INDUSTRIAL TRAINING

Exposure to Weld Shop

Maruti Suzuki India Limited

Submitted to: Submitted by:

Dr. K.D. Gupta Bharat Pahuja
Dr. M.N Mishra Roll No.: 18001004903
Mechanical Dept. Mechanical
1
Training Certificate

2
Contents
1) Introduction to company profile
1.1) Introduction
1.2) Manufacturing facilities
1.3) Models by MSIL
1.4) Verticals in MSIL
1.5) Standard practices in MSIL

2) Overview to Production Vertical

2.1) Divisions involved in manufacturing of a car

3) Overview to Weld Shop

3.1) Safety precautions & PPE
3.2) Introduction to Industrial robots
3.3) Classification of robot
3.4) Introduction to Welding
3.5) Types Of Robotic Guns Used In Spot Welding
3.6) Shop layout

3
4) Introduction to Project
4.1) Introduction
4.2) Inspection
4.3) Types of spot welding
4.4) Destructive & non destructive testing (heading)
4.5) Typical spot welding defects
4.6) Auditing of MOS check sheets

4
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

1.3) Models by MSIL

Maruti Suzuki is currently having 16 models in their portfolio with a price range
of 3 Lacs ~ 12 Lacs. (i.e. Alto,Wagon-R,Swift,Dzire,Ciaz,Brezza,Ignis etc). 5
 1.4) Verticals in MSIL

MSIL

QA Supply Chain Production HR, IT & Sales &

Finance Marketing

1.5) Standard practices in MSIL

Japanese Norms:
5S 3G
SEIRI - Sort GENCHI - GOTO THE SPOT
SEITON - Set in Order GENBUTSU - SEE THE ACTUAL PROBLEM
SEISO - Shine, GENJITSU - TAKE THE REALISTIC
SEIKETSU - Standardize ACTION
SHITSUKE - Sustain.

6
Glimpse from Maruti’s Model Portfolio

7
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 8
3.1) Personal Protective Euipment (PPE) Used in Welding :

 Goggles

 Helmet

 Safety Glasses

 Ear plugs

 Flame Retardant Clothing

 Gloves

 Safety Foot ware

9
3.2) INDUSTRIAL ROBOT

An industrial robot is an automatically controlled, reprogrammable, multipurpose

manipulator programmable in three or more axes

Manipulator
Welding gun Controller

Servo
controlled Air/water
axes Integrated supply
cables 10
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 11
3.4) Introduction to Welding

Types of welding used in MSIL Weld Shop:

Spot welding
CO2 welding
Brazing
Stud Welding
Nut Welding

12
SPOT WELDING MIG WELDING

STUD WELDING NUT WELDING

13
3..5 ) TYPES OF ROBOTIC GUNS USED IN SPOT WELDING

X- TYPE ROBO GUN C -TYPE GUN

Also known as “scissors” C guns are generally the cheapest and

or “pinch” the most commonly used

14
3.6) Shop Layout :

Each line is divided into 5 main areas as :

 Under Body
 Main Body
 Side Body
 Door Line
 White Body

15
PROJECT REPORT ON
Spot Verification As Per Engg. Dwg.
&
Auditing of MOS Check sheets
(MOS: MARUTI OPERATION STANDARDS)

16
4.1) Introduction
Weld quality plays a very important role in welding of body components reason
being if the weld quality is poor, having the defects or not as per the designed
parameters then in the later stages these welding defects can cause functional
issues in vehicle or any sheet metal failures.

To ensure the that welding & fitment is per the design parameters, there are
various check sheets in which various set parameters are checked like:

4.2 Inspection

4.21 Design vs. Actual Spot pitch

4.22 Design vs. Actual torque values
4.23 Design vs. Actual level difference (LD) & gap measurement in door, hood
with respect to body
4.24 Design vs. Actual Weld bead lengths

17
4.21) Design vs. Actual Spot pitch:
 A typical automotive car body consists of about 300 sheet metal parts, joined
by about 3500-4000 spot welds.

 As the automated assembly process is not perfect, some spot welds may be
absent when the vehicle leaves the assembly line.
The actual spot weld position compared to nominal spot weld position as per
Engg.Drwng :

18
FLOOR BODY
4.22) Design vs. Actual torque values (Sample Check
sheet):
Auditing plays a very important role in order to confirm or to assure the processes
that are being carried out are in accordance or in compliance with the standards or
set parameters
Area : Vehicle Body Shift : Date :

Time :
Component Lot : 1 2 3

Bolt Count
LH : LH : LH :
LH-4
RH : RH : RH :
RH-4
Front Door Bolts
4 no's both LH/RH Torque Range
40-50 40-50 40-50
(In Nm)

Min/Max

Bolt Count
LH : LH : LH :
LH-2
RH : RH : RH :
RH-2
Hood Bolts
2 No's both LH/RH Torque Range
30-40 30-40 30-40
(In Nm)

Min/Max
19
4.23) Design vs. Actual level difference (LD) & Gap
Measurement (Sample check sheet) :
Level Difference (LD):
Level difference or LD as it is commonly called is the difference in the levels of two
consecutive panels of the car body.

Body Gap:
The term body gap includes the gap that must be present between two consecutive
panels.
Door Photograph Area : Vehicle Body Date :

Time :
Door Model : Eeco Super Carry

Point A Gap (In mm) 5 +/- 1 6 +/- 1

A
Measured/Corrected 40-50 40-50

B Point B Gap (In mm) 3 +/- 1 4 +/- 1

LH : LH :
C D
Measured/Corrected
RH : RH :

LD b/w C &D In mm 2 +/- 0.5 3 +/- 0.5

Measured/Corrected
20
4.3) Types of spot welding

1. Single spot weld positions by direct welding

2. Series multiple-spot welding
3. Direct multiple-spot welding

4.4) Destructive & non destructive testing

Destructive Tests Non-destructive Tests

Tension Test  Visual Test
 Impact Test  Radiographic Test
 Torsional Test  Ultrasonic Test
 Fatigue Test
 Bend Test
 Hardness Test

21
4.5) Typical spot welding defects
 The main reasons of this failure are:
 Improper surface or electrode condition
 Excessive welding current
 Insufficient welding pressure
 Improper fit-up of parts
 Improper weld sequence timing

I. Cracks
II. Porosity
III. Stick Weld
IV. Sheet Metal Distortion
V. Nugget Diameter
Cracks Stick Weld

22
Nugget Sheet Distortion
THANK YOU

23