MARUTI SUZUKI

A Vocational/Internship Training submitted in partial fulfilment of the requirements for the award of degree of

BACHELOR OF TECHNOLOGY

in

MECHANICAL ENGINEERING

Submitted by

RITESH KUMAR

(Reg. No.19102151009)

Under the Guidance of

Mr. Jawed Karim

Government Engineering College,Siwan

Session :- 2019-2023

Affliated

To

Bihar Engineering University,Patna

 ACKNOWLEDGEMENT

I acknowledge my gratitude to my mentor, Er. Jawed Karim Workshop Manager. The supervision
and support that he gave truly help the progression and smoothness of the internship program.
The co-operation is much indeed appreciated.

My grateful thanks also goes to Mr. Ravishankar Prasad Singh HR MANAGER, Ramkrishna
Motors. A big contribution and hard worked from both of you during the four week is very great
indeed. All projects during the program would be nothing without the enthusiasm and
imagination from both of you. Besides, this internship program makes me realized the
value of working together as a team and as a new experience in working environment,
which challenges us every minute. Not forget, great appreciation go to the rest of MSIL
staffs that help me from time to time during the project.

My grateful thanks also go to Asst. Prof. Md Irshad Alam HOD Mechanical for giving me a
chance to be part of MSIL for the industrial training.

Last but not least I would like to thank my friends who worked together as an intern at Maruti
Suzuki India Limited for the wise ideas and help throughout the project that encouraged,
supported and helped me in completing this program successfully.

Ritesh Kumar
19102151009
GEC, Siwan
 TABLE OF CONTENTS

1. Introduction about the company

1.1. Historical background

1.2. Shareholding
1.3. Maruti's quality policy
1.4. Quality system
1.5. Employee quality measures
1.6. Performance of MSIL
1.7. Exports

2. Different shops in MSIL

2.1. Press shop
2.2. Weld shop
2.3.Paint shop
2.4. Engine assembly shop
2.5. Assembly shop
2.6. Machine shop
2.7. Vehicle inspection
2.8. Vehicle flow in MSIL

3. About the project

3.1. Need for the Project
3.2. Objective
3.3. Research methodology

4. Conclusion
5. References
 INTRODUCTION

1.1 HISTORICAL BACKGROUND

Maruti Suzuki India Limited (MSIL) was established in Feb 1981 through an Act of Parliament,
to meet the growing demand of a personal mode of transport caused by the lack of an efficient
public transport system. Suzuki Motor Company was chosen from seven prospective partners
worldwide. This was done not only due to their undisputed leadership in small cars but also to
their commitment to actively bring to MSIL, contemporary technology and Japanese
management practices (which had catapulted Japan over USA to the status of the top auto
manufacturing country in the world).
A license and a Joint Venture agreement were signed between the Govt of India and Suzuki
Motor Company (now Suzuki Motor Corporation of Japan) in Oct 1982.

The Objectives of MUL then were:

1. Modernization of the Indian Automobile Industry.

2. Production of fuel-efficient vehicles to conserve scarce resources.
3. Production of a large number of motor vehicles, which was necessary for economic growth.

Maruti created history by going into production in a record time of 13 months. On 14 December
1983, the then Prime Minister of India, Mrs. Indira Gandhi, handed over the keys of the first car
to Mr. Harpal Singh of Delhi. Volume targets were routinely exceeded, and in March 1994,
Maruti became the first Indian company to produce over one million vehicles, a landmark yet to
be achieved by any other car company in India. Maruti is the highest volume car manufacturer in
Asia, outside Japan and Korea, having produced over 3.5 million vehicles by December 2001.
Maruti is one of the most successful automobile joint ventures, and has made profits every year
since inception till 2000-01. In 2000-01, although Maruti generated operating profits on an
income of Rs. 92.5 billion, high depreciation on new model launches resulted in a book loss.
Maruti is on track for profits in 2001-02, with a profit of Rs 300 million in the first half. In this
period, sales have increased by 5.3%, against an industry decline of 6.1%.

