
scan)
 Final inspection can be done by the experts team

Figure 3 Lifting m/c in workshop

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3.2. Showroom

Figure 4

They have a very beautiful furnishing having a large floor area for displaying the top model
cars of Maruti Suzuki. The showroom is fully air conditioned and very good in looking. All
the time at least 4 to 5 person are stand there to asset the customer very kindly and friendly.

Figure 5 Showcase & Dealing room

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4. Tools Equipment For And A Garage, Service Station And

Specaialist Repairshop &Powertools

Many of the tools and items of equipment are necessary to enable the motor vehicle
workshop to cope with the wide variety of servicing and repair work. The following is a list
of tools and equipment in the auto shop.

4.1. Hand tools: Many kind types and sizes of tools are used in automobile work.

i. D.E. spanner set: These are the most commonly used type of spanner in garage.
The opening should be the right size to fit the nut or bolt. If the spanner opening is
too large, it could round off the corners of the hex. These make the use of the
proper spanner more difficult. These spanners are available in different sizes
ranging from 6 to 32mm.
ii. Ring spanner: In ring spanners the end openings completely enclose the nut or the
bolt head, so that they do not slip and cause damage. Further, the end holes in the
ring spanners are twelve sided, because of which they can be used in restricted
spaces, since the nut or the bolt head can be worked upon even when the swing of
the spanner is restricted to 15.
iii. Tubular spanner: These are also used for the same purpose as ring spanner. It will
be like a long tube having hexagonal ends at each end of different size. They may
vary in size from 8mm to 32mm. it can be used where double end and ring spanner
cannot be used.
iv. Socket spanners: These types of spanners are useful in restricted spaces where
common types of spanners cannot be used. They consist of sockets of different sizes
which can be used with various types of handles. The handles have projection at
one end around which the sockets fit. One type of handle has a universal joint at the
projection end which makes it possible to work with the handle at an inclination
with the socket. A ratchet handle is also available which obviates necessity of
lifting of the socket from the nut or the bolt head.
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v. Adjustable wrenches: This wrench has jaws that can be adjusted to fit nuts and
bolt heads of various sizes. These types of wrenches have advantage that these can
be suitable for a large number of nut and bolt head sizes.
vi. Torque wrenches: Important nuts and bolts in automobile work have to be
tightened with a specified amount of torque, because excessive torque may result in
their breakage while less torque they will remain loose. This is made possible by a
torque wrench. It is a specialised form of socket spanners.
vii. Screw driver: The screw driver is used to drive, or turn screws. The most common
type has a single flat blade for driving screws with slotted heads. There are also the
Phillips head and reed, and prince screw drivers.
viii. Hammers: A medium weight ball pen hammer is the one commonly used in
automobile work. It should be gripped on the end of the handle. When you swing
the hammer, the face should strike the object squarely, and not an angle.
ix. Pliers: pliers are a special type of adjustable wrench. The two legs move on a pivot
so that items of various sizes can be gripped. There are two types gripping pliers
and cutting plier.
x. Pullers: Pullers come in a variety of types and sizes and are used to remove wheels,
gears and bearing from shafts from housings. Each pulling operation differs from
the other, and care must be exercised to prevent damage to the parts during pulling.
xi. Spark plug spanner: For removing or tightening spark plugs.
xii. Feeler gauge: For measurements such as valve clearance, spark plug gap, contact
breaker gap etc., we use feeler gauges which are simply blades of different
thickness.
xiii. Valve spring compressor: Valve spring compressors or lifters are used to
compress the valve spring to facilitate the removal of the valve retain lock or keeper
from the valve stem.
xiv. Piston ring compressor: Piston ring compressors are places around the piston
covering the rings. As the compressor is tightened, it compresses the piston rings
into their grooves on the piston. Then the piston and rod assembly is installed into
the cylinder.
xv. Piston ring expander: It is generally use to expand and remove the piston rings
from their grooves without breaking.
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Figure 6 Hand tools

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4.2. Service station equipment

A large number of different types of equipment are required in a garage or service station
for carrying out different types of repair works. Different types of equipment are required
to cope up with the wide variety of work to be done can be classified as under.

Special equipment for service station

i. Compressed air plant

ii. Car washing machine
iii. Lifting tackles
a) Hydraulic jack
b) Car lift
c) Axle stands
d) Jib crane
e) A chain hoist
iv. Chassis dynamometer
v. Wheel balancer
vi. Tire remover
vii. Brake drum lathe
viii. Brake shoe lining riveting machine
ix. Spark plug tester
x. High pressure grease gu
xi. Wheel alignment gauges
xii. Degreasing plant

4.3. Special equipment for engine repair:

i. Crankshaft grinding machine

ii. Cylinder head surface grinding machine
iii. Line boring machine
iv. Connecting rod big end bearing boring machine
v. Cam shaft grinding machine
 23

vi. Valve refacer machine

vii. Hydraulic press
viii. Cylinder boring machine
ix. Cylinder honing machine
x. Connecting rod rebabbitting jig

4.4. Special equipment for compression engines

i. Bench nozzle testing and cleaning equipment

ii. Fuel injector tester
iii. Fuel pump tester
iv. Nozzle and needle grinding and lapping machines.
v.
4.5. Power tools: Power tools are increasingly used in modern automated auto
workshops. They are operated by pneumatic, electric, hydraulic powers. Their use
envisages quicker, effortless and efficient service.

Pneumatic Nut and Bolt Tightener: It tightens and loosens the nuts and bolts in no time.
This is a portable machine whose working end can be changed to suit different sizes of
bolts and nuts.
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5. Working in workshop
While working in the workshop I have seen and learnt about how a workshop running at full
speed and achieve target as much faster as they can, so they meet the customer requirement and
satisfaction.

There are four departments in workshop as follows:

1. Body shop

2. Painting shop

3. Service shop

4. Washing

When a car enters the workshop, firstly they made a repair order for the customer in which the
customer tells the problem what he is facing with the car, or it may be its general repairs. Then
the service adviser inspect the car and he told the technician what he find at first stage then the
technician fully examine the whole car & each n every parts of the car and then he noted down
in the job card. Generally the company provide 4 free general services, in which the mechanic
or technician checks the engine oil, lubricating oil, water, air filter, A/C filter and other
electronic controls. And if he detects any problem which might reduce the car efficiency he
will notify to the service advisor and then service advisor calls to the customer and tell him
about the defects and then if the customer is ready to repair it then the service adviser tell to the
mechanic and then mechanic repair the problem so the car run effortlessly.
Defected cars are selected on the basis of their faults and then send to it their specified category
of shop such as if any car having damage related to tits body then it send to the body shop or if
any engine, brake, wheel alignment then it send to the service shop.

Figure 7 Service adviser room

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5.1. Body shop

In the body shop of CM Auto (maruti) those cars having some damage on its body are repaired.
Dents, breaking of body parts, etc. are some common problems which come to the body shop.

Figure 8 Damage car body

5.1.1 Denting
Denting is a process in which the body of the car is not repair or replaced in these a selected
portion or we can say it a defected part of body of the car on which dents, marks, scratches,
stains, are to be repaired by some devices and equipment.

Figure 9 Denting shop

5.2. Paint shop

Paint shop is the kind of parlor for cars, the aesthetic look of the cars are prepared here in this
paint shop. Priming, painting, etc. are some processes perform in this shop.
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Figure 10 Paint shop

5.3. Service shop

In service shop, as name shows in this shop the general service or repairing is done like regular
service or any problem related to internal mechanisms, engines, etc. changing of engine oil,
brake oil, clutch oil , gear oil, changing of air filter, etc. comes under this shop.
In this shop four types of services are to be done they are as follows:
1. Free services

2. Paid services

3. Running repair services

4. Quick Services

Figure 11 Opening of engine

Figure 12 Repairing gear box

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5.3.1. Free services

Under this type of service category only those types of customer’s cars are to be repaired which
are within period of company’s warranty. When any customer buys a new car the company
provided them first 3 to 4 services are free that means customer did not need to be pay for his
first four services. Only those parts to be repaired which are in fall under warranty period
otherwise it will be go in paid service.

