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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 who helped me during the past six weeks. The exposure and experience gained at Maruti has been unique. I would like to thank Mr. Sanjeev Bhatnaagar. (DPM Assembly Shop-1) 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. Mahinder Vikram Singh , Training Incharges their able guidance and keen interest in my training.
ROHIT GITM GURGAON
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In order to get faster result over a particular period, maximum utilization of is very much required. So if the proper utilization of time will be done then the maximum efficiency will be produced with in the industry. My topic “Time study of ETSA & Rear axle sub assembly and design layout of line no.1 (assembely-1)”at Maruti is very much related with above fact. There are many reasons for wanting to know the amount of time a particular task should take to be completed. It may simply be for reasons of curiosity. But realistically, it is for any of three reasons: (1) to accomplish planning, (2) determine performance and (3) establish costs. In this project I have calculated the total time that the each worker at each station took to complete its task in ETSA(Engine Transmission Sub Assembly of WagonR) and rear axle sub assembly of line no-4 (Eeco & Ritz) and I also design the layout of line no.1(Omni & Ritz).I have calculated time at different station with the help of stop watch and for layout design I visit all the station of line no.1 to find how many workers are engaged there and note all the workers working in different sections of line no.1 and know its category(category such as permanent, T.T, casual, apprentice, repairmen & reliever. After finding various details of 3 sections –trim, chasis and final of line no.1, I designed the layout of line no.1.
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• Introduction to MSIL
Organisational structure of MSIL
• Production overview • Milestones reached by MSIL • How a car is made in reality • Different shops in MSIL
Project report on Plant Improvement
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TERMS OF PRODUCTION VOLUME, COSTS AND PROFITS. WE MUST NOT ONLY MAINTAIN LE“TO BECOME AN INTERNATIONALLY COMPETETIVE COMPANY IN ADERSHIP IN INDIA BUT SHOULD ASPIRE TO BE AMONGST THE GLOBAL PLAYERS. THE CULTURE, THINKING AND ACTIONS HAVE ALL TO BE CONSISTENT WITH THIS VISION “
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An aerial view of the MSIL ,Gurgaon.
PLANT LAYOUT OF
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MARUTI SUZUKI INDIA LIMITED MARUTI SUZUKI INDIA LIMITED GITM GURGAON Page 6 .
Mrs. Maruti revolutionized the way Indians looked at cars.5 billion. Production of large number of motor vehicles. The objectives of MSIL then were: 1. the then Prime Minister of India. Harpal Singh of Delhi. THE REVOLUTION: Maruti created history by going into production in a record time of 13 months. MSIL 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. handed over the keys of the first car to Mr. In 2000-01. This was done not only due to their undisputed leadership in small cars but also due 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). and in March 1994. Maruti is one of the most successful automobile joint ventures.5% of the total market share.(The Economist). GITM GURGAON Page 7 . and has made profits every year since inception till 2000-01. Volume targets were routinely exceeded. On 14 December 1983. Maruti holds about 54. Indira Gandhi. 2. A license and a Joint Venture agreement were signed between Govt. of India and Suzuki Motor Company (now Suzuki Motor Corporation of Japan) in Oct 1982. 92. Modernization of the Indian Automobile Industry. which was necessary for economic growth. Suzuki Motor Company was chosen from seven prospective partners worldwide. Despite there being more than 10 companies now in the passenger car market. to meet the growing demand of a personal mode of transport caused by the lack of an efficient public transport system. Production of fuel-efficient vehicles to conserve scarce resources. Maruti became the first Indian company to produce over one million vehicles. although Maruti generated operating profits on an income of Rs. high depreciation on new model launches resulted in a book loss. "No other car company so completely dominates its home market" .ABOUT MARUTI SUZUKI INDIA LIMITED THE START OF A NEW ERA: Maruti Suzuki India Limited (MSIL) was established in Feb 1981 through an Act of Parliament. 3.
Division to Head of departments. The employeemanagement relationship is therefore characterized by: • Customer obsession • Fast. • • • • • GITM GURGAON Page 8 . Maruti has taken several measures like a flat organizational structure. From the beginning it was a conscious decision to send people to SUZUKI Motor Corporation for on the job training for line technician supervisors and engineers. It also creates an environment that builds trust.TRANSFER OF TECHNOLOGY: Every 26 seconds a vehicle rolls out of the Maruti plant. flexible and first mover • Innovation and creativity • Networking and partnership Openness and learning Participative management Team work and kaizen Communication and information sharing Open office culture for easy accessibility To implement this philosophy. It is this underlying philosophy that has moulded its workforce into a team with common goals and objectives. ETHOS OF MARUTI: Employees are Maruti’s greatest strength and asset. since the best equipment alone can’t guarantee high quality and productivity. and a common canteen to all. Other visible features of this philosophy are an open office. At present 20% of its workforce has been trained under this program. These help them to imbibe the culture in a way that merely transferring technology through documents can never replicate. It is therefore imperative that the transfer of contemporary technology from its partner SUZUKI is a smooth process. transparency and a sense of belonging amongst employees. Great stresses are laid on training and motivating the people who man and maintain the equipment. There are only three levels of responsibilities ranging from the Board of Directors. common uniforms at all levels. The structure ensures better communication and speedy decision making process.
