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ACKNOWLEDGEMENT

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

Company Profile:

Maruti Suzuki is one of India's leading automobile manufacturers and the market leader in the car segment, both in terms of volume of vehicles sold and revenue earned. Until recently, 18.28% of the company was owned by the Indian government, and 54.2% by Suzuki of Japan. The Indian government held an initial public offering of 25% of the company in June 2003. As of May 10, 2007, Govt. of India sold its complete share to Indian financial institutions. With this, Govt. of India no longer has stake in Maruti Udyog. Maruti Udyog Limited (MUL) was established in February 1981, though the actual production commenced in 1983 with the Maruti 800, based on the Suzuki Alto car which at the time was the only modern car available in India, its' only competitors- the Hindustan Ambassador and Premier Padmini were both around 25 years out of date at that point. Through 2004, Maruti has produced over 5 Million vehicles. Maruti are sold in India and various several other countries, depending upon export orders. Cars similar to Maruti (but not manufactured by Maruti Udyog) are sold by Suzuki and manufactured in Pakistan and other South Asian countries. The company annually exports more than 50,000 cars and has an extremely large domestic market in India selling over 730,000 cars annually. Maruti 800, till 2004, was the India's largest selling compact car ever since it was launched in 1983. More than a million units of this car have been sold worldwide so far. Currently, Maruti Alto tops the sales charts and Maruti Swift is the largest selling in A2 segment. Due to the large number of Maruti 800s sold in the Indian market, the term "Maruti" is commonly used to refer to this compact car model. Till recently the term "Maruti", in popular Indian culture, was associated to the Maruti 800 model. Maruti Suzuki India Limited, a subsidiary of Suzuki Motor Corporation of Japan, has been the leader of the Indian car market for over two decades.

Its manufacturing facilities are located at two facilities Gurgaon and Manesar south of New Delhi. Marutis Gurgaon facility has an installed capacity of 350,000 units per annum. The Manesar facilities, launched in February 2007 comprise a vehicle assembly plant with a capacity of 100,000 units per year and a Diesel Engine plant with an annual capacity of 100,000 engines and transmissions. Manesar and Gurgaon facilities have a combined capability to produce over 700,000 units annually. More than half the cars sold in India are Maruti cars. The company is a subsidiary of Suzuki Motor Corporation, Japan, which owns 54.2 per cent of Maruti. The rest is owned by the public and financial institutions. It is listed on the Bombay Stock Exchange and National Stock Exchange in India. During 2007-08, Maruti Suzuki sold 764,842 cars, of which 53,024 were exported. In all, over six million Maruti cars are on Indian roads since the first car was rolled out on December 14, 1983. Maruti Suzuki offers 12 models, Maruti 800, Omni, Alto, Versa, Gypsy, A Star, Wagon R, Zen Estilo, Swift, Swift Dzire, SX4, Grand Vitara. Swift, Swift dzire, A star and SX4 are maufactured in Manesar, Grand Vitara is imported from Japan as a completely built unit (CBU), remaining all models are manufactured in Maruti Suzuki's Gurgaon Plant. Suzuki Motor Corporation, the parent company, is a global leader in mini and compact cars for three decades. Suzukis technical superiority lies in its ability to pack power and performance into a compact, lightweight engine that is clean and fuel efficient. Maruti is clearly an employer of choice for automotive engineers and young managers from across the country. Nearly 75,000 people are employed directly by Maruti and its partners.

The company vouches for customer satisfaction. For its sincere efforts it has been rated (by customers) first in customer satisfaction among all car makers in India for nine years in a row in annual survey by J D Power Asia Pacific. Maruti Suzuki was born as a government company, with Suzuki as a minor partner to make a people's car for middle class India. Over the years, the product range has widened, ownership has changed hands and the customer has evolved. What remains unchanged, then and now, is Marutis mission to motorize India.