5.3.2. Paid services

In these type of service customer have to pay for his cars services whenever he visit for getting
service. In this category warranty period cover cars are not to be included for repairing, but in
some rushes cases it can be repaired if some might faults are to be solve.

5.3.2. Running repair

In these the running cars to be repaired that means they come & order for repair and then go in
a same day after the service done which are to be listed in job card.

5.3.3. Quick services

In Quick Service Station, the car comes for general repair like to check engine oil, lubricating
oil, water level in battery and wind shied cleaning reservoir, air filter, A/C filter and other
electronic controls and if require top-up it.
According to the repair order the store keeper gives the parts, which are to be used to repair the
car and placed in it carefully. It is a quick and short period of time service.

5.3.4. Washing
In washing the final cleaning is done with water and car washing shampoo. An automatic
machine first washes the car then the whole washes are done by washers (manpower).
Sometimes it is done first then after service accordingly customer’s requirement.

Figure 13 Washing shop

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6. WORKING IN DURING SERVICES IN WORKSHOP

6.1. Replacement of the oil filter cartridge

The oil filter cartridge is present at the bottom of the car which can be open with the ratchet.
After opening it the used engine oil is taken out and after that the new cartridge is put in with a
new washer. New washer is used to get proper fitting so that the oil should not leak.

6.2. Air filter

A particulate air filter is a device composed of fibrous materials which removes solid
particulates such as dust, pollen, mold, and bacteria from the air. A chemical air filter consists
of an absorbent or catalyst for the removal of airborne molecular contaminants such as volatile
organic compounds or ozone. Air filters are used in applications where air quality is important,
notably in building ventilation systems and in engines.

Figure 14 Inserting new air filter

6.3. A/C filter

A particulate a/c filter is a device composed of fibrous materials which removes solid
particulates such as dust, pollen, mold, and bacteria from the a/c of car to release filtered cooled
air inside the car. A chemical air filter consists of an absorbent or catalyst for the removal of
airborne molecular contaminants such as volatile organic compounds or ozone. A/c filters are
used in applications where air quality is important, notably in building ventilation systems and
in vehicle cabinet.
 29

Figure 15 Left side new a/c filter other side polluted a/c filter

6.4. Engine oil

Motor oil, engine oil, or engine lubricant is any of various well-developed lubricants
(comprising oil enhanced with additives, for example, in many cases, extreme pressure
additives) that are used for lubrication of internal combustion engines. The main function of
these lubricants is to reduce wear on moving parts; they also clean, inhibit corrosion, improve
sealing, and cool the engine by carrying heat away from moving parts.

Figure 16 Filling engine oil in engine

6.5. Clutch plate

A clutch is a mechanical device that engages and disengages the power transmission,
especially from driving shaft to driven shaft. Clutches are used whenever the transmission of
power or motion must be controlled either in amount or over time. The vast majority of
clutches ultimately rely on frictional forces for their operation. The purpose of friction clutches
is to connect a moving member to another that is moving at a different speed or stationary,
often to synchronize the speeds, and/or to transmit power. Usually, as little slippage (difference
in speeds) as possible between the two members is desired.
 30

Figure 17 Clutch plate

6.6. Brake
A brake is a mechanical device which inhibits motion, slowing or stopping a moving object or
preventing its motion. Most brakes commonly use friction between two surfaces pressed
together to convert the kinetic energy of the moving object into heat, though other methods of
energy conversion may be employed. The brake disc (or rotor in American English) is usually
made of cast iron, but may in some cases be made of composites such as reinforced carbon–
carbon or ceramic matrix composites. This is connected to the wheel and/or the axle. To retard
the wheel, friction material in the form of brake pads, mounted on a device called a brake
caliper, is forced mechanically, hydraulically, pneumatically, or electromagnetically against
both sides of the disc. Friction causes the disc and attached wheel to slow or stop.

Figure 18 Brake wheel

Figure 19 Disc brake assembly

 31

6.7. Brake pad

Brake pads are a component of disc brakes used in automotive and other applications. Brake
pads are steel backing plates with friction material bound to the surface that faces the disk
brake rotor.
Brake pads are designed for high friction with brake pad material embedded in the disc in the
process of bedding while wearing evenly. Friction can be divided into two parts. They are:
adhesive and abrasive.

Depending on the properties of the material of both the pad and the disc and the configuration
and the usage, pad and disc wear rates will vary considerably. The properties that determine
material wear involve trade-offs between performance and longevity.
The brake pads must usually be replaced regularly (depending on pad material, and drive style),
and some are equipped with a mechanism that alerts drivers that replacement is needed, such as
a thin piece of soft metal that rubs against the disc when the pads are too thin causing the
brakes to squeal, a soft metal tab embedded in the pad material that closes an electric circuit
and lights a warning light when the brake pad gets thin, or an electronic sensor.
Generally road-going vehicles have two brake pads per caliper, while up to six are installed on
each racing caliper, with varying frictional properties in a staggered pattern for optimum
performance.
Early brake pads (and linings) contained asbestos, producing dust which should not be inhaled.
Although newer pads can be made of ceramics, Kevlar, and other plastics, but again inhalation
of brake dust should still be avoided regardless of material.

Figure 20 Disc brake pad

 32

6.8. Wheel alignment & balancing

Wheel alignment and Wheel Balancing are totally two different things. Wheel alignment
consists of adjusting the angles of the wheels so that they are perpendicular to the ground and
parallel to each other. The purpose of these adjustments is maximum tire life and a vehicle that
tracks straight and true when driving along a straight and level road. Wheel Balancing, on the
other hand allows the tires and wheels to spin without causing any vibrations. This is
accomplished by checking for any heavy spots on the wheel-tire combination and
compensating for it by placing a measured lead weight on the opposite site of the wheel from
where the heavy spot is.

Figure 21 Wheel alignment

Figure 22 Wheel balancing

6.9. Final Inspection

In final inspection, the last inspection is done so, that there should not be any single problem
left in the car before handle to the customer.
This work station is just for the zero error service. This increases the customer satisfaction and
hence increases the standard of the workshop as well as the service which is providing.

Figure 23 Checking all spare parts are tight or not

 33

7. CONCLUSION

It was a great internship in CM Auto Sale Private Limited full of knowledge. I really enjoyed
the training period. I have learnt about different services and the major minor defects generally
seen in the car and how to solve them.
Most of the time I used to do the free services and some repair also like I have change the brake
pads, tiers, replacing the engine oil, coolant and many other things, then I have made a note for
that in repair order.
I also seen that how an organization work under extreme pressure and how to handle it like
when so many cars have to repair in the limited time it is really a very big task, I have also
worked with GM and completed a small project there.
Overall it was a good experience and it increases my interest in the Automobile engineering.
 34

PART -2 OF TRAINING
IN MARUTI SUZUKI INDIA LIMITED, GURUGRAM PLANT
 35

8. About Company Profile

Maruti Suzuki India Limited, formerly known as Maruti Udyog Limited, is an automobile
manufacturer in India. It is a 56.21% owned subsidiary of the Japanese car and motorcycle
manufacturer Suzuki Motor Corporation. . 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. As of July 2018, it had a market share of 53% of the Indian
passenger car market.[8] Maruti Suzuki manufactures and sells popular cars such as the
Ciaz, Ertiga, Wagon R, Alto K10, Swift, Celerio, Swift Dzire, Baleno and Baleno RS, Omni,
Alto 800, Eeco, Ignis, S-Cross. The company is headquartered at New Delhi. In May 2015,
the company produced its fifteen millionth vehicles in India, a Swift Dzire.

