Maruti Suzuki

CHAPTER NO. 1

INTRODUCTION

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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 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 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).

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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.

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.

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 the 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.
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Mart’s emphasis is 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.

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.

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 $
120.5 million), up 270 per cent over 2002-03.

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1200000

1000000

800000

600000 Exports Domestic Total

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400000

200000

0
1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 200

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 per cent 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.

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EXPORTS

In 2014-15, company exported 48,899 vehicles to 50 countries. There was a marginal

decline of 4.5 per cent in the export sale compared to 2013-14.

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.

Europe is the largest destination of Maruti’s exports where it is selling over 70% of its
exported quantity, and the top ten destination 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.

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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
I. 5 S

II. 4 M

III. 3 M

IV. 3 G

V. 3 K

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

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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 regarding 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

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DIFFERENT SHOPS IN MSIL

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 todesign
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:

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.

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

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6. Piling/ stacking

Stamping line

There are six presses of capacity varying from 1500T to 4000T.

Of these five are transfer presses and one is semi-automatic press line, wherein the loading is
manual. The die can be changed to obtain different body components.

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

Process Outline

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

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 sub 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.

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
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main body. The side body panels are prepared on the sub lines.

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.

Paint Shop
In the paint shop following processes is carried out

Pre-treatment

The body is thoroughly washed to remove the dirt and oil scales.

ED coat

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

Intermediate coat

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

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, i.e. the paint body ok is sent to the assembly shop.

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 1999)

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.

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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

Block line:

Main parts on the block line are:

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

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

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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

ASSEMBLY SHOP

The assembly shop receives the 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. Components of Zen, alto, wagon-r are fitted on a common assembly
line. The sequencing of models is done by PLC i.e. 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

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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

Major activities performed in Machine Shop

Process design/development and equipment planning for new engine components to be

machined in machine shop.

1. Procurement, installation and commissioning of new machining lines / Modification of

existing machining lines for new variants
2. Indigenization of machines for reduction in project cost
3. Development (Indigenization) of raw material for machine shop
4. Designing of Jigs, Fixtures and procurement of wear parts, inspection gauges
5. Development / Indigenization of cutting tools, holders and wear parts.
6. Preparation of standards related to Machine shop.
7. Support to shops for trouble shooting in operation and quality related problems

VEHICLE INSPECTION

Vehicle inspection has the following testing stations:

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

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 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 following repair areas depending upon the
type of defects:
a. Assembly repair
b. Weld repair
c. Paint repair
d. Engine assembly repair

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2.7 VEHICLE FLOW IN M.S.I.L

PRESSSHOP
PAINT SHOP
M/
CASTING
C
ENGINE ASSY. WELD SHOP
ASSY. SHOP

VEHICLE INSPECTION

STORAGE

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About The Project

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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.

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.

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

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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 repairing area we were supposed to
make the repairman module for the repair area and assembly line area.

1st 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 assembly line and repairing
area.

Following are the Module prepared in Excel sheet and presented in the report as the
image of the sheet.

WORK DONE

Repairman Training Module

GENERAL REPAIR

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APPEARANCE RELATED DEFECTS

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ELECTRICAL DEFECTS
4

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LOOSE PART RELATED DEFECTS

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SECONDARY DEFECTS

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GENERAL DEFECTS

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SYSTEM RELATED DEFECTS-1

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SYSTEM RELATED DEFECTS-2

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SPECIFIC REPAIR

Specific repair sub group is defined as inspection Check points to be checked

and repair methodology used for repairing specific vital part in vehicle i.e. steering
column repair, knuckle repair, brake fail repair, drive shaft repair etc. The module
prepared contains the checkpoints to be checked before repair, the repair method and the
checkpoints to be checked after repair including the relevant photographs.

Specific repair can be subdivided into the following repair areas:

1. Brake fail repair

2. Steering column repair
3. Knuckle repair
4. Door change and door hinge bolt repair
5. Drive shaft repair
6. Bumper repair
7. Instrument panel repair

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BRAKE FAIL REPAIR

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STEERING COLUMN CHANGE AND REPAIR METHOD

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KNUCKLE REPAIR METHOD

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DOOR CHANGE AND DOOR HINGE BOLT REPAIR

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3.4.2.5. DRIVE SHAFT CHANGE AND REPAIR METHOD

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BUMPER CHANGE AND REPAIR METHOD

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INSTUMENT PANEL REPAIR METHOD

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After the each excel sheet was prepared and completed, the data was sent to vendor so as to be
printed in flex and board. The sample image sent by the vender is given in fig 1.

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Finally the module was printed in A0 size board and displayed for centralized
information flow in the assembly line. The image of the board installed in the assembly line-
3 after completion of project is provided below in fig 2.

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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 Marutians’ will always be memorable.

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REFERENCES:
 Maruti Suzuki training guide book
 Maruti Suzuki Operating Standards (MOS)
 Maruti Suzuki Inspection Standards (MIS)
 Internet
 Work Instruction Sheets (WIS)

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