RAHUL-21001004936

SUMMER TRAINING
Weld Shop-1 (WS-1) Maruti
Suzuki India Limited

Deenbandhu Chotu Ram University of Science and technology

Murthal Sonepat (Haryana)

Under the Guidance : Name-Rahul

Mr. Satish kumar Roll no.-21001004936
(MGR) MP-G1 Mechanical 4th year
Training Certificate
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Contents
1) Introduction to company profile
1) Introduction
2) Manufacturing facilities
3) Models by MSIL
4) Verticals in MSIL
5) Standard practices in MSIL

2) Overview to Production Vertical

1) Divisions involved in manufacturing of a car

3) Overview to Weld Shop

1) Safety precautions & PPE
2) Introduction to Industrial robots
3) Classification of robot
4) Introduction to Welding
5) Types Of Robotic Guns Used In Spot Welding
6) Shop layout
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1.1) Introduction to company profile

•Maruti Suzuki is an automobile manufacturer in India,earlier company was
known as Maruti Udyog Limited.It is a 56.21% owned subsidiary of the
Japanese company known as Suzuki Motor Corporation.

•It had a market share of 53% in car segment.

•Company primary focus is to develop & provide Safety,quality & budget

friendly
•cars.

•1.2) Manufacturing facilities

•1.Gurgaon : 7 lacs Car per Annum 2.Manesar : 8 lacs
Car per Annum 3.Gujrat : 2.5 lacs Car per Annum

Maruti Suzuki is currently having 16 models in their portfolio with a price range of 3
•1.3)
Lacs ~Models byAlto,Wagon-R,Swift,Dzire,Ciaz,Brezza,Ignis
12 Lacs. (i.e. MSIL etc).
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1.2) Verticals in MSIL

MSIL

HR, IT & Sales &

QA Supply Chain Production Finance Marketing

1.5) Standard practices in MSIL

Japanese Norms:
5S
- Sort 3G
SEIRI - GOTO THE SPOT
- Set in Order GENCHI
SEITON - SEE THE ACTUAL
- Shine, GENBUTSU
SEISO PROBLEM
GENJITSU
SEIKETSU - Standardize - TAKE THE
SHITSUKE - Sustain. REALISTIC
ACTION
Glimpse from Maruti’s Model
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2) Overview to Production Vertical
Various divisions involved in manufacturing of a
car are as:
Press
Shop

Weld Shop

Paint Shop

Assembly Shop

Vehicle
Inspection
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3.1) Personal Protective Equipment (PPE)

Used in Welding :
 Goggles

 Helmet

 Safety Glasses

 Ear plugs

 Flame Retardant Clothing

 Gloves

 Safety Foot ware

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3.2) INDUSTRIAL ROBOT

An industrial robot is an automatically controlled, reprogrammable,
multipurpose manipulator programmable in three or more axes

Welding gun Manipulator Controller

Integrated
Servo controlled axes Air/water supply
cables
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3.3) CLASSIFICATIONS OF ROBOTS
Based upon their programming type :
 Cartesian
 Articulated
 Scara

ARTICULATED ROBOTS
Also called six degrees of freedom

Axis 1 - Rotates robot (at the base of

the robot)
Axis 2 - Forward / back extension of robot's
lower arm
Axis 3 - Raises / lowers robot's upper arm
Axis 4 - Rotates robot's upper arm
(wrist roll)
Axis 5 - Raises / lowers wrist of robot's
arm
Axis 6 - Rotates wrist of the robot's
arm
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3.4) Introduction to Welding

Types of welding used in MSIL Weld Shop:

 Spot welding
 CO2 welding
 Brazing
 Stud Welding
 Nut Welding
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SPOT WELDING MIG WELDING

STUD WELDING NUT WELDING

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3..5 ) TYPES OF ROBOTIC GUNS

USED IN SPOT WELDING

X- TYPE ROBO GUN C -TYPE GUN

Also known as “scissors” or C guns are generally the cheapest and the most
“pinch” commonly used
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3.6) Shop Layout :

Each line is divided into 5 main areas as :
 Under Body
 Main Body
 Side Body
 Door Line
 White Body
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PROJECT REPORT ON
Work instruction sheet (WIS)
of IT gun repair (Moving arm
replacement).
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4.1) Introduction
Operation procedure of IT gun repair
(Moving arm replacement).

1. Do KYT.
2. Unscrew all the bolts of cover as shown in
fig.
3. Disconnect the cylinder and the arm.
4. Loosened the bolts / screws of timer and
pin and remove moving arm from it gun
5. Replacing the new moving arm and fit
into the IT gun.
6. Checking the connection of IT gun.
7. Tight the bolts of cover.
8. Open the air water supply check the gun
operation with weld off.
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4.2 Key Points
 Use hand gloves, googles, mask, safety
shoes.
 Use proper tools
 Connection are two should be in series and
one which is parallel in circuit.
 All bolts should be proper tightened.
 ELCB power off during repairing work
 Check gun water flow after tip removed.
4.3 IT gun Repair(moving Arm Replacement).

Cover Bolts Timer bolts Moving arm

IT gun
Moving arm Cover
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4.3 WIS of IT gun Repair

THANK YOU