Maruti revolutionized the way Indians looked at cars. "No other car company so completely
dominates its home market" (The Economist). Despite there being 11 companies now in the
passenger car market, Maruti holds about 60% of the total market share. MUL is also the first
and only car company in the world to lead its home market in terms of both market share and in
the JD Power Customer Satisfaction study (JD Power Asia Pacific 2000 India Customer
Satisfaction studies).
1.2 SHAREHOLDING

Maruti Suzuki India Limited was set up as a deemed public limited company in 1981 by an Act
of Parliament. MSIL was classified in the Public Sector as long as the equity of Government of
India remained over 51%. A License and Joint Venture Agreement was signed in 1982, with
Suzuki Motor Corporation (SMC) acquiring 26% of the equity. SMC increased its equity to 40%
in 1989.
In 1992. Maruti ceased to be a government company, as SMC's equity holding went up to 50%.
In 2002, SMC's share went up to 54.2%, making MSIL a subsidiary of SMC. The Govt. of India
holds 46.6%, and employees trust holds the balance 0.2%.

In 2005, SMC's share went up to about 74%, making MSIL a subsidiary of SMC. The Govt. of
India holds about 26%, and employees trust holding the balance.

1.3 MARUTI'S QUALITY POLICY

It has always been Maruti's endeavor to achieve customer satisfaction through continuous
improvement of its product and services by following PDCA (Plan-Do-Check-Act) in all
functions of its organization.

1.4 QUALITY SYSTEM - ISO 9001:2001

At Maruti, the approach to quality is in keeping with the Japanese practice-"build it into the
product". Technicians themselves inspect the quality of the work. Supervisors educate and
instruct technicians to continually improve productivity and quality. The movement of quality
indicators is reviewed in weekly meetings by the top management.

In 2001. Maruti Suzuki India Limited became the first automobile sector in the world to get an
ISO 9001:2001 certifications. AV Belgium, global auditors for the International Organization for
standardization (ISO), certified Maruti after a four day long audit, covering varied parameters
like Customer focused organization. Leadership, Involvement of people. Process approach,
System approach management, continual improvement etc. In May 1995, Maruti got ISO-9002
certification. The audit for this covered Quality Assurance, production installation, marketing
and sales as well as after sales services. Maruti was also one of the first companies in the world
to pioneer ISO 9000 certification for its dealers.

In October 1993. MSIL passed the Conformity of Production (cop) audit, which is based on a
European Union directive. This authenticated its quality systems and testing facilities for export
to Europe.
Mart's emphasis on total quality has meant that today it is in a position to guide vendors and
dealers in establishing and consolidating their individual quality systems. This commitment to
quality has ensured a consistently satisfying product and world class sales and after sales
services.

1.5 EMPLOYEE QUALITY MEASURES

KAIZEN is based on the concept of making incremental improvements in our products. It

incorporates a series of continuous small and simple improvements, which aim at involving
employees at all levels. The suggestion scheme is based on the same principle. Under this
scheme employees are encouraged to make suggestions for improvement in any area of mart's
operation. Over 50,000 suggestions are received from employees every year.

"Quality circles are a group of five to eight members from a particular work area who work as a
team to identify the priorities and solve work related problems in the area. Maruti believes that it
is this unwavering commitment to quality that will lead to the further growth of the organization
as competition increases.

1.6 PERFORMANCE OF MSIL

Maruti had a successful fiscal in 2003-04. Maruti's Total Income (net of excise) during the year
was Rs. 97.510.2 million (US $ 2.17 billion), a growth of 31 per cent over the previous year. The
company's Net Profit during this period was Rs. 5421.8 million (US S 120.5 million), up 270 per
cent over 2002-03.
5.36 lac vehicles in the domestic and export markets during 2004-05. This resulted in gross sales
revenue of Rs. 113,538 million (Net of Excise), a growth of 19.7 per cent over 2003- 04. For the
year 2004-05. company achieved its highest ever sales volume of 487,402 units against 420,947
in 2003-04 in the domestic sector. In volume terms, passenger car sales accounted for over 77.3
percent of the Indian passenger vehicles market and grew by 17.8 per cent from 696,153 units in
2003-04 to 819,918 units in 2004- 05.

1.7 EXPORTS

In 2004-05. the company exported 48,899 vehicles to 50 countries. There was a marginal decline
of 4.5 per cent in the export sale compared to 2003-04.
Maruti has entered some unconventional markets like Angola, Benin, Djibouti, Ethiopia,
Morocco, Uganda, Chile, Costa Rica and El Salvador. The Middle-East region has also opened
up and is showing good potential for growth. Some markets in this region where Maruti is are
Saudi Arabia, Kuwait, Bahrain, Qatar and UAE. The markets outside of Europe that have large
quantities, in the current year, are Algeria, Saudi Arabia, Silence and Bangladesh.