Maruti’s Gurgaon facility has a major role in India’s automotive history. Since it rolled out
the Maruti 800 in 1983, the company has grown to become the top automaker in India,
now manufacturing one in every two passenger vehicles sold. Its success has encouraged
several other automakers to invest in India’s frugal manufacturing capabilities, making the
country one of the top production bases and markets for passenger vehicles and
components.
 36

9. History

Maruti was established in February 1981 with production starting in 1983 with the Maruti
700 Which is 100 % Indian Made & The Second Model is Maruti 800 DX based on the
Suzuki SS80 Which is imported From Japan Car Manufacturer SUZUKI As of May 2007, the
Government of India, through Ministry of Disinvestment, sold its complete share to Indian
financial institutions and no longer has any stake in Maruti Udyog.

In 1989, the Maruti 1000 was introduced and the 970 cc, three-box was India's first
contemporary sedan. By 1991, 65 per cent of the components, for all vehicles produced,
were indigenized. After liberalization of the Indian economy in 1991, Suzuki increased its
stake in Maruti to 50 per cent, making the company a 50-50 JV with the Government of
India the other stake holder.

In 1993, the Zen, a 993 cc, hatchback was launched and in 1994 the 1298 cc Esteem was
introduced. Maruti produced its 1 millionth vehicle since the commencement of
production in 1994. Maruti's second plant was opened with annual capacity reaching
200,000 units. Maruti launched a 24-hour emergency on-road vehicle service. In 1998, the
new Maruti 800 was released, the first change in design since 1986. Zen D, a 1527 cc
diesel hatchback and Maruti's first diesel vehicle and a redesigned Omni were introduced.
In 1999, the 1.6 litre Maruti Baleno three-box saloon and Wagon R were also launched.

In 2000, Maruti became the first car company in India to launch a Call Centre for internal
and customer services. The new Alto model was released. In 2001, Maruti True Value,
selling and buying used cars was launched. In October of the same year the Maruti Versa
was launched. In 2002, Esteem Diesel was introduced. Two new subsidiaries were also
started: Maruti Insurance Distributor Services and Maruti Insurance Brokers Limited.
Suzuki Motor Corporation increased its stake in Maruti to 54.2 per cent.

In 2003, the new Suzuki Grand Vitara XL-7 was introduced while the Zen and the Wagon R
were upgraded and redesigned. Maruti Udyog Ltd was listed on BSE and NSE after a public
issue, which was oversubscribed tenfold. In 2004, the Alto became India's bestselling car
overtaking the Maruti 800 after nearly two decades. The five-seater Versa 5-seater, a new
variant, was created while the Esteem was re-launched. Maruti Udyog closed the financial
year 2003-04 with an annual sale of 472,122 units, the highest ever since the company
began operations and the fiftieth lakh (5 millionths) car rolled out in April 2005. The 1.3
litre Suzuki Swift five-door hatchback was introduced in 2005.

In 2006 Suzuki and Maruti set up another joint venture, "Maruti Suzuki Automobiles
India", to build two new manufacturing plants, one for vehicles and one for engines.
Cleaner cars were also introduced, with several new models meeting the new "Bharat
Stage III" standards.

Maruti Suzuki is now looking to shift its current manufacturing facility located in the
downtown Gurgaon as apparently it is short of space and logistics. It is hunting for a huge
700 acres of plot of land.
 37

10. Manufacturing facilities

Maruti Suzuki has three manufacturing facilities in India. All manufacturing facilities have
a combined production capacity of 1,700,000 vehicles annually. The Gurgaon
manufacturing facility has three fully integrated manufacturing plants and is spread over
300 acres (1.2 km2). The Gurgaon facilities also manufacture 240,000 K-Series engines
annually. The Gurgaon Facilities manufactures the Alto 800, WagonR, Ertiga, S-Cross,
Vitara Brezza, Ignis and Eeco.

The Manesar manufacturing plant was inaugurated in February 2007 and is spread over
600 acres (2.4 km2). Initially it had a production capacity of 100,000 vehicles annually but
this was increased to 300,000 vehicles annually in October 2008. The production capacity
was further increased by 250,000 vehicles taking total production capacity to 800,000
vehicles annually. The Manesar Plant produces the Alto 800, Alto K10, Swift, Ciaz, Baleno,
Baleno RS and Celerio. On 25 June 2012, Haryana State Industries and Infrastructure
Development Corporation demanded Maruti Suzuki to pay an additional Rs 235 crore for
enhanced land acquisition for its Haryana plant expansion. The agency reminded Maruti
that failure to pay the amount would lead to further proceedings and vacating the
enhanced land acquisition. The launch of the Dzire happened in the month of May 2017
and the variant is said to have good mileage.

The Gujarat manufacturing plant became operational in February 2017. The plant current
capacity is about 250,000 units per year. But with new investments Maruti Suzuki has plan
to take it to 450,000 units per year.

In 2012, the company decided to merge Suzuki Powertrain India Limited (SPIL) with itself.
SPIL was started as a JV by Suzuki Motor Corp. along with Maruti Suzuki. It has the
facilities available for manufacturing diesel engines and transmissions. The demand for
transmissions for all Maruti Suzuki cars is met by the production from SPIL.
 38

11. Products and services

11.1. Current models

Model Launched Category Image

Omni 1984–present Minivan

WagonR 1999–present Hatchback

Swift 2005–present Hatchback

DZire 2008–present Sedan

Eeco 2009–present Minivan

Alto 800 2014-present Hatchback

Alto K10 2010–present Hatchback

Ertiga 2012–present Mini MPV

 39

Alto 800 2012–present Hatchback

Celerio 2014–present Hatchback

Ciaz 2014–present Sedan

Baleno 2015–present Hatchback

S-Cross 2015–present Mini SUV

Vitara Brezza 2016–present Mini SUV

Ignis 2017–2019 Hatchback

CelerioX 2017–present Hatchback

Table 1
 40

11.2. Discontinued models

Model Launched Discontinued Category Image

800 1983 2010 Hatchback

Gypsy E 1985 2000 Mini SUV

1000 1990 2000 Sedan

Zen 1993 2003 Hatchback

Esteem 1994 2010 Sedan

Baleno 1999 2007 Sedan

 41

Alto 2000 2012 Hatchback

Versa 2001 2010 Minivan

Grand Vitara XL7 2003 2007 Mini SUV

Grand Vitara 2007 2015 Mini SUV

Zen Estilo 2007 2013 Hatchback

A-star 2008 2014 Hatchback

SX4 2008 2014 Sedan

 42

Swift Dzire 2008 2017 Sedan

Ritz 2008 2016 Hatchback

Kizashi 2011 2014 Sedan

Gypsy King 1985 2018 Mini SUV

Table 2

11.3. Sales and service network

Maruti Suzuki has 1,820 sales outlets across 1,471 cities in India. The company aims to
double its sales network to 4,000 outlets by 2020. It has 3,145 service stations across
1,506 cities throughout India. Maruti's dealership network is larger than that of Hyundai,
Mahindra, Honda, Tata, Toyota and Ford combined.Service is a major revenue generator
of the company. Most of the service stations are managed on franchise basis, where
Maruti Suzuki trains the local staff. Other automobile companies have not been able to
match this benchmark set by Maruti Suzuki. The Express Service stations help many
stranded vehicles on the highways by sending across their repair man to the vehicle.