The Govt. FIIs. of India hold 10. with Suzuki Motor Corporation (SMC) acquiring 26% of the equity. of India held 46.6%.2%. Maruti ceased to be a government company. rest of the shares are distributed between the public. As of Sept 2006. Insurance companies.SHAREHOLDING: Maruti Suzuki India Limited was set up as a deemed public limited company in 1981 by an Act of Parliament. Mutual funds etc. Govt. Suzuki holds 54. In 1992. SMC's share went up to 54. as SMC's equity holding went up to 50%. SMC increased its equity to 40% in 1989. VISION OF MARUTI: • To be The leader in the Indian automobile industry • Creating customer delight and shareholder’s wealth • Be A pride of India GITM GURGAON Page 9 . making MSIL a subsidiary of SMC. A License and Joint Venture Agreement was signed in 1982. In 2002.21% shares. MSIL was classified in the Public Sector as long as the equity of Government of India remained over 51%. and employees trust holds the balance 0.2%.27%.
CLEANING CLEANLINESS DISCIPLINE 3M OF MSIL In factory various problems occur which hamper production and adversely affect the quality of products. 5 S OF MSIL SEIRI SEITON SEISO SEIKETSU SHITSUKE PROPER SELECTION ARRANGEMENT .MARUTI SUZUKI INDIA CULTURE Building a distinctive organizational culture is one of the most challenging tasks faced by any company. also satisfies the expectations of those outside the organizational environment. Most of these problems occur due to 3M: MURI MUDA MURA INCONVENIENCE WASTAGE INCONSISTENCY GITM GURGAON Page 10 . By organizational culture. which is built over the years. Such an approach might look like giving dividend in the short term but will definitely lead to stagnation and frustration in the long term. There is no use for a work ethic that creates highly efficient pseudo-robots out of the employees. A harmony between the work culture and organizational objectives is hence very essential. It is the duty of every employee to work towards sustaining the “MARUTI CULTURE”. is meant an organizational philosophy. It also defines implicitly how the external agents perceive the organization. which guides the actions and behavioral pattern of the members. Hence the necessity of a work culture which. while appealing to those within.
At all levels. “In case of an abnormality. The organizational structure has deliberately been kept very flat to facilitate communication. throughout the company employees can communicate on any business. organizational or personal concern. without having to cross many channels. all managers strive to facilitate both top-down as well as bottom-up communications. all concerned members should actually go to the place where the problem has occurred.3G OF MSIL 3G means. see the actual thing and take Realistic action to solve the problem”. In the Japanese language this point is compiled in 3 words: GENCHI GENBUTSU GENJITSU ACTUAL PLACE ACTUAL THING ACTUALLY 3K OF MSIL KIMERAARETA KOTO GA: KIHON DORI: KICHIN TO MAMORU: What has been decided As per the standard Must be followed COMMUNICATION CHANNELS As a part of open culture. GITM GURGAON Page 11 .
. the departments are Exports.A. Maruti Suzuki india Limited has a total of 3354 employees (not including trainees or Japanese experts). Information Services. Engineering. Designations in the Company are based on the functional responsibility in terms of the Company's philosophy of de linking designations and functional responsibility from the salary levels. Materials Management information & Resource Management Information.ORGANISATIONAL STRUCTURE AT MSIL MSIL is a functional organization. Materials. Sales Planning. GITM GURGAON Page 12 . & Services. Production. . For example: In Marketing & Sales Division. which are headed by Department Managers who report to the respective divisional managers. Sales & Dispatch. Spares. Production Engineering. etc.South. Personnel & Administration.North-I. In Information Services Division. Q. A Divisional Manager heads each Division. Production Management Information. the departments are Marketing & Sales Information. The total operations of the Company are divided into Divisions like Marketing & Sales. Finance. Each Division is further divided into Departments. North-II & MSS-N. . RO-East. Divisions are further divided into Departments. The Company is divided into different divisions according to the various functional areas. Marketing.West.