BACKGROUND OF THE INDIAN AUTO INDUSTRY


Although the Indian car industry was established in the late forties, there was little growth or technical progress, as passenger cars were given very low priority in the scheme of Centralized Economic Planning. In the 1980s, the car industry was undergoing technological stagnation and was characterized by low production volumes, high cost and low productivity. The consumer had very little choice and the market was selling just around 30,000 cars per year. There was a clear need to provide a cost effective, reliable and quality car to the customers. Maruti Suzuki India Limited was incorporated in such a scenario as a fully owned Government Company on February 24, 1981 with a resolve to bring about expansion and technological modernization, of the automobile sector. Thus MSIL, when started was entrusted with the task of achieving the following policy objectives: Modernization of Indian Automobile Industry. Production of Vehicles in large volumes, which was necessary for economic Production of Fuel-efficient vehicles to conserve scarce resources.

growth.

Choice of product and collaborator


To achieve the above objectives, one of the foremost tasks before. Maruti Suzuki India Limited was to determine the most suitable product mix and to select the most suitable foreign partner who would be willing to accept MSIL s requirements in terms of product mix, technology transfer, and equality participation and had the required technological expertise and experience in producing high quality, reliable and fuel efficient vehicles. After extensive discussion with several major European and Japanese car

manufacturers, MUL chose Suzuki Motor Corporation (SMC) further increased its equity holding to 50% in the year 1992, converting . Maruti Suzuki India Limited, into a NonGovernment Company with a total Equity base of Rs. 1322.92 million.

BACKGROUND OF SMC
SUZUKI was founded in 1909 as Suzuki Loom Manufacturing Company. It started manufacturing motorcycles in 1952 and has become a world leader in the manufacture of two-wheelers .SUZUKI started producing cars from 1955.Today it is Japans largest manufacturers of small , fuel-efficient cars. At present the companys name is SUZUKI MOTOR CORPORATION.

SUZUKI AND MARUTIS WORLD-CLASS MANUFACTURING FACILITIES AT MANESAR


On February 06,2007 Mr. Bhupendera Singh Hooda , Chief Minister of Haryana inaugurated three world-class manufacturing facilities set up by SMC and Maruti Suzuki India Limited.

The facilities inaugurated were as follows:


MSILs fourth car Assembly plant. A diesel engine and transmission plant, set up under a joint venture of SMC and MSILcalled Suzuki Power train India Limited (SPIL) SMCs two-wheeler plant in Gurgaon, Suzuki Motorcycle India Private Limited (SMIPL).

INTRODUCTION TO MARUTI SUZUKI INDIA LIMITED


A License and a Joint Venture Agreement was signed with Suzuki Motor Company of Japan, in OCT. 1982 Market leader with over 54% Share in Domestic Car Market Exporting cars to over 70 countries around the world including most advance Western European Markets. Maruti has revolutionized the Indian Automobile and Component Industry and has set standards in quality of products and service.

MARUTI INSTALLED CAPACITY


PLANT 1 200,000 units PLANT 2 150,000 units PALNT 3 150,000 units PLANT 4 100,000 units

COMPANY MISSION
A leader in the Indian Automobile Industry. Creating Customer Delight and Shareholders wealth. A pride of India!

LEADERSHIP
By Market share and brand equity By operational practices By people strategy

CUSTOMER DELIGHT
Values for money Quality Service

SHARE HOLDERS WEALTH


High Profitability & Image

A PRIDE OF INDIA
As a corporate citizen Products People Practices Customers

VALUES
Customer Obsession Fast, Flexible, First Mover Innovation and creativity Networking and partnership Openness and learning

QUALITY POLICY
To increase consumer satisfaction through continuous improvement of products and services, this is achieved by following PDCA functions and levels of Maruti Organizations.

PLAN DO

QUALITY POLICY

ACT

CHECK

QUALITY TOOLS
5S 4M 3M 3G 3K

What is 5S?
SEIRI SEITION SEISO PROPER SELECTION ARRANGEMENT CLEANING

SEIKETSO CLEANLINESS SHITSUKE DISCIPLINE

What is 4M?
The factory is essentially a mix of man, materials, machines and methods. These should move continuously and effectively to produce a quality product at low cost. The most essential work in quality control is to thoroughly investigate regarding the problems concerning quality, decide suitable counter measures and carry out improvements accordingly.