11.4. NEXA
In 2015 Maruti Suzuki launched NEXA, a new dealership format for its premium cars.

Maruti currently sells the Baleno, Baleno RS, S-Cross, Ciaz and Ignis through NEXA outlets.
S-Cross was the first car to be sold through NEXA outlets. Several new models will be
 43

added to both channels as part of the Company's medium term goal of 2 million annual
sales by 2020.

11.5. Maruti Insurance

Launched in 2002 Maruti Suzuki provides vehicle insurance to its customers with the help
of the National Insurance Company, Bajaj Allianz, New India Assurance and Royal
Sundaram. The service was set up the company with the inception of two subsidiaries
Maruti Insurance Distributors Services Pvt. Ltd and Insurance Brokers Pvt. Limited

This service started as a benefit or value addition to customers and was able to ramp up
easily. By December 2005 they were able to sell more than two million insurance policies
since its inception.

11.6. Maruti Finance

To promote its bottom line growth, Maruti Suzuki launched Maruti Finance in January
2002. Prior to the start of this service Maruti Suzuki had started two joint ventures
Citicorp Maruti and Maruti Countrywide with Citi Group and GE Countrywide respectively
to assist its client in securing loan Maruti Suzuki tied up with ABN Amro Bank, HDFC Bank,
ICICI Limited, Kotak Mahindra, Standard Chartered Bank, and Sundaram to start this
venture including its strategic partners in car finance. Again the company entered into a
strategic partnership with SBI in March 2003 Since March 2003, Maruti has sold over
12,000 vehicles through SBI-Maruti Finance. SBI-Maruti Finance is currently available in
166 cities across India.

11.7. Maruti TrueValue

Maruti True service offered by Maruti Suzuki to its customers. It is a market place for used
Maruti Suzuki Vehicles. One can buy, sell or exchange used Maruti or Non Maruti vehicles
with the help of this service in India. As of 10 August 2017 there are 1,190 outlets across
936 cities

11.8. Maruti Accessories

Many of the auto component companies other than Maruti Suzuki started to offer
components and accessories that were compatible. This caused a serious threat and loss
of revenue to Maruti Suzuki. Maruti Suzuki started a new initiative under the brand
 44

name Maruti Genuine Accessories to offer accessories like alloy wheels, body cover,
carpets, door visors, fog lamps, stereo systems, seat covers and other car care products.
These products are sold through dealer outlets and authorized service stations
throughout India.

11.9. Maruti Driving School

As part of its corporate social responsibility Maruti Suzuki launched the Maruti Driving
School in Delhi. Later the services were extended to other cities of India as well. These
schools are modelled on international standards, where learners go through classroom
and practical sessions. Many international practices like road behaviour and attitudes are
also taught in these schools. Before driving actual vehicles participants are trained on
simulators.

At the launch ceremony for the school Jagdish Khattar stated "We are very concerned
about mounting deaths on Indian roads. These can be brought down if government,
industry and the voluntary sector work together in an integrated manner. But we felt that
Maruti should first do something in this regard and hence this initiative of Maruti Driving
Schools."
 45

12. DIFFERENT SHOPS IN MARUTI SUZUKI INDIA LIMITED IN

GURUGRAM

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 deptt. conducts various tests to ensure that no defects remain
before the car is dispatched via trucks to various parts of the country.

Figure 24
 46

12.1. 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. 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

12.1.1. 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.
12.1.2. Blanking line: There are two blanking lines; ROSL (Rotary Oscillatory shear
line) for rectangular shapes and the others employing die cutting for irregular
shapes.
12.1.3. 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.
Process flow of Press Shop activity :-

Steel coil Blank Panel

Figure 25
 47

12.2. 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:

12.2.1. 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.

12.2.2. 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.
12.2.3. 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.
 48

The flow chart for a typical car body weld line looks as follows:

Figure 26
 49

13. PAINT SHOP

In paint shop following processes are carried out:

1. Pretreatment Process
2. Electro deposition
3. Sol Sealer and under coat
4. Intermediate coat
5. Top coating

13.1. Pretreatment Process: In this process 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.

Figure 27

WR- Water Rinse

DI- Demineralised water or deionized
ED- Electro deposition

13.2. Electro deposition: In this process vehicle is dipped in the ED solution. In this
around 300V is passed through the vehicle body to make paint to be attached.
ED is 17% of paint rest is water and some additives.

Figure 28

13.3. Sol Sealer and undercoat process: Here the left in the body (due to
welding) are filled w i t h s o l - s e a l e r t o p r o v i d e w a t e r p r o o f i n g .
 50

U n d e r c o a t i s d o n e o n t h e s u r f a c e above wheels to prevent damage of

body in that portion.

13.4. Intermediate coating: This process is done by spray-painting method

using 8 Yaskawa 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. O u t s i d e p o r t i o n o f v e h i c l e i s p a i n t e d b y r o b o t s
a n d i n s i d e i s d o n e manually. Paint thickness is taken care, after that
vehicle is sent to IC oven. Oven temperature is 198+/-5’ degree Celsius.

13.5. Top coat painting: Top coating is done after checking in dry sanding. There
are 2 sub coatings Base coat and Clear coat. Here 11 colors are used; 8 metallic
and 3 solid. Only metallic colors are coated with clear coating. Here also outside
portion of vehicle is painted by robots and inside is done manually.
Next vehicle will move to final inspection and will be sent to assembly.

Figure 29
 51

Full Paint Process through pictures:

Figure 30
 52

14. 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

15. 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.
 53

16. Assembly Shop

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 ALTO800 (Domestic & Export Mainly), OMNI
(Passenger & Cargo), EECO, IGNIS, Super Carry & WAGON R (new model). The
Whole process of assembling undergoes through different number of stations. The
Assembly shop can be further subdivided as following:

 Trim
 Chassis
 Final

16.1. 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-assembly.
This sub assembly involves the fitting of the speedometer console, ashtray and stereo
system.
 54

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 clementine application on the windshield, Motoman robots are employed.
Here a process check is done

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

Figure 31

16.2. 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.
 55

Chassis Line: Here, the car is loaded on overhead jigs as shown below:

Figure 32

16.3. 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 litters of petrol are 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.

Here, as both the engine and wheels have been fitted, the car once again moves over the
conveyor belt.
 56

17. 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
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.

17.1. 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:
 57

 Minimum tyre 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 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 isn’t holding the steering wheel. Figure no. 5
shows the toe-in tester machine.

17.2. 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.

17.3. 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.

17.4. 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
 58

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, 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
 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.
 59

17.5. 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.

17.6. 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.

17.7. 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

17.8. 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.

17.9. 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
 60

braking, acceleration, handling, performance etc. Distance travelled 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

17.10. 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 misses. 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 OK’ed vehicles are later picked by the Sales and
Dispatch drivers.
 61

Project: To Ensure Zero Incident

 62

18. PC-GV (plant control in gurugram vehicle)

Production planning and control is concerned with implementing the plans, i.e. the detailed
scheduling of jobs, assigning of workloads to machines (and people), and the actual flow of
work through the system. Production is an organized activity of converting row materials
into useful products. Production activity takes place in a wide range of manufacturing and
service sectors. Production system requires the optimal utilization of natural resources like
men, money, machine, materials and time. Production planning and control coordinate with
different departments: such as production, marketing, logistics, warehouse and other
departments depending upon the nature of organization.

19. Safety
Safety is the condition of being protected from harm or other non-desirable outcome.

Importance of safety in maruti Suzuki india limited is “to ensure zero incidents in plant”

M.D. San – “zero accident, zero defects”

Generally Maruti Suzuki is balancing on 4 pillars, these are as follow:

1. Cost
2. Quality
3. Production
4. And most importantly Safety

Figure 33
 63

19.1. HEINRICH LAW:

Figure 34

It simply says; if there are 300 accidents taking place then out of 300 29 will lead to a
harmful accidents and 1 out them will be the serious one.