The following system of designations would be practiced without any exception within the Company. For external dealings a different set of designations may be followed. who will be designated as Divisional Manager. The Company has been divided into three layers of management. to identify their location in the Company. only the designations linked to functional responsibility will be used. Remaining employees of the Company will have no specific designation and would simply use the name of the Division/Department/Section to which they belong. Internally. Division GITM GURGAON Page 13 .SYSTEM OF DESIGNATION There will be a dual set of designations. For the purposes of defining explicit responsibility centers. The Divisional Managers would appoint section Managers. Department Section An official of the Company. The MD would make appointment to positions of Divisional Managers and Department Managers only. Department Manager. Section Manager respectively would head each of these responsibility centers.
Designation Flowchart M a n ( M J o i n t ( J D D D D e e p p i v s u a i o t y r t m M D S e n e i o E S T e p r x e u c p h a u E c e n M M i r e n D e n a l i v s n a t y x e u t g M c u a D a D c g i n ) n ) t o M i o M e r a n a g e / A r s s t . M a n a g e r a n a n a n a l a g M g e r a e ( D n r a ( D V g M e P r M ) / C ( D ) / D G D G V M g D i r e c t o r a g i n g D i r e c t o r t i v e t i v e r v i s i c i a o n r GITM GURGAON Page 14 .
By introducing automation at various levels. But over the years as the demand has increased Maruti has risen to the task and responded tremendously to the market. Maruti is now churning out close to 10 lakh vehicles from the plants that were planned only for 5 lakh. GITM GURGAON Page 15 . streamlining and refinement of material handling systems and operator motivation and incentives.OVERVIEW OF PRODUCTION AT MARUTI The plants were setup with an initial collective capacity of 5 lakh cars per year.
a new variant Baleno LXi. All other variants upgraded Maruti Insurance. Haryana Launch of SX4 GITM GURGAON Page 16 . Listed on BSE and NSE after a public issue oversubscribed 10 times Alto becomes India's new best selling car LPG variant of 'Omni Cargo' Versa 5-seater. Two new subsidiaries started: Maruti Insurance Distributor Services and Maruti Insurance Brokers Limited Alto Spin LXi.MILESTONES REACHED BY MARUTI 2007 • 2006 • 2005 • 2004 • • • • • 2003 • • • 2002 • • • • • WagonR Pride Esteem Diesel. the highest ever since the company began operations 20 years ago The fiftieth lakh car rolls out in April. with electronic power steering Special edition of Maruti 800. 2005 WagonR Lx & Lxi LPGew car plant and the diesel engine facility commenced operations during 2006-2007 at Manesar. a new variant Maruti closed the financial year 2003-04 with an annual sale of 472122 units. India’s first colour-coordinated car New Suzuki Grand Vitara XL-7 Enters into partnership with State Bank of India Production of 4 millionth vehicle.
• 2001 • • • 2000 • • • 1999 • • • • • 1998 • • • Maruti Finance in Mumbai with 10 finance companies Zen LXi Maruti Versa. MUV) Launch of website as part of CRM initiatives Maruti True Value launched in Bangalore and Delhi 1997 • • • 1998 Esteem (1299cc. 3 box car) LX. hatchback car) New (Omni & Omni E) (796cc. 3 Box Car) Wagon R Zen D (1527 cc diesel. a luxury estate car Maruti 800 EX (796cc. hatchback car) Zen VXi (993cc. VX and AX New Maruti 800 (796cc. MUV. India’s first luxury MPV Alto Vxi First car company in India to launch a Call Center New Alto Altura. high roof) Baleno (1600cc.hatchback Car) Standard and Deluxe Produced the 2 millionth vehicle since the commencement of production GITM GURGAON Page 17 . hatchback car with power steering) Omni XL ( 796cc.
4WD.000 vehicles (cumsilative production) Exported first lot of 500 cars to Hungary Installed capacity increased to 100. 3 box).3L (1298cc. hatchback Car) Produced 100. 3 box car)LX Produced the 1 millionth vehicle since the commencement of production With the launch of second plant. installed capacity reached 200. which was later exported in Europe and elsewhere as the Alto Esteem1.000 units Maruti 1000(970cc.1996 • • • Gypsy King (1298cc. hatchback Car).000 units GITM GURGAON Page 18 . off road vehicle) Zen Automatic (993cc. India’s first contemporary sedan Reaches cumsilative indigenisation of 65 percent for all vehicles produced Zen(993cc. hatchback car) Launch of 24-hour emergency on-road vehicle service 1995 • 1994 • • 1993 • 1991 • 1990 • 1988 • 1987 • 1986 • • Maruti 800 ( New Model-796cc.
