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com/

PROJECT REPORT
ON

Auto closing system (Concept, design & fabrication)

of floor service pit to improve safety of human.

SUBMITTED BY

-------------------
4TH YEAR ELECTRICAL ENGINEERING
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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 kei 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Hindustan Ambassador and Premier Padmini were both around 25 years out of date at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.
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It’s manufacturing facilities are located at two facilities Gurgaon and Manesar south of
New Delhi. Maruti’s 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. Suzuki’s 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.
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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 Maruti’s 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.

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 Production of Vehicles in large volumes, which was necessary for economic
growth.
 Production of Fuel-efficient vehicles to conserve scarce resources.

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 Non-
Government Company with a total Equity base of Rs. 1322.92 million.

BACKGROUND OF SMC
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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 Japan’s largest
manufacturers of small , fuel-efficient cars. At present the company’s name is SUZUKI
MOTOR CORPORATION.

SUZUKI AND MARUTI’S 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:

 MSIL’s 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)

 SMC’s 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

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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!
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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

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A PRIDE OF INDIA

 As a corporate citizen

 Products

 People

 Practices

 Customers

VALUES

 Customer Obsession

 Fast, Flexible, First Mover

 Innovation and creativity

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 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.

DO
PLAN

QUALITY
POLICY

ACT CHECK
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QUALITY TOOLS

 5S
 4M
 3M
 3G
 3K

What is 5S?

SEIRI – PROPER SELECTION

SEITION – ARRANGEMENT

SEISO – CLEANING

SEIKETSO – CLEANLINESS
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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:

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MURI – INCONVENIENCE

MUDA – WASTAGE

MURA – INCONSISTENCY

What is 3G?

In Japanese Language 3G is:

GENCHI – GO TO ACTUAL PLACE

GENBUTSU – SEE THE ACTUAL THING

GENJITSU – TAKE APPROPRIATE ACTION

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INTRODUCTION TO VARIOUS MODELS

PRODUCT RANGE

MODELS SPECIFICATIONS YEAR OF LAUNCH

MARUTI 800 (FIRST

796CC, HATCHBACK DECEMBER 1983
MODEL)

OMNI 796CC, MUV NOVEMBER 1984

GYPSY 992CC, 4WD DECEMBER 1985

MARUTI 800 (MODIFIED) 796CC, HATCHBACK APRIL 1986

MARUTI 1000 996CC, SEDAN OCTOBER 1990

ZEN 996CC, HATCHBACK OCTOBER 1993

ESTEEM 1.3L LX 1296CC, SEDAN NOVEMBER 994

ESTEEM 1.3L VX 1296CC, SEDAN NOVEMBER1995

ESTEEM 1.3L AX 1296CC, SEDAN JUNE 1996

ZEN AX (AUTOMATIC) 996CC, HATCHBACK OCTOBER 1996

GYPSY KING 1296CC, 4WD NOVEMBER1996

OMNI (E) 796CC, MUV DECEMBER 1996

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GYPSY (E) 1296CC, 4WD DECEMBER 1996

MARUTI 800 (NEW

796CC, HATCHBACK SEPTEMBER 997
MODEL)

ESTEEM 98 1296CC, SEDAN OCTOBER 1997

NEW OMNI & OMNI-E 796CC, MUV FEBRUARY 1998

ZEN VX & ZEN VX JULY 1998

996CC, HATCHBACK
AUTOMATIC

1200CC,
ZEN D AUGUST 1998
HATCHBACK

MARUTI 800 EX 796CC, HATCHBACK JANUARY 1999

ZEN LX 996CC, HATCHBACK JANUARY 1999

ZEN CLASSIC 996CC, HATCHBACK AUGUST 1999

ZEN VXI 996CC, HATCHBACK OCTOBER 1999

OMNI XL 796CC, MUV OCTOBER 1999

BALENO 1586CC, SEDAN DECEMBER 1999

1096CC,
WAGON R JANUARY 2000
HATCHBACK

1586CC,
ALTURA HATCHBACK MARCH 2000
(BALENO)

ALTO LX, LXI 796CC, HATCHBACK SEPTEMBER 000

VERSA 1296CC, MUV DECEMBER 2001

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1296CC,
SWIFT MAY 2005
HATCHBACK

1096CC,
ZEN ESTILO DECEMBER 2006
HATCHBACK

1296CC,
SWIFT DIESEL FEBRUARY 2007
HATCHBACK

SWIFT DIESEL FEBRUARY 2007

GRAND VITARA MARCH 2007

SX4 1.600CC MAY 2007

SWIFT DZIRE MARCH 2008

A- STAR NOVEMBER 2008

RITZ 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

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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 company’s 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.