So, In Maruti Suzuki all types of incident (accident) which happened in past and the
incident that is most likely to be happen are taken care. There are near miss incidents,
major incident and things which may lead to any incident, all are the concern of safety.

19.2. Policies for safety

Various policies are made in order to achieve “zero accident, zero accident”.

19.2.1 KYT: Kikan (danger) Yochi (prediction) Tra (training)

19.2.2. HHT: hiyari hato training (don’t ignore near face)
19.2.3. Robo Safety: safety plug of robot (keep the safety plug in pocket whenever you
try to get in work volume of robot)
19.2.4. LOTO: lock out tag out
19.2.5. MARU: danger area.
19.2.6. ROKO-TOKO:
19.2.7. WIS: work instruction sheet ( set of sequence order of work instruction step).
19.2.8. POKO-YOKE: fool proofing.
19.2.9. 5S: (policy to maintain the tool in workplace)
I. Seri: proper selection.
II. Seiton: arrangement.
 64

III. Sciso: cleanness.

IV. Seiketsu: standardization.
V. Shitshke: discipline.
19.2.10. 3G:
I. Genchi: go to actual place.
II. Genbutsu: see the actual thing.
III. Genjitsu: take the necessary action.
19.2.11. 3K:
I. Kimerareta Kota Ga: what has been decided.
II. Kihin Dori Ni: asper standard.
III. Kchin To Mamoeu: must be followed.
19.2.12. 3M:
I. Muri: inconvenience.
II. Muda: wastage (7types of waste – 1. Transportation, 2. Inventory, 3. Motion, 4.
Waiting, 5. Overproduction, 6. Over-processing, 7. Defects).
III. Mura: inconsistency.
19.2.13. Quality Policy: (P.D.C.A) plan-do-check-act. Customer satisfaction
through continuous improvement of product & services by ensuring
standardization, training & adherence to rule across organization.

Figure 35
 65

19.3. Steps to ensure safety:

A. Identify the incident:
1. Already occurred: it considered the incident that happened in past and collect
their data for further study.
2. Likely to occur: these are the incident which might occurred in future e.g. fire
extinguisher placed to prevent any future fire incident.
B. Root cause of incident:
1. Man: if the worker is one of the reasons of incident. Retraining/ training of
worker is done, make him follow rules and audit is taken for his response in
future work.
In new worker his work is being audit for 27 days which is called “new joinees
audit”
 Training/re-training
 Rule follow
 Audit
2. Method: If incident happened because of working method then update the
working method which is made modification in WIS.
3. Material
4. Machine: repair of machine is done and regular check of machinery.
C. Counter measures to be taken:
1. Temporary: if permanent counter measure will take long time(normally one
more than a month) in execution.
2. Permanent: it is the countermeasures which reduce the chances of incident in
future.
 66

19.4. PPE: Personal Protective Equipment

The chart below summarizes the types of personal protective equipment that is being used
in different shops:

Press Shop - Personal Protective Equipment

Body
Equipment Illustration Reason
Part
Eyes Goggles Protects from:

 flying
particles,
debris

head Helmet Protects against:

 electric shock
 heat
 burns
 fires

Ears - Ear muffs, ear Protects against:

hearing plugs
 noise

Feet and Boots, gloves, Protects against:

hands Kevlar gloves
 electric shock
 heat
 burns
 fires

Table 3
 67

Weld Shop - Personal Protective Equipment

Body Part Equipment Illustration Reason
Eyes and face Welding Protects from:
helmet, hand
shield, or  radiation
goggles  flying
particles,
debris
 hot slag,
sparks
 intense light
 irritation and
chemical burns

Lungs Respirators Protects against:

(breathing)
 fumes and
oxides

Exposed skin Fire/Flame Protects against:

(other than resistant
feet, hands, and clothing and  heat, fires
head) aprons  burns
 radiation

Ears - hearing Ear muffs, ear Protects against:

plugs
 noise

Feet and hands Boots, gloves, Protects against:

Kevlar gloves
 electric shock
 heat
 burns
 fires

Table 4
 68

Paint Shop- Personal Protective Equipment

Body Part Equipment Illustration Reason
Lungs Respirators Protects against:
(breathing)
 fumes and
oxides

Exposed skin resistant clothing Protects against:

and aprons
 paint
 radiation

Feet and Boots, gloves, Protects against:

hands Kevlar gloves
 electric shock
 heat
 burns
 fires

Table 5

Assembly Shop - Personal Protective Equipment

Body Part Equipment Illustration Reason
Hands and Gloves and Protects from:
Eyes Google
 cut
 electric shock
 heat
 burns
 fire
 flying particles, debris

Ears - Ear muffs, ear Protects against:

hearing plugs
 noise

head Helmet Protects against:

 accidental shock

Table 6
 69

20. Project-1: Audit for different countermeasures regarding safety in

gurugram vehicle plant

General format for audit

Incident:

Countermeasure:

TITLE

Sr. no. Location Shop Status Remark

10

Table 7
 70

Incident: [35/PS1/gurugram/31-may-18/cut injury] PS1 apprentice got cut injury due to breaking of
door glass, while going for dinner in b-shift. Glass broke during pushing door from glass position of
door.

Countermeasure: Display provide to be on doors mentioning "please do not touch the glass".

20.2. Display Of "Please Do Not Touch The Glass" On The Doors

Sr.
Location Shop Status Remark
no.

1 ps2 entry- extrior door PS2 ok

ps2entry 'air shower 1' outer

2 PS2 ok
door

ps2 entry 'air shower 1' inner

3 PS2 ok
door

ps2 entry 'air shower 2' outer

4 PS2 ok
door

ps2 entry 'air shower 2' inner

5 PS2 ok
door

6 ps2 exit - exterior door PS2 ok

no handle present on outer sideno handle

7 loading area exterior door PS2 ok
present on outer side

8 loading area inner door PS2 ok bar not required

do not touch the glass" indication is missing

9 top coat boot PS2 NG
and bar is not there but it is not required
 71

there

door to smoke 'smoke area'

10 PS2 ok bar not required
from 'masking rest area'

11 mixing room near "pb ok" PS2 ok

paint testing lob exterior

12 PS2 ok
door

13 paint testing lob middle door PS2 ok

14 paint testing lob inner door PS2 ok

15 TL-2 PS2 ok bar not required

16 door opposite to TL-2 PS2 ok bar not required

17 ED Oven PS2 ok bar not required

18 Office door PS2 ok bar not required

19 Office meeting room door PS2 ok bar not required

20 door between F10 & F11 PS2 ok

door of shop dust level

21 PS2 ok
measuring pt.-32

near door of shop dust level

22 PS2 ok
measuring pt.-32

door of shop dust level

23 PS2 ok
measuring pt.-30

door of shop dust level

24 PS2 ok
measuring pt.-10 outer
 72

door of shop dust level

25 PS2 ok
measuring pt.-10 inner

26 gate no. 5 (exit door) ws1 ok

27 layout room ws1 ok

door b/w Jig maintanence

28 ws1 ok
store and emergency light 2

29 Jig maintenance store ws1 ok

30 weld 1 office ws1 ok

31 inside weld 1 office ws1 ok

32 suppler quality assurance ws1 NG push/pull indication is missing

33 body check room ws1 ok also have indication of don't touch the glass

34 Gen. scrap (MP1) door 1 Ws1 ok also have indication of don't touch the glass

35 inside general scrap ws1 ok also have indication of don't touch the glass

Maintenance deptt. (near

36 pannel checker LT FT door ws1 NG push/pull indication is missing
Omini)