License and JV agreement signed between Maruti Suzuki india Ltd. 1956. a 796 cc hatchback. Production was started under JVA GITM GURGAON Page 19 .1985 • 1984 • • Omni.000 units Launch of Maruti Gypsy (970cc. 4WD off-road vehicle) 1983 • • 1982 • 1981 • Maruti Suzuki india Ltd was incorporated under the provisions of the Indian Companies Act. a 796cc MUV Installed capacity reached 40. India’s first affordable car. and SMC of Japan Maruti 800.
Then. GITM GURGAON Page 20 . these are send to the assembly shop. various parts are fitted at various canopies or stations. From the paint shop. conducts various tests to ensure that no defects remain before the car is dispatched via trucks to various parts of the country. and the car engine and other transmission parts are also fitted in the assembly shop itself. where these are coated and glazed.rolled sheets. where through a conveyor system. The machine shop and the Engine assembly shops are located close to the respective assemblies.I deptt. the V. where they are welded to make the frame of the car. the parts are send to the weld shop. From the press shop. From the weld shop. these frames are transferred via conveyors to the paint shop.HOW IS A CAR MADE The making of a car starts from the press shop. where the raw material is obtained in the form of cold.
The flow chart for a typical car body weld line looks as follows: GITM GURGAON Page 21 .
The basic layout of a paint shop is as follows: From weld shop GITM GURGAON Page 22 .
The features of an assembly shop is shown as follows : Trim line: The car body moves over the conveyor on mounts. as shown below: Chassis Line: Here. as both the engine and wheels have been fitted. the car once again moves over the conveyor belt. GITM GURGAON Page 23 . the car is loaded on overhead jigs as shown below: Final Line: Here.
(c) Stamping line: there are six presses of capacity varying from 1500 Ton to 4000 Ton. These components are manufactured in the press shop at Maruti due to design secrecy and huge investment requirements. GITM GURGAON Page 24 . out of which five are transfer presses and one is semi-automatic press. These may be divided as A. The press shop can be explained under following headings: (a) Raw material (b) Blanking line (c) Stamping line (a) Raw material: The raw material is in the form of cold rolled steel coils. (b) Blanking line: There are two blanking lines. The weld shop as per the requirements picks the finished body parts from the press shop. It is specified in terms of steel grade and width of coil required. Centrally located between weld 1. weld 2 and weld 3 supplies components to all the three plants. ‘A’ components are large outer components as for example roof. The die can be changed to obtain different body components. ‘B’ and ‘C’ components are manufactured by joint ventures or bought from vendors. The coils weigh about 15000 kg.DIFFERENT SHOPS IN MARUTI SUZUKI INDIA LIMITED 1. The press shop maintains an inventory of at least two days. door panels etc. ROSL (Rotary Oscillatory shear line) for rectangular shapes and the others employing die cutting for irregular shapes. PRESS SHOP The press shop can be regarded as the starting point of the car manufacturing process. B and C. The press shop has a batch production system whereas the plants have a line production system.
central underbody. The body is checked for dent. 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. These underbodies are put on the conveyor and welded together to give the underbody. In a typical car body 1400 different components are welded together. hood and back door are attached on the main body with the help of bolts and screws to make it a “white body”. It is sent to the paint shop thereafter.2. front engine room panel. burr and spatter and these defects are repaired. Welding jigs Spot welding guns Kawasaki welding robots Hemming machines Punching machines PROCESS OUTLINE: The shop has different lines for different models. These comprise of rear underbody. GITM GURGAON Page 25 . each of. WHITE BODY: The doors. which is further divided into three parts: UNDER BODY: Here different underbody panels are welded together. The weld shops have the following facilities. 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”. After inspection and repairs the body is called WBOK. MAIN BODY: As the body moves on.
After applying the coat. For metallic coating. the PBOK.3. (e) Topcoat: This is done by spray-painting method using 20 Kawasaki Robots. The five units are: (a) Pre-treatment (PT): The body is thoroughly washed to remove the dirt and oil scales. (d) Intermediate coat: This is done by spray-painting method using 10 Kawasaki Robots. PAINT SHOP In the paint shop following processes are carried out: There are five plants/units that provide a uniform painting over the white body coming from the weld shop. the paint body ok is sent to the assembly shop. In paint shop all the models are painted on the same line. double coats are applied and aluminum flakes are provided to shine the metallic paints. GITM GURGAON Page 26 . at 240V-dc supply. After inspection and touch up. i.e. (c) Sol-sealer and under coat: Here the left in the body (due to welding) are filled with sol-sealer to provide waterproofing. Then the body is treated with ZnPO4 (phosphating) to prevent corroding of the body. the body is dried in the oven. Painting done is basically an intermediate coating to provide base for the final coat. Under coat is done on the surface above wheels to prevent damage of body in that portion. (b) ED coat: This is done by electric deposition method. After applying the ED coat the body is baked in oven.