MAN MACHINE MATERIAL METHODS

What is 3M?
In Japanese Language 3M is: MURI MUDA MURA INCONVENIENCE WASTAGE INCONSISTENCY

What is 3G?
In Japanese Language 3G is: GENCHI GENBUTSU GENJITSU GO TO ACTUAL PLACE

SEE THE ACTUAL THING TAKE APPROPRIATE ACTION

INTRODUCTION TO VARIOUS MODELS


PRODUCT RANGE

MODELS MARUTI 800 (FIRST MODEL) OMNI GYPSY MARUTI 800 (MODIFIED) MARUTI 1000 ZEN ESTEEM 1.3L LX ESTEEM 1.3L VX ESTEEM 1.3L AX ZEN AX (AUTOMATIC) GYPSY KING OMNI (E) GYPSY (E) MARUTI 800 (NEW MODEL) ESTEEM 98 NEW OMNI & OMNI-E ZEN VX & ZEN VX AUTOMATIC ZEN D MARUTI 800 EX ZEN LX

SPECIFICATIONS 796CC, HATCHBACK 796CC, MUV 992CC, 4WD 796CC, HATCHBACK 996CC, SEDAN 996CC, HATCHBACK 1296CC, SEDAN 1296CC, SEDAN 1296CC, SEDAN 996CC, HATCHBACK 1296CC, 4WD 796CC, MUV 1296CC, 4WD 796CC, HATCHBACK 1296CC, SEDAN 796CC, MUV 996CC, HATCHBACK 1200CC, HATCHBACK 796CC, HATCHBACK 996CC, HATCHBACK

YEAR OF LAUNCH DECEMBER 1983 NOVEMBER 1984 DECEMBER 1985 APRIL 1986 OCTOBER 1990 OCTOBER 1993 NOVEMBER 994 NOVEMBER1995 JUNE 1996 OCTOBER 1996 NOVEMBER1996 DECEMBER 1996 DECEMBER 1996 SEPTEMBER 997 OCTOBER 1997 FEBRUARY 1998 JULY 1998

AUGUST 1998 JANUARY 1999 JANUARY 1999

ZEN CLASSIC ZEN VXI OMNI XL BALENO WAGON R

996CC, HATCHBACK 996CC, HATCHBACK 796CC, MUV 1586CC, SEDAN 1096CC, HATCHBACK

AUGUST 1999 OCTOBER 1999 OCTOBER 1999 DECEMBER 1999 JANUARY 2000

1586CC, ALTURA ALTO LX, LXI VERSA SWIFT ZEN ESTILO SWIFT DIESEL SWIFT DIESEL GRAND VITARA SX4 SWIFT DZIRE A- STAR RITZ HATCHBACK (BALENO) 796CC, HATCHBACK 1296CC, MUV 1296CC, HATCHBACK 1096CC, HATCHBACK 1296CC, HATCHBACK 1.600CC MARCH 2000 SEPTEMBER 000 DECEMBER 2001 MAY 2005 DECEMBER 2006 FEBRUARY 2007 FEBRUARY 2007 MARCH 2007 MAY 2007 MARCH 2008 NOVEMBER 2008 MAY 2009

ORGANISATIONAL STRUCTURE
Maruti has believed, since the very beginning that it is its employees who could make it into an organization with a difference .Accordingly, as against the traditional hierarchical System of management, which causes unnecessary delays in decision-making, we have built up a flat organization with a family type of atmosphere at our place of work.

The company is divided into different divisions according to the various functional areas. A Divisional Manager heads each Division. Divisions are further divided into

Departments that are headed by Department Managers who report to the respective Divisional Managers. Designations in the company are based on the functional responsibility and not levels as in terms of the companys philosophy designations and functional responsibility are de-linked from the salary levels.