37 general srap door 2 ws1 ok also have indication of don't touch the glass

38 door at w1-01 ( near 02-w1) ws1 ok

02-w1 back of 151 unloading

39 ws1 ok
bay
 73

40 metal recipt area 03-w1 ws1 ok

41 03-w1 unloading bay 154 ws1 ok

near emergency light 26 &

42 prs ok
layout table

43 office door (1) prs ok

44 office door (2) prs ok

45 inside office door (1) prs ok

46 emergency exit office door prs ok

push pull indication covered with The Flag

47 maintenance deptt. P.S prs ok
and flower

48 near auto rapid door no. 1 ws-2,3 ok

49 office W.S - 2,3 ws-2,3 ok

50 near toilet 102's exit ws-2,3 ok

door near engine sub

51 as-3 ok
assembly

52 exit (ps-1) ps-1 ok

53 ps-1 (lab) ps-1 ok

54 change room ps-1 ok

55 ED root ps-1 ok

56 PT room ps-1 ok

57 sealer room ps-1 ok

 74

58 chemical store ps-1 ok

59 rectifier room ps-1 ok

60 Sheet store B2 ps-1 ok

61 office air washer-1 ps-1 ok

62 office air washer-2 ps-1 ok

63 office air washer-3 ps-1 ok

64 office air washer-4 ps-1 ok

65 L1 outer door ps-1 ok

66 L1 inner door ps-1 ok

67 L2 outer door ps-1 ok

68 L2 inner door ps-1 ok

69 L3 outer door ps-1 ok

70 L3 inner door ps-1 ok

71 L4 outer door ps-1 ok

72 L4 inner door ps-1 ok

73 Near Toilet-77 ps-1 ok

no display of "please do not touch the glass

74 Office door ps-1 NG
and vertical handelin inner side of the door

Table 8
 75

Incident: worker got hit by clamp in engine sub assembly

Counter measures: 1. worker must wear goggle while clampling the pipes. 2. piler must be in good
condition.

20.3. Audit for Goggle And Plier Condition In Engine Sub-Assembly

Sr. no. location shop status remark

radiation assembly
1 in engine sub AS-3 ok
assembly

heater house
2 assembly in engine AS-3 ok
sub assembly

engine
transmission
3 AS-3 ok
assembly in engine
sub-assembly

Table 9
 76

Incident: [62/TCMTW/TCMTW/MPT/19-jun-18/near miss] operator was shifting the FG stock from

old canteen area to line location. The trolley used was having it's lock break. While handling the trolley
on the ramp and holding it by sides, suddenly door opened and operator's finger get twisted.

Countermeasure: Ramp design to be modified. L shaped ramp with less slope angle to be
implemented.

20.4. Slope Angle Of Ramp

Sr.
Location Shop Status/slope (in deg.) Remark
no.

1 between A1-10 & A1-11 AS-1 3.24 deg

2 A1-01, ENTRY AS-1 7.66 deg.

3 B/W A1-86 & A1-87 AS-1 4.64 deg.

4 A1-84 AS-1 3 deg.

5 A1-81 AS-1 3.65 deg.

6 A1-73 AS-1 3.24 deg.

7 A1-61 AS-1 3.3 deg.

8 A1-60 AS-1 6.15 deg.

9 A1-52 AS-1 4.05 deg.

10 Auto gate no. 2 AS-3 5.1 deg.

11 Auto gate no. 3 AS-3 5.816 deg.

Table 10
 77

Incident: [81/AS-MC/2-MAY-2018/CRUSHING INJURY] person was working by

standing on syncro trolley. After completing work person hit his hand on synchro trolly lever
at toggle clamp area. After reversing back of his finger crushed in b/w toggle clamp and
lever.

Countermeasure: Colour of tooggle clamp & cover to be painted RED to highlight danger
area.

20.5. TOGGLE CLAMP PAINTED RED COLOUR

Sr. no. Location Shop Status Remark

1 station 18, line 1 AS-1 OK
2 station 19, line 1 AS-1 OK
3 station 20, line 1 AS-1 OK
4 station 25, line 5 AS-1 OK Red-yellow painted
5 station 27, line 5 AS-1 NG yellow painted
6 station 29, line 5 AS-1 NG silver painted
7 station 35, line 5 AS-1 NG yellow painted
8 Station 31 AS-3 OK
Table 11
 78

Incident: (23/VI-G3/VI/gurugram/2-sep-18/near miss) YBA rh front wheel slipped into toe-in pit, toe-in
tester no. 1. table remain in lock condition, not become free on loading movement. Rt. Fender dent and ft.
bumper got damage at lower side.

Countermeasure: under monitoring

20.6. Monitoring Of Toe-in Tester

Sr.
Location Shop Status Remark
no.

Toe tester near L7 in tester line 1(steering

1 VI-G1 OK tester is in free condition
wheel stn., Toe-in adj. stn.)

Toe tester near L7 in tester line 1(steering

2 VI-G1 OK tester is in free condition
wheel stn., Toe-in adj. stn.)

Toe tester near L7 in tester line 1(steering

3 VI-G1 OK tester is in free condition
wheel stn., Toe-in adj. stn.)

Toe tester near L7 in tester line 3(steering

4 VI-G1 OK tester is in free condition
wheel stn. Toe-in adj. stn.)

Toe tester near L7 in tester line 3(steering

5 VI-G1 OK tester is in free condition
wheel stn. Toe-in adj. stn.)

Toe tester near L7 in tester line 3(steering

6 VI-G1 OK tester is in free condition
wheel stn. Toe-in adj. stn.)

Toe tester near L7 in tester line 2(steering

7 VI-G1 OK tester is in free condition
wheel stn. Toe-in adj. stn.)

Toe tester near L7 in tester line 2(steering

8 VI-G1 OK tester is in free condition
wheel stn. Toe-in adj. stn.)
 79

toe tester near L7 in tester line 3(steering

9 VI-G1 OK tester is in free condition
wheel stn., Toe-in adj. stn.)

10 turning tester near L8 in tester line 1 VI-G1 OK tester is in free condition

11 turning tester near L8 in tester line 1 VI-G1 OK tester is in free condition

12 turning tester near L8 in tester line 1 VI-G1 OK tester is in free condition

13 turning tester near L8 in tester line 2 VI-G1 OK tester is in free condition

14 turning tester near L8 in tester line 2 VI-G1 OK tester is in free condition

15 turning tester near L8 in tester line 2 VI-G1 OK tester is in free condition

16 turning tester near L8 in tester line 3 VI-G1 OK tester is in free condition

17 turning tester near L8 in tester line 3 VI-G1 OK tester is in free condition

18 turning tester near L8 in tester line 3 VI-G1 OK tester is in free condition

19 toe-in tester, VI-3 VI-G3 OK tester is in free condition

20 toe-in tester, VI-3 VI-G3 OK tester is in free condition

21 toe-in tester, VI-3 VI-G3 OK tester is in free condition

Table 12
 80

Incident: (19/line 4,axle mtg.,as1/as1/gurugram/31-sep-18/near miss) YE3 vehicle out from hanger seat.
During rare axle mounting parking cable stuck with lifter and when lifter moving back to home position,
it pulled the body and it came out from the hanger seat.

Countermeasure: operator of sub-assembly and axle mounting station has to ensure parking cable
grommet position to avoid cable opening after sub assembly and before to axle mounting.