F8D engine (5-speed transmission. The unmachined crankshaft and camshaft forgings. 796cc MPFI) for Car800 and Alto. The cylinder head and transmission case are aluminum castings while crankshaft and camshaft are steel forgings. one Main Line and a Firing Test. cylinder head. transmission case. Shop. cylinder head and cylinder block castings are brought in as raw material from vendors. It has the following lines Transmission Case Line Cylinder Head Line Cylinder Block Line Crankshaft Line Camshaft Line ENGINE ASSEMBLY Engine assembly 3 is currently used to assemble the 1061cc engine for WagonR. camshaft and crankshaft are received here from the machine shop. Engine assembly is divided into 3 main Sub-Assemblies. transmission case.MACHINE SHOP The machine shop is the source of all major components for the Engine Assy. The sub assemblies are: Cylinder Block Line Cylinder Head Line Transmission Line The cylinder block. GITM GURGAON Page 27 .
Here the body is loaded on an over head conveyor. Assembly I mainly produces MARUTI 800 (Domestic & Export Mainly). Here amongst the first tasks done is attaching the hydraulic supporters for the boot. and door trims parking brake cable. There are about 375 employees in two shifts. roof silencer and cabin lamp.e. EECO.ASSEMBLY SHOP -I There are 3 assembly shops in MSIL which produce on an average 1750 cars daily. model stickers and emblems. Steering gear case is put inside to be fixed later. fitments are made at various stations. Trim 2 GITM GURGAON Page 28 . ZEN ESTILO (Domestic& Export).The various fitments made here are door/floor grommets. The assembly shop receives PB-OK i. paint body OK from the paint shop. The assembly line check sheet is put inside the body. electric wiring. The Whole process of assembling undergoes through different number of stations. OMNI(Passenger & Cargo). As the conveyor moves the body. Door is removed here and sent to final line . inner and outer door openers. The Asssembly shop can be further subdivided as following Trim Chassis Final TRIM LINE Trim can be further subdivided as following: Trim 1 This is the beginning of the assembly line conveyor.RITZ & WAGON R(new model).
accelerator. engine cum transmission case assembly. tie rods. brake pipes. ashtray and stereo system. fuel tank and rear brake drum. which is received from an instrument panel subassembly.It starts with Rear combination light fitment. wiper sprayer and motor. A process check is done at the end of chassis 2. quarter glasses and connecting pipe between fuel lid and fuel tank. Trim 2 ends with the fitment of the instrument panel. This sub assembly involves the fitting of the speedometer console. front coil spring with knuckle. fuel pipes. GITM GURGAON Page 29 . brake pedals. rear suspension. clutch. Trim 3 The fittings done here are rear inside cover for boot. The tie rod and drive shafts are connected to the knuckle to complete the front suspension system and ID plate fixation. hence body is loaded on overhead jigs. fuse box. Here underbody fitments are made. For cemendine application on the windshield. seat belts. gearshift rod. back door glass and windshield. Process check is done at the end of Chassis 1. . There is a knuckle sub assembly that feeds the line with knuckles for the front suspension system. Steering gear is mounted. Here a process check is done CHASSIS The chassis receives a trim up body. stabilizer bars and tyres. steering wheel. door glasses and a/c panel fitment. Motoman robots are employed. Chassis 2 The fitments made here the exhaust system (silencer and catalytic converter). Other operations done here are vacuum booster/ brake master cylinder fitment. Chassis is subdivided as following: Chassis 1 Various fitments made here are rear shock absorbers. front and rear bumpers.
It is handed over to the vehicle inspection department. Coolant is also filled. scuff.FINAL Since all the fitments have been made. roof trim and carpet. The vehicle is said to be AB-OK now. Clutch cable and parking brake connections are made. battery and air cleaner. seats. Final 2 Five liters of petrol is filled in the vehicle. A/C vaccum and charging is also done here. The vehicle is loaded on the final conveyor. the body is referred as vehicle from now onwards. the refrigerant used here is R134a (400 gm +. Final area is further subdivided as: Final 1 The fitments made here are Spare wheel cover.Door Assembly is also done here. Brakes are evacuated and brake oil is filled.50). Final 3 There is a process check at the end of this line. GITM GURGAON Page 30 . boot carpet.
At each checkpoint different parameters are checked. 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 GITM GURGAON Page 31 .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. 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.VEHICLE INSPECTION . 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.