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The hierarchy diagram of MSIL

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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
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 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
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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
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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 personnel’s 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 company’s information
needs were not affected.
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Project
Safety system on floor pit to provide protection against fall
inside it
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Air cylinder Pit cover

Tyre sensors

Area
sensors
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Project Description

 Open pit 4x2 square meter & 2 meter deep is provided inside the working area for

repairing under the vehicles.

 The pit is open from top , side safety railings can not be provided as vehicles are to

be brought on it by starting & there were some incidents of working operators falling

inside & getting serious injuries.

 Manual covers were being used to cover it but due to absence of any fool proof

system many times pit remains open from top.

Objective

 To provide fool proof safe cover over pit which can be automatically operated when

vehicle is brought over it & as soon as vehicle is taken off from it the cover should

automatically close.

 Pit should not be closed when operator is standing inside pit & waiting for next

vehicle to come
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 Auto closing to have clearance from Safety department & no extra material to be

procured from outside, only in-house material available inside the Maintenance

department to be used

Methedology adopted

 Initial study was done on site to check the safety risk, it was found that the pit can

not be reallocated to other area & it is required to carry on the repairs.

 Manual cover is not used to closed the pit as it is very heavy & slips when somebody

walks on it.

 Idea of providing a horizontal gate over pit with guided rails came, in this a gate was

fabricated as per opening’s size & rollers were provided on corners & rails were

provided to guide

rollers to traverse

smoothly.
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 The system worked well & with a push of hand the cover could be closed & opened.

But the problem of this system was nobody closed it after use & it is kept in open

condition many times & in open condition the risk of falling inside pit was still

persisting.

 More study was done to provide automatic system on door so that it can open &
closed automatically as per requirements.

 It was thought that a pneumatic cylinder should be provided to slide the gate over pit

which will be operated by providing sensing system .

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CASE NO-1 : 4 sensors were provided on top of pit where front tyres are positioned .

Sensors will sense the presence of vehicle on pit & will send signal to control panel to
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open the air valve solenoid which will operate the gate by activating the air cylinder

towards open position.

After the gate opened the operator could do the repair work from beneath the vehicle.
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After the job is finished the car is driven off the pit. The issue of closing back the door

automatically remained.

CASE NO-2 : When vehicle is driven off the pit the door remains open & risk of falling

inside pit remains there, in this case the de-activation of sensors S1 & S2 is linked to

auto closing of pit

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The problem of automatically closing & opening the pit door was solved by activating &

de-activating the sensors S1 & S2.

SAFETY CONCERN : In case someone is standing between the closing door &
does not notice the movement of closing the door he can be trapped in between the
door & pit wall & serious accident can happen.

New idea of closing the door in between in case some one or some object comes
between at the time of closing the door by pneumatic pressure.

CASE NO-3 : At the time of closing of door if someone or some object comes in
between the door 2 area sensors (S3) provided at both sides of pit which will sense the
presence of human or object & will stop the door suddenly & get it reversed to its home
(OPEN) position. With this system no one will be trapped between moving door & pit
wall
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CASE NO-4 : At the time of closing the door if nothing is inside the pit & both area

sensors are clear of any obstruction the door will be closed safely & nobody will fall

inside the pit

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DOUBLE ACTING CYLINDER

5/2 DOUBLE PILOT

SOLENOID VALVE

3/2 SPRING
RETURN PUSH 3/2 SPRING
BUTTON RETURN PUSH
BUTTON

F R L

COMPRESSOR
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CIRCUIT DIAGRAM

The safety project implemented by the team is working in MSIL Gurgaon plant in

Assembly Shop-3 since 1st week of December’2009.

It was a great learning experience by working in a team. Mr. Manoj Attri (Engineer MP2)

& his team has helped me in completing the project in time.

They provided me with every help from arranging the material & getting the structures

fabricated.
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