Continent wise exports since inception

Europe is the largest destination of Maruti's exports where it is selling over 70% of its exported
quantity, and the top ten destinations of the cumulative exports have been Netherlands, Italy,
Germany, Chile, U.K., Hungary, Nepal, Greece. France and Poland in that order.

MUL continues to be the market leader. During 2004-05, in the passenger car market, had a
market share of 50.9 per cent as compared to 51.41 per cent in 2003-04.

MARUTI INSTALLED CAPACITY

I. PLANT 1-200,000 units

II PLANT 2-150,000 units
III. PLANT 3-150,000 units
IV. PLANT 4-100,000 units

QUALITY TOOLS

1. 5 S
II. 4 M
III. 3 M
IV. 3 G
V. 3K
What is 5S?

In Japanese Language 5S is:

SEIRI-PROPER SELECTION
SEITION-ARRANGEMENT
SEISO-CLEANING
SEIKETSO-CLEANLINESS
SHITSUKE-DISCIPLINE

What is 3M?

In Japanese Language 3M is:

MURI-INCONVENIENCE
MUDA-WASTAGE
MURA-INCONSISTENCY

What is 3G?

In Japanese Language 3G is:

GENCHI-GO TO ACTUAL PLACE
GENBUTSU-SEE THE ACTUAL THING
GENJITSU-TAKE APPROPRIATE ACTION

What is 4M?

The factory is essentially a mix of man, materials, machines and methods. These should move
continuously and effectively to produce a quality product at low cost. The most essential work in
quality control is to thoroughly investigate the problems concerning quality, decide suitable
counter measures and carry out improvements accordingly.

• Man
• Machine
• Material
• Methods

What is 3K?
In Japanese Language 3k is:
KIMERARETA KOTO GO WHAT HAS BEEN DECIDED
KICHIN TO MAMORU - MUST BE FOLLOWED
KIHON DORI NI-AS PER STANDARDS
 DIFFERENT SHOPS IN MSIL

2.1 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, it supplies components to all the three plants. The
press shop has a batch production system whereas the plants have a line production system. The
press shop maintains an inventory of at least two days. The weld shop as per the requirements
picks the finished body parts from the press shop. These may be divided as A, B and C. A
components are large outer components as for example roof, door panels etc. these components
are manufactured in the press shop at Maruti. Due to design secrecy and huge investment
requirements, B and C components are manufactured by joint ventures or bought from vendors.
The press shop can be explained under following headings:

2.1.1 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.

2.1.2 Blanking line

There are two blanking lines: ROSL (Rotary Oscillatory shear line) for rectangular shapes and
the others employing die cutting for irregular shapes. The sequence of the operations on the
blanking line is as follows:

1. Uncoiling
2. Cleaning
3. Leveling
4. Measuring
5. Shearing cutting
6. Piling stacking

2.1.3 Stamping line

There are six presses of capacity varying from 1500T to 4000T. Of these five are transfer presses
and one is a semi-automatic press line, wherein the loading is manual. The die can be changed to
obtain different body components.
2.2 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.

1. Welding jigs
2. Spot welding guns
3. Kawasaki welding robots
4. Hemming machines
5. Punching machines

2.2.1 Process Outline

The shop has different lines for different models, each of which is further divided into three parts

2.2.1.1 Under Body

Here different underbody panels are welded together. These comprises of rear underbody. central
underbody, front engine room panel. These underbody panels are prepared on suh line starting
from singular components. The sub lines have specific jigs for each. There are chain hosts for
transferring the jobs from one jig to another on sub lines. Finally these underbodies are put on
the conveyor and welded together to give the underbody.

2.2.1.2 Main Body

The chassis no. is punched on the cowl top and it is welded to the front engine room panel. As
the body moves on the conveyor roof and side body panels are welded to it to give the main
body. The side body panels are prepared on the sub lines.

2.2.1.3 White Body

The doors, hood and back door are attached on the main body with the help of bolts and
screws to the main body 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.
2.3 Paint Shop
In the paint shop following processes is carried out

2.3.1 Pre-treatment
The body is thoroughly washed to remove the dirt and oil scales

2.3.2 ED coat
This is done by electric deposition method. After applying the ED coat the body is baked in
oven.

2.3.3 Intermediate coat

This is done by spray painting method. After applying the coat, the body is dried in the oven.

2.3.4 Final coat

For metallic coating, double coats are applied and aluminum flakes provide to shine the metallic
paints. This is also done by spray painting method.