Baleno has rear wheel allowance of toe-in 3. GITM GURGAON Page 32 . WagonR and Baleno.5. Toe-In Test This is the first inspection point for a vehicle once it comes off the assembly line conveyor. Figure no. 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. The objectives of doing the toe-in test are as follows: Minimum tyre wear Steering position OK Minimum side slip Toe-In refers to the alignment of the wheels. the driver isn’t holding the steering wheel. Statistical analysis and experiments has given a value of toe-in 2 and toe-out 1 for front wheels in Car800. The wheels are either pointing slightly inwards (toe-in) or outwards (toe-out).5 and toe-out 0. Before the vehicle is accepted for this test it is checked for external damages. Also when a car is in motion then the wheels tend to align outwards so vehicles are generally set with a toe-in condition. 5 shows the toe-in tester machine.e.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. feel of the brakes and floor carpet. It is not possible to have a wheel alignment such that the wheels are perfectly straight (ideally this leads to minimum tyre wear).
At the headlamp tester. door gap and fouling. Various weld defects are level difference. The vehicle is loaded on a conveyor. doors. paint miss. tyres and glasses. the vehicle is OK in slipping otherwise NOT OK. The vehicle is visually inspected for weld. 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 machine is calibrated for 2 unit toe-in and 1 unit toe-out. pin holes sealer application and sanding marks. interiors. orange peel. paint and assembly defects and the same are marked on the diagrammatic representation given on the checksheet. weather strips. overflow. a yellow cross represents the position of the headlamp whereas the point where it should ideally be is shown as green rectangle. The vehicle is driven in all the gears and the various parameters checked are as follows: GITM GURGAON Page 33 . dents. emblems. the headlight beam adjustment. routing and clamping. Various paint defects are paint peel off. fuel lid. Apart from checking the headlamp. seats. If the vehicle slipping falls in between the calibration limits. HEAD LAMP TESTER Often the car driver faces the problem. Because of the maladjustment the light beam falls on unwanted objects. turning radius and other things are also checked at this checkpoint. bumper.SLIP TESTER This machine checks vehicle slipping after the toe in adjustment. seat belts. 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. front hood.D plate. shade mismatch. scratches. The appearance check points are I.
hazard lamp. 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. switch operation Choke: operation/ function Abnormal noise of any kind from wheels/body/engine should not be there. reverse light Blower: Operation of switch at different speeds. side turn signal. air direction control. Parking brake force is also checked here. The vehicle is moved onto the drums. fins Heater: functioning. head lamp high/low. sponginess. cabin lamp/door switch/fog lamp. switch operation A/C: functioning. Rear view mirror: blurred image/ distortion Fuel/Temperature gauge: function Lamps: Parking. Here the brake pedal is checked for hardness. GITM GURGAON Page 34 . vehicle brakes are employed and the corresponding resistance force is measured with the help of computerized machine. fresh/recirculating air control. The measured force is displayed on the screen and must lie between the values prescribed by the company. Brake Tester The front and rear brake forces are measured here. brake light. play and noise.
all window glasses are rolled up and doors closed. clutch lever play (Car800).e. The defects are noted on the checksheet to be repaired in assembly or engine assembly.Engine Room Here the engine is inspected for various kinds of defects such as tappet noise. then the particular leak defect is repaired in the shower repair section following which the vehicle is sent for the road test. idling rpm with and without A/C switched on. Road Test GITM GURGAON Page 35 . In case of MPI cars. Pit Inspection The underbody of the vehicle is checked for: Brake fluid/coolant/fuel/engine oil leakage Red and yellow paint on nuts. The DLC cable is connected to a computer which shows not ok if there is any malfunctioning in the engine. When the vehicle exits from other side of the shower tester an inspector checks the cabin for water seepage. a DLC (Data Link Connector) cable is used to detect the working of Electronic Control Module and various sensors. If water is found. exhaust emissions as per the standards laid down. the vehicle is sealed i. While passing through. 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 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.
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. acceleration. hood etc is noted down Final Check This is the last of the vehicle inspection checks. Here the overall appearance of the vehicle is checked again. 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. 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. 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 miss.Road test of a vehicle consists of a track on which the vehicle is run at predetermined speed. Finally the chassis and engine number on the I. cleanliness and Cemedine(windscreen sealer) leftovers are checked for. Also secondary defects i. dents. wheels .e. handling. reverse braking and Steering positioning is also checked. performance etc. Distance traveled after application of brakes. GITM GURGAON Page 36 .D. engine. Scratches. doors. The track is designed so as to check the various aspects of the vehicle such as braking. FC OK’ed vehicles are later picked by the Sales and Dispatch drivers.