The total operations of the Company are divided into Divisions like Marketing & Sales, Spares, Engineering, Q.A. & Services, Production, Production Engineering, Materials, Information Services, Finance, Personnel & Administration, etc. Each division is furthering divided into Departments and headed by Departmental Managers who is assisted by Supervisory Executives.

The hierarchy diagram of MSIL

DIVISIONS AND DEPARTMENTS


Corporate Services Division Legal & Secretarial Department Corporate Communication Cell Protocol Strategic Initiative Group Recruitment & Management Compensation

Human Resource Division Employee Relations Department Establishment & Time Office Factory Administration Department Organizational Development Department

Production Division Plant- 1 Plant- 2 Plant- 3 Plant- 6 at Manesar

Production Engineering Production Engineering Division Production Service Division

Engineering Directorate QAIN Division Service Division Service- 1-5 MSS(D) Parts Inspection Division Engineering Division

Supply Chain division Supply Chain- 1,2,3 Division Shipping & transport Department Imports Department Consumables Department

Information Technology Division Application Group1 (AG1) Application Group2 (AG2) Application Group3 (AG3) Information Technology Strategies(ITS) IT Operation and Services(ITOS)

Marketing & Sales Secretariat Marketing Strategy & Development

Marketing

Sales Exports Web-IT, E-Commerce

Spare Parts Division Spare Parts Procurement Warehousing & Dispatch Spare Parts Sales Accessories

Vigilance Division Security Wing Vigilance Wing

Finance Division Budget, Cost & Accounts Department Income Accounting

The total project costs, priority, completion time and personnels required were estimated. Initial plans were drawn up as to how the project would proceed to its final implementation, while running the existing system so that companys information needs were not affected

Milestones
1981 1982 1983 1984 1985 1986 1987 1988 1992 1994 1995 1996 1997 1998

Maruti Udyog Ltd. was incorporated. Stepped into a JV with SMC of Japan. Maruti 800, a 796 cc hatchback, India's first affordable car was produced. Installed capacity reached 40,000 units. Omni, a 796 cc MUV was in production. Launch of Maruti Gypsy (970cc, 4WD off-road vehicle). Produced 100,000 vehicles (cumulative production). Exported first lot of 500 cars to Hungary. Installed capacity increased to 100,000 units. SMC increases its stake to 50 per cent. Produced the 1 millionth vehicle since the commencement of production. Second plant launched, the installed capacity reached 200,000 units. Launch of 24-hour emergency on-road vehicle service. Produced the 2 millionth vehicle since the commencement of production. Launch of website as part of CRM initiatives. Launch of Maruti - Suzuki innovative traffic beat in Delhi and Chennai as social initiatives.

1999

2000 2001

IDTR (Institute of Driving Training and Research) launched jointly with Delhi government to promote safe driving habits. Launch of customer information centers in Hyderabad, Bangalore, and Chennai. SMC increases its stake to 54.2 per cent. Launch of Maruti Finance with 10 finance companies in Mumbai. Start of Maruti True value in Mumbai.

2002

Production of 4 millionth vehicle.

2003

Listed on BSE and NSE after a public issue oversubscribed 10 times.

2004 2005. 2006.


Maruti closed the financial year 2003-04 with an annual sale of 472122 units, the highest ever since the company began operations 20 years ago. The fiftieth lakh car rolls out in April, 2005. Maruti tops jd power csi survey for record seventh time in a row Govt of India awarded O SUZUKI with coveted padma bhusan Board of directors give approval to new name MUL to become maruti Suzuki India limited. M-800 crosses 25 lakh mark MSIL celebrates SILVER JUBILEE MSIL launches national road safety program. Capacity to manufacture expanded from 800,000 to a million units(Gurgaon plus Manesar) annually All India engineering export promotion council(EEPC) award. MSIL achieved highest sales ever in Dec2009

2007

2008.

2009