The PBOK, ie, the paint body ok is sent to the assembly shop.

2.4. ENGINE ASSEMBLY SHOP

There are four engine assembly shops out of which three assemble engines having cast iron
cylinder block and one having that made of aluminum.
The models produced in the four shops are as below.
Engine-1 Car, Omni. (Established 1985)
Engine-2 (Al) - Zen, Esteem, Baleno, Gypsy. Versa (Established 1992)
Engine-3 - Alto. Wagon R(Established 1995)
Engine-4 Currently not working. (Established 1990)

2.4.1 Parts of an Engine

1. Cylinder head
2. Cylinder block
3. Crankshaft
4. Camshaft
5. Transmission case

These parts are supplied by the machine shop to the engine assembly and all other parts of the
engine are assembled around these five main parts. There are therefore five main lines in the
shop namely, Cylinder head line, Cylinder block line, Transmission line, Main line and firing test
area.
2.4.1.1 Cylinder head line:
A sub assembly integrating the throttle body, inlet and exhaust manifold and fuel injectors cater
to this line.
Main parts:
1. Inlet and exhaust valves
2. Cotter valves
3. Retainer springs
4. Rocker arm assembly
5. Throttle body
6. Inlet and exhaust manifold

2.4.1.2 Block line:

Main parts on the block line are;

1. Crankshaft
2. Pistons
3. Oil pun
4. Alternator generator
5. Starter motor
6. Flywheel
7. Clutch

2.4.1.3 Transmission line

Several sub-assemblies involved in making the input shaft, countershaft etc. supply to the T/M
line.
Main parts are
1. Clutch release shaft
2. Gear box assembly
3. Transmission oil pan

2.4.1.4 Main line

It starts where the cylinder block and cylinder head are joined.
Main parts are:
1. Camshaft
2. Pulley belt drive for valve timing
3. 4 A.C Compressors
4. Water pump
5. Air filter
2.5 ASSEMBLY SHOP

The assembly shop receives the PB-OK i.c. 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. Components of Zen, alto, wagon-r are fitted on a common assembly line. The
sequencing of models is done by PLC Le. Programmable Logic Control. There are three
Assembly shops named ASSY-1, ASSY-2 and ASSY-3. Plant 2 and Plant 3 has similar setup but
in Plant-1 there are separate assembly lines for separate models. Altering the speed of the
conveyor can alter the capacity of production.
The Assy-2 conveyor runs at 3.23m/min. the conveyor belt can run at the maximum speed of
4m/min. the assembly shop has a continuous production system. The assembly lines in plant 2
and Plant 3 both rare basically U shaped multi production lines. The assembly line can be
subdivided into the followings:

1. Trim line
2. Chassis line
3. Final line

2.6 MACHINE SHOP:

The machine shop is the source of all major components for the engine assembly shop. The
un-machined crankshaft and camshaft forgings, transmission case, cylinder head and cylinder
block castings are brought in the form of raw materials from the vendors. The cylinder heads and
transmission case is aluminum castings while crankshaft and camshaft are steel forgings.

It has the following lines:

1. Transmission case line:
2. Cylinder head line
3. Cylinder block line
4. Crankshaft line
5. Camshaft line

2.6.1 Major activities performed in Machine Shop

1. Process design/development and equipment planning for new engine components to be
machined in machine shop.
2. Procurement, installation and commissioning of new machining lines / Modification of
existing machining lines for new variants
3. Indigenization of machines for reduction in project cost
4. Development (Indigenization) of raw material for machine shop
5. Designing of Jigs, Fixtures and procurement of wear parts, inspection gauges
6. Development Indigenization of cutting tools, holders and wear parts.
7. Preparation of standards related to Machine shop.
8. Support to shops for trouble shooting in operation and quality related problems

2.7 VEHICLE INSPECTION

Vehicle inspection has the following testing stations:

a. Toe in test
b. Slip test
c. Headlamp test
d. Appearance test
e. Drum test f. Brake test
g. Shower test
h. Road test.
i. Final check

2.7.1 General Procedure of Inspection

In vehicle inspection the vehicle is checked at checkpoints in the above-mentioned order. At each
check point different parameters are checked. Each vehicle is issued a check sheet in which the
operator at checkpoints 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 upon the type of defects:

a. Assembly repair
b. Weld repair
e. Paint repair
d. Engine assembly repair
2.7 VEHICLE FLOW IN M.S.I.L ↓