Line balancing. The main purpose of implementing time study in ETSA & Rear Axle Sub Assembly and layout design is to- Identify and Eliminate hidden waste of time. This can be achieved by doing the time study of the various working stations of line. thus standard time of each process can be found.Hidden waste refers to those waste which are not visible during the process but still exist.Standard time of each action performed by the worker is calculated by using MOST.NEED FOR THE PROJECT The need of the project is to increase the productivity of the workers both in terms of quality and quantity. Man power reduction.The goal in balancing an assembly line is to assign tasks to stations such that equal amount of work is performed at each station.To optimize the Line by calculating the required Man power & removing the extra workers from the line. GITM GURGAON Page 37 . To calculate standard time of each process.
These include factors such as: Are the workers standing all day? Are they working in a cold environment? Do they have to wear safety equipment? Method to Calculate Time: In this project I have calculated time at different stations by using stop watch. 100% is normal. This factor is calculated by an Industrial Engineer trained to observe and determine the rating. where necessary. The Standard Time is the product of three factors: 1.Introduction to Time Study In business efficiency studies. 1. Fatigue. and Delay Allowances. an additional allowance to cover contingent elements which may occur but have not been observed. 1. 110% is working faster than normal. Observed Time . Time Study (an Industrial Engineering term) is the time required for a person to complete a task or operation at a defined rate of working. Before calculating the time at each. PFD Allowance .The pace the person is working at. It includes appropriate allowances to allow the person to recover from fatigue and. Rating Factor . If we analyze all the relevant details of station and accurately knew the amount of component that each operator fit in the object then only accurate time is measured with the stop watch. 90% is working slower than normal.The time required to complete the task. GITM GURGAON Page 38 .Personal. first we have saw that how many operator at each station has and what is their method of doing the work.
Stations of Rear Axle Sub Assembly Station no. clamps. In this section there are 3 stations in which different operation performed by each operator. hose pipe. drum head.1 Station no. helical springs etc.2R Station no.1: GITM GURGAON Page 39 . In this section there are two stations on conveyor belt and one station for engine mounting. parking cable.3 DESCRIPTION OF STATIONS AT REAR AXLE SUB ASSEMBLY: STATION NO. sticker. plug. trailing arm.Rear Axle Sub Assembly Line No. spindle rear.4 In rear axle sub assembly of line no. E rings.2L Station no.4 rear axle of Eeco & Ritz are made. bump stopper. oil filling in Eeco. The components such as brake sub assembly. break pipe. In this various components attached to the axle frame.
2 (R&L) the component such as trailing arms. hose pipes. At station no. oil filing etc. In this station only one worker is engaged. hose pipe.4 Eeco & Ritz at each station is shown below in the table.In this station the axle of Eeco & Ritz first transfer from trolleys to the station no1 with the help of crane and then component such as brake sub assembly.2: In this station 2 workers are engaged on left and right side. Standard time of both cars of line no. so that standard time can be obtained. Time Calculation: Time at each station is calculated 3 times with the stop watch. clamps. helical springs also attach at the same time. brake pipes. STATION NO. GITM GURGAON Page 40 .3: In this station the axle is moved from conveyer belt to lift and from lift it is attached to car body with the help of bolts and lateral rod. parking cable and drum head attach on the axle body. STATION NO. done on axle frame.
Operator working at rear axle sub assembly Time Study Data Sheet Axle Sub Assembly Station no.53"16 8.1 Eeco loading from trolley total time taken(in seconds) 1.62min 1"44.2 Ecco Ritz 1"15.42min station no.08sec station no.51"68total) 17"18sec Ritz loading fetching of component 1"20"38min (total) 12.3 Ritz Ecco Ecco(lining front fender) 1.53"16 1.22sec 2. station no.86(seconds) GITM GURGAON Page 41 .
56sec .90sec TIME(RITZ) 75. The time observed is as follow: PERSON 1 OPERARIONS Total time PERSON 2 GITM GURGAON Page 42 TIME(EECO) 69. Two operators work on this station below the lift.ENGINE MOUNTING STATION At this station an engine is fited to the car by using an automatin lift.
OPERARIONS Total time TIME(EECO) 68. Definition: Definition of Line Lay out Line Layout is the physical arrangement of equipment.98sec Line Layout of Line no. safety and quality of Products.54sec TIME(RITZ) 102. facilities & man power within a line.e. gravity) GITM GURGAON Page 43 .Distances Operators have to move . Optimizing the Layout of a line can improve productivity.Distances Equipment has to move .Distances Material has to move . The Line Layout can be indicated on a floor plan showing the distances between different features of the line.Energy required to move items against resistance (i. This is valid for: .Types of Handling Equipments needed .5 INTRODUCTION: A line layout study is an engineering study used to analyze different physical configurations for an industrial plant. Unnecessary efforts of materials handling can be avoided when the Line Layout is optimized.