20.7. Monitoring Of Position Of Parking Cable

Sr. no. Location Shop Status Remark

1 31 AS-3 OK

2 31 AS-3 OK

3 31 AS-3 OK

4 24, LINE 1 AS-1 OK

5 24, LINE 1 AS-1 OK

6 24, LINE 1 AS-1 OK

7 18, LINE 5 AS-1 OK

8 18, LINE 5 AS-1 OK

9 18, LINE 5 AS-1 OK

10 19, LINE 4 AS-1 OK

11 19, LINE 4 AS-1 OK

12 19, LINE 4 AS-1 OK

Table 13
 81

Incident: for remove heater hose clamp in dismentaling vehicle, operator went to pick nose plier from
near by table. When he bend to pick the tool from lower self of work table, got close to protruding metal
wire of dismentled instrumental panel , which was palced on the table and touched his right eye lid and
cur injury occured.

Counter measure: new tool tray fabricated at height to prevented bending while picking tools.

20.8. Audit For Working Table In Dismantle Area

Sr. no. location shop status remark

seat opening work table, near battery control board dismantle

1 ok
storage area

control board dismantle

2 tool table, near battery storage ok
area

control board dismantle

3 I.P opening work table ok
area

control board dismantle

4 tool table, near tyre storage area ok
area

Table 14
 82

Incident: worker got hurt near eyebrow. As he get down to take the tool and a wire came out from work
piece got into him near eyebrow

Counter measures: 1. tool table position nearer to working spce. 2. updated WIS. 3. tool marking on
working table. 4. tool apartment shift to level of working table level.

20.9. Audit In Dismantle Area

Sr. no. location shop status remark

tool table position nearer to working

1 control board dismantle area ok
space

2 updated WIS control board dismantle area ok

tool apartment shift to level of

3 control board dismantle area ok
working table level

4 tool marking is done on working table control board dismantle area ok

Table 15
 83

Incident: (25/VI-G1 headlight testor/VI-G1/gurugram/20-aug-18/near miss] YE3 model hit with headlamp
machine no.2 during reversing. Omly dent observed at back door.

Counter measure: mirrors to be fitted in this area for better view.

20.10. Mirrors In Break Tester Area

Sr.
Location Shop Status Remark
no.

1 break testor, tester line 4 near L9 VI-G1 OK 3 mirrors are fitted in different positions

2 drum teaster, tester line 4 near L9 VI-G1 OK 2 mirrors are fitted in different positions

2 in front top, 2 in rear top and 1 in ground

3 break testor, tester line 1 VI-G1 OK
mirrors are fitted in different positions

2 in front top, 2 in rear top and 1 in ground

4 break tester, tester line 2 VI-G1 OK
mirrors are fitted in different positions

2 in front top, 2 in rear top and 1 in ground

5 break tester, tester line 3 VI-G1 OK
mirrors are fitted in different positions

Table 16
 84

Incident: [33/MXArea, WS- MB/WS-MB/1-oct-18/cut injury] worker was walking in mx

area as the walkway was bocked with a movable trail panel trolley. His foot hit with mx
material trolley guide fixed on floor and he stumbled forward. As a reflex action, he tried to
prevent him from falling on floor using his hand. His hand fell on the panels kept on the trail
panel trolley in the front and the person's ring finger of the left hand received a cut injury.

Countermeasure: trolley guide should be at a safe distance from gangway(300mm gap b/w
gangway and trolley guide)

20.11. Distance Of Trollry Guide From Gangway

Sr. no. Location Shop Status Remark

1 near station no. 34l, line 5 AS-1 NG distance is 70mm

near station no. 48l, line 5,

2 opposite to station no. 5R, line AS-1 NG distance is 100mm
4

3 near station no. 54L, line 5 AS-1 NG distance is 60mm

4 near station no. 59L, line 5 AS-1 NG distance is 80mm

5 near station no. 62L, line 5 AS-1 NG distance is 80mm

6 near station no. 64L, line 5 AS-1 NG distance is 240mm

7 near station no. 23R, line 4 AS-1 NG distance is 80mm

8 near station no. 28L, line 4 AS-1 NG distance is 40mm

9 near station no. 30L, line 4 AS-1 NG distance is 70mm

10 near station no. 32L, line 4 AS-1 NG distance is 210mm

11 near station no. 33L, line 4 AS-1 OK distance is 430mm

12 near station no. 34L, line 4 AS-1 OK distance is 650mm

Table 17
 85

Countermeasure: arm cover PPE provided to two or more operator those who are doing
torquing operation.

20.12. Arm cover uses by worker in IP torquing operation.

Sr. no. Location Shop Status Remark

sub-assembly of IP, near sation no worker was wearing the arm
1 AS-1 NG
10 of line 5 cover PPE

SUB-ASSEMBLY OF IP, no worker was wearing the arm

2 AS-1 NG
LINE 4, FCI Conveyor cover PPE
Table 18

incident: [81/AS-MC/2-MAY-2018/CRUSHING INJURY] person was working by standing

on syncro trolley. After completing work person hit his hand on synchro trolly lever at toggle
clamp area. After reversing back of his finger crushed in b/w toggle clamp and lever.

countermeasure: increase the height of toggle clamp (above hand reach)

20.13. height of toogle clamp not in reachable area of worker

Sr. no. location shop status remark

1 station 18, line 1 AS-1 NG
2 station 19, line 1 AS-1 NG
3 station 20, line 1 AS-1 NG
4 station 22, line 1 AS-1 NG
5 station 25, line 1 AS-1 NG
6 station 29, line 1 AS-1 NG
7 station 36, line 1 AS-1 NG
8 station 31 AS-3 NG
Table 19
 86

Incident: [36?/AS1/gurugram/29-may-18/cut injury] unauthorised crossing of conveyor in line of AS1.

While going to toilet worker was without helmet.

Countermeasures: helmet stand must be in toilet.

20.14. Helmet Stand Near Toilet

Sr. no. Location Shop Status Remark

1 toilet no. 94 ws-1 ok
2 toilet no. 95 ws-1 ok
3 toilet no. 96 ws-1 ok
4 toilet no. 98 ps ok
5 toilet no. 99 ps ok
6 toilet no. 100 ws-2,3 ok capacity of 2only
7 toilet no. 101 ws-2,3 ok
8 toilet no. 102 ws-2,3 ok
9 near rapid door -1, gangway 11 ws-2,3 ok
10 toilet no. 120 AS-3 NG no helmet stand
11 toilet no. 115 AS-3 NG no helmet stand
toilet no. 60 AS-1 OK
toilet no. 77 AS-1 NG no helmet stand
toilet no. 58 AS-1 ok
toilet no. 61 AS-1 ok
Table 20
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incident: in press shop og gurugram , a worker hit by forklift. As worker was not following the gangway and
focklifter did not get slow on the junction point.

countermeasures: 1. conditions of the gangways to be cheacked and repair if needed. 2. speed limit of focklift
is 10 km/h inside the shop. 3. focklift must slow down near the junction point.

20.15. gangway in press shop

Sr.
location shop status remark
no.
1 transfer press 4000 Ton PRS NG almost washout
2 transfer press 3000 Ton PRS NG almost washout
3 transfer press 2500 ton(1) PRS NG require little repair
4 blanking line PRS ok
Table 21

incident: [81/AS-MC/2-MAY-2018/CRUSHING INJURY] person was working by standing

on syncro trolley. After completing work person hit his hand on synchro trolly lever at toggle
clamp area. After reversing back of his finger crushed in b/w toggle clamp and lever.

countermeasure: increase the height of toggle clamp (above hand reach)

20.16. height of toogle clamp not in reachable area of worker

Sr. no. location shop status remark

1 station 18, line 1 AS-1 NG
2 station 19, line 1 AS-1 NG
3 station 20, line 1 AS-1 NG
4 station 22, line 1 AS-1 NG
5 station 25, line 1 AS-1 NG
6 station 29, line 1 AS-1 NG
7 station 36, line 1 AS-1 NG
8 station 31 AS-3 NG
Table 22
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incident: in paint shop, worker was going for lunch and in hurry he push the the glass instead of pushing the door
by handel. Unfortunately glass beak and worker got hurt

counermeasure: 1. put a door handel on the door horizontally. 2. push-pull indication mention on the door. 3. do
not touch the glass indication placed on the door.