Casting

↓ ↓
ENGINE
ASSY

↓ ↓
M/C
SHOP

↓
3.1 NEED FOR THE PROJECT

Repairman Training Module

In vehicle inspection the vehicle is checked at checkpoints. At each check point different
parameters are checked. Each vehicle is issued a check sheet in which the operator at check
points marks down the defects if any, otherwise he marks an OK stamp. After the road test if the
vehicle have 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 respective repair areas depending upon the
type of defect to the following repair areas: Assembly repair, Weld repair, Paint repair, Engine
assembly repair area etc.
In a repairing station skilled repairmen are present to rectify the defects. A repairman training
module is essential because it provides the proper ways to inspect and repair specific parts like
steering column repairing, knuckle repairing, bumper repairing, brake fail repairing, drive shaft
repairing etc. and at the same time providing the various Do's and Don'ts while repairing the
vehicle.
This in turn helps in reducing the flow of secondary defects by the repairman to the
customer end.

3.2 OBJECTIVES

To prepare a Repairman training module and so as to be displayed at the plant at various

locations in assembly line for the enlightenment of in-line operators and repairmen which in turn
would help reducing the defects and increasing the direct pass thus increasing the production and
reducing the production cost of the company

3.3 RESEARCH METHODOLOGY

The methodology we followed to carry out this project required patience and care. We were first
needed to study the Assembly Shop-3 and the various repairing area extensively so as to get
acquainted with the procedure followed at the respective substations in the assembly line by the
in-line operators and the repairmen at repairing bays. After doing extensive study in line and at
the repair area we were supposed to make the repairman module for the repair area and assembly
line area.

1" challenging task was to interview each and every operator about various important points that
should be kept in mind while performing the operation which are not mentioned in MOS. Then
the suggestions of each operator were duly noted. Then the next task was to sum up almost
similar points as one point. Then they were grouped together under many subgroups. Then the
points were verified by supervisors for their genuinity and were further modified if required.

After being sub grouped we were supposed to take a photo to be used as visual aid
for understanding the point in a better way. The repercussion if not followed is also
mentioned alongside the Do's and Don'ts. Finally the above collected data were sorted
out and was documented in a proper way in Microsoft Excel sheet.

The Excel sheet which was prepared was sent to the Vendor shop to be printed out in a flex and
board to be displayed in various locations in the assembly line and repair area.
3.4 WORK DONE
Repairman Training Modulde

3.4.1 GENERAL REPAIR

3.4.1.1 APPEARANCE RELATED DEFECTS

S. REPAIR PRECAUTION EFFECTS IF NOT FOLLOWED

NO.

1. Do not use Anabond (502) on Open Joints Application of Anabond on open

and Parts. In case it is to be used, use screw joints will cause Seal patch & hence
driver tip for application. Do not use the same appearance not ok.
directly from the bottle.

2. Do not use Thinner on Head lamp, Use of thinner may cause Blackness
Speedometer Glass or any plastic item. In of the glass.
case of thinner falls down on ang part, the
part needs to be changed.

3. Cosmo Spray should be done after shaking
the bottle. It should be sprayed from a
distance of 1 feet. Other parts should be
hidden while sprag application. Handover the
vehicle after spray gets checksheets
Not following the procedure of
Cosmo Spray application may cause
patches & appearance

4. If Vindshield repair or change, offer vehicle If vehicle is offered immediately after

to V.I. after 80 minutes. windshield repair, it may lead to
Shower leakage as cemandine may
not have set properly
5. In case of Brake oil splash on the bumper (or 1. If not washed properly &
any plastic part), immediately wash it with immediately, it will cause paint
cloth and dispose of the cloth in a red dustbin. peel-off and bumper crack.
2. If cloth is not disposed, and is
used for ang purpose on plastic parts,
it will lead part paint

6. In case of Manual petrol filling, check that Petrol spillage on the vehicle will
petrol shouldn't spill on the body. lead to paint peel off or shade getting
disturbed.
 CONCLUSION

Finally concluding the project I want to state that Maruti Suzuki India Limited has provided me
an opportunity to study and gain knowledge in vehicle production. During the process of the
project I came to learn the various effective techniques to avoid defects in production line and
the various ways of repairing a vehicle. But out of all those the support and brotherhood given by
the Marulians will always he memorable.

REFERENCES:

● Maruti Suzuki training guide book

● Maruti Suzuki Operating Standards (MOS)
● Maruti Suzuki Inspection Standards (MIS)
● Internet Work Instruction Sheets (WIS)