T. permanent.5 mainly contains three most important sections. apprentice. reliver and repairmen. The category of each worker at each station is shown in table 4. permanent. GITM GURGAON Page 44 .5(WAGON-R) Line no. reliver and repairmen. apprentice.T. The categories such as casual. The category of each worker at each station is shown in table 5. The sections are: Trim Chassis Final Trim: Trim of line no. Final: Final of line no. In final sections 47 workers are engaged at its different stations and all are of different categories. In trim sections 34 workers are engaged at its different stations and all are of different categories. apprentice. T. T.5 has 29 stations on its right side and 29 stations on its left side.5 has 23 stations on its right side and 23 stations on its left side. The categories such as casual. The categories such as casual.T. permanent.Line Lay out of line no. The category of each worker at each station is shown in table 3.5 has 14 stations on its right side and 14 stations on its left side. reliver and repairmen. Chassis: Chassis of line no. In chassis sections 26 workers are engaged at its different stations and all are of different categories.T.
Table Notations: C-CASUAL T. Category of worker C C C C T.T P P GITM GURGAON Page 45 .T .T-TRAINEE P-PERMANENT A-APPRENTICE Trim Data: Left Station (table no.T C C C C C C T.1) Station 1L 2L 3L 4L 5L 6L 7L 8L 11L 12L 14L 15L1 15L2 16L 18L 20L 21L 23L . R C C C T.
Trim Data: Right Station Station 1R 2R 3R 4R 5R 6R 7R 8R 9R 11R 12R 14R 18R 20R 21R 23R IPSA ETSA Category of worker C C C C C C C T. C C C .T C C C C P C C P 2P 5C 1P 1T.T 5C RELIEVER-3 Chassis Data: Left Station Station 24L 25L 26L 27L 28L 29L GITM GURGAON Page 46 Category of worker C C APP.
33L 34L 35L 36L 37L REAR AXLE ASSEMBLY CENTRE LEFT C C C C P C C. C C C C C C C P .C Chassis Data: Right Station Station 24R 25R 26R 27R 28R 29R 31R 34R 35R 36R 37R REAR AXLE ASSEMBLY GITM GURGAON Page 47 Category of worker C C APP.
C RELIVER-3 Final Data: Left Station Station 38L 39L 41L 42L 43L 46L 47L 48L 49L 50L 52L 53L 55L 56L 57L 58L 59L 60L GITM GURGAON Page 48 Category of worker C C P .T C C P C . APP. APP.RIGHT C. C C P P C T. C(underbody-PIT) C P P P .
61L 62L 63L 65L P P P P Final Data: Right Station Station 38R 39R 41R 42R 43R 44R 47R 48R 49R 50R 51R 52R 53R 55R 56R 57R 58R 59R 60R 61R GITM GURGAON Page 49 Category of worker C C C T.T P C C C C C C C C C C C P P C P .
chassis & final sections and also showing all the working stations that 3 section of line no. Blue tape is stick on white showing the trim.1 has. Every stations on white board is shown with the of marker and all workers on each station are then implement with the of above tables. After doing all the above stated task line layout is made on white board. ONLINE-2 LINE LAY OUT Line layout is made on white board in which 2 tapes of blue and red color stick on it borders. In this line layout each worker assigned different color of magnets and then each magnet are put on mark station in white board according to its category.62R 64R 66R RELIEVER-2 DRIVER-2 P P P WORKERS AT CNG STATION -5 REPAIRMAN-10 (OFFLINE-2 . GITM GURGAON Page 50 .
GITM GURGAON Page 51 . It provides me an opportunity to gain experience on the practical application our technical knowledge. The overall experience that I have gained at Maruti helped me a lot in my future. I have done my industrial training in the ASSEMBLY SHOP-1 of MARUTI SUZUKI INDIA LIMITED. Time Study is a very useful tool which can be employed in manufacturing companies like Maruti which have to constantly cater to ever increasing demand from the market with very small lead times.CONCLUSION The 6 weeks Industrial Training is indeed the most important part of our curriculum at the Mechanical Engineering Department of GITM GURGAON. In the end I would like to thank my Mentor at Maruti and all staff members of assembly shop -1 who have encouraged and inspired me to achieve higher goals. In my training I have leaned 2 topics TIME STUDY TECHNIQUE AND LINE LAY OUT DESIGN.
LINE LAY OUT OF LINE NO. GITM GURGAON Page 52 .4 is known.5 is made. Standard time for each operation in ENGINE MOUNTING.RESULT 1. Standard time for each operation in REAR AXLE SUB ASSEMBLY is known. LINE NO. 2. 3.
GITM GURGAON Page 53 .
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