20.17. door handel bar and push/pull indication check

Sr. no. location shop status remark
1 gate no. 5 (exit door) w1 ok
2 layout room w1 ok
door b/w Jig maintanence store and
3 w1 ok
emergency light 2
4 Jig maintenance store w1 ok
5 weld 1 office w1 ok
6 inside weld 1 office w1 ok
push/pull indication is
7 suppler quality assurance w1 NG
missing
also have indication of
8 body check room w1 ok
don't touch the glass
also have indication of
9 Gen. scrap (MP1) door 1 W1 ok
don't touch the glass
also have indication of
10 inside general scrap w1 ok
don't touch the glass
maintenance deptt. (near pannel push/pull indication is
11 w1 NG
checker LT FT door Omini) missing
also have indication of
12 general srap door 2 w1 ok
don't touch the glass
13 door at w1-01 ( near 02-w1) w1 ok
14 02-w1 back of 151 unloading bay w1 ok
15 metal recipt area 03-w1 w1 ok
16 03-w1 unloading bay 154 w1 ok
17 near emergency light 26 & layout table ps ok
18 office door (1) ps ok
19 office door (2) ps ok
20 inside office door (1) ps ok
21 emergency exit office door ps ok
push pull indication
22 maintenance deptt. P.S ps ok covered with The Flag
and flower
23 near auto rapid door no. 1 ws- 2,3 ok
24 office W.S - 2,3 ws-2,3 ok
25 near toilet 102's exit ws-2,3 ok
26 door near engine sub assembly as-3 ok
Table 23
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incident: worker got hurt while working inside the pit as vehicle was moved from the platform

countermeasure: no vehicle will leave the platform before worker get out from the pit.

20.18. audit of no person while car is moving

Sr.
no. location shop status remark
safety switch is present which is
1 V.I. line AS-3 ok pressed by worker after he came out of
the pit
safety switch is present which is
2 V.I. line AS-4 ok pressed by worker after he came out of
the pit
safety switch is present which is
3 V.I. line AS-5 ok pressed by worker after he came out of
the pit
safety switch is present which is
4 V.I. line AS-6 ok pressed by worker after he came out of
the pit
Table 24
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21. Project 2: study of sensors of safety

Sensors are sophisticated devices that are frequently used to detect and respond to electrical
or optical signals. A Sensor converts the physical parameter (for example: temperature,
blood pressure, humidity, speed, etc.) into a signal which can be measured electrically.

These sensors are used to achieve zero incidents goal in plant. Various sensors are being
used to ensure safety and reduce any incidents throughout the vehicle manufacturing
processes at different stages.

21.2. Sensor at end of line

In AS-1, sensors are used to avoid accidental foot trap in between the floor and conveyor at
the end of the assembly line. Net is used for safety which is called safety net. The concept
is whenever worker or anyone (who work at end point of assembly line) fall he can hold the
net as per the natural reflex. When the net is being pulled the sensor generate an electric
signal which stop the whole line as the net is linked with the net.

21.3. Fool Proofing: Poka-Yoke

Poka-yoke is a Japanese term that means "mistake-proofing". A poka-yoke is any
mechanism in a lean manufacturing process that helps an equipment operator avoid
(yokeru) mistakes (poka). Its purpose is to eliminate product defects by preventing,
correcting, or drawing attention to human errors as they occur.

Maruti-Suzuki calls the “Pika Pika” system; this is their interpretation of the “poke
yoke” or error proofing system. The system guides the correct selection of component parts
during assembly and prevents incorrect parts being used. Hence CC-Link is playing a key
role maintaining vehicle quality by ensuring errors are eliminated at source, preventing
expensive re-work and making sure defects do not reach the customer. CC-Link(Control
and Communication Link) is a high performance Device level network that is based on
10MBit twisted pair wiring. This network is used to interconnect a wide variety of
automation devices including I/O, Controllers, HMIs, VFDs and Servo products. When
configuring systems for remote I/O control, solutions will generally include a network
Master station and the remote I/O node. Remote I/O nodes can be specified from any of the
following types including digital, analog, temperature, high-speed counter or positioning.
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Parts comprising of Pika-Pika

MAIN
CONTROL
PANEL

ANDON VTS CCLINK

PIKA PIKA CLW GOT

Figure 36 Hierarchal chart for Pika Pika

21.3.2. PIKA PIKA

Pika Pika is basically lights which may be pull chord type or push button type LED. These
are basically installed at an over the racks where the components for the fitments are being
placed

The main use of placing these lights are that they tells the worker on line that for the
coming vehicle what type of component is to be fitted as per the fitment requirement
ambiguities are eroded via help of this Pika Pika system as on a shelf/rack comprising of
various equipment that needs to be fitted in vehicle are model wise and the line man don’t
get embroiled in such a situation that which part is to be fitted in this vehicle a green blip
type lights glows on the correct part

This ultimately saves time and also effort of worker to check vehicles model first and
moreover it also helps in yielding the production and result in producing more and more
cars to meet market demand and also via this error proofing an official can easily judge
where he is lacking and which lineman needs more training for greater yield

And if due to any mistake or wrong part fitment worker forgets to work over the light that
will ultimately result in the line stoppage as the Pika Pika system is connected to the limit
switches that are adherent to the conveyer which transfers the information to the main panel
which ultimately takes action via the intelligent units installed in it which result in line
stoppage and that information is displayed on the ANDON display comprising of station
number and part name
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Figure 37 Over view of Pika Pika installed on trim line

LIMIT SWITCHES

In electrical engineering a limit switch is a switch operated by the motion of a machine part
or presence of an object. They are used for control of a machine, as safety interlocks or to
count objects passing a point. A limit switch is an electromechanical device that consists
of an actuator mechanically linked to a set of contacts. When an object comes into contact
with the actuator, the device operates the contacts to make or break an electrical
connection. Limit switches are used in a variety of applications and environments because
of their ruggedness, ease of installation, and reliability of operation. They can determine the
presence or absence, passing, positioning, and end of travel of an object. They were first
used to define the limit of travel of an object; hence the name “Limit Switch.”

Figure 38 Limit switch

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22. CONCLUSION

I have done my industrial training in the PC-GV department of MARUTI SUZUKI

INDIA LIMITED. In my training I have learned about Safety measure in working
enviroment, Punctuality and Vehicle Manufacturing Processes.

Safety in any working process is the most important factor, Safety include the safety of the
persons, machines, material and their interaction during for process. In manufacturing
companies like Maruti which have to constantly cater to ever increasing demand from the
market with very small lead times have very crucial importance of safety. Safety audits are
being conducting frequently over a time to ensure “Zero Incident”. Punctuality is most
important ethics in life and working environment in MSIL teaches this ethics to everyone
who enters in the gate of MSTL plant gurugram. Advancement in vehicle manufacturing
processes manufacture complicated engineering machine in effective way and also these
processes take care of safety in plant as well as safety in product.

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 PC-GV who have
guide, encouraged and inspired me to achieve higher goals.
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23. REFERENCES

List of references
1. https://www.marutisuzuki.com/
2. https://www.google.com/webhp?hl=en&sa=X&ved=0ahUKEwiCusf4iuHhAhXMs
48KHVRDA7YQPAgH
3. https://en.wikipedia.org/wiki/Maruti_Suzuki
4. Data provided by company.
5. Incident list of last couple of months includes all the incident occurred all over the
plants of Suzuki.