Maruti - Vehicle Manufactering Process - Electrical Engg. (EE) Summer Industrial Trianing Project

PROJECT REPORT
ON
 Study of vehicle manufacturing processes from raw material

to finish vehicles.
SUBMITTED BY
-------------------
TH
4 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Hindustan Ambassador and Premier Padmini were both around 25 years out of date at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.
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.

 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
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.
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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

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
 PALNT 3 150,000 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

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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
QUALITY TOOLS
 5S
 4M
 3M
 3G
 3K
What is 5S?
SEIRI – PROPER SELECTION
SEITION – ARRANGEMENT
SEISO – 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 – 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

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
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
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
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.

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)

 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 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.
Production Division of Maruti Suzuki India Limited
Production Division in Maruti Suzuki India Limited has been renamed as
Production Business Vertical (PBV) after inclusion of Projects, Production
Engineering, Vehicle Inspection & Supplier Quality Assurance divisions in it.
Major components of PBV
 Press Shop and Blanking Line
 Weld Shop (1,2 & 3)
 Paint Shop (1,2,& 3)
 Engine Assembly (1,2,& 3)
 Assembly Shop (1,2,& 3)
 Machine Shop (1,2,& 3)
 Materials – X (1,2,& 3)
 Plant maintenance
 KB Casting
 KB Engine
 KB Machine Shop
 Production facility at Manesar Plant
 SQA (Supplier Quality Assurance)
 Production Engineering & Projects
 Vehicle Inspection (VI)

Milestones
 Maruti Udyog Ltd. was incorporated.
1981
 Stepped into a JV with SMC of Japan.

1982
 Maruti 800, a 796 cc hatchback, India's first affordable car

1983 was produced.
 Installed capacity reached 40,000 units. Omni, a 796 cc MUV

1984 was in production.
 Launch of Maruti Gypsy (970cc, 4WD off-road vehicle).

1985
 Produced 100,000 vehicles (cumulative production).

1986
 Exported first lot of 500 cars to Hungary.

1987
 Installed capacity increased to 100,000 units.

1988
 SMC increases its stake to 50 per cent.

1992
 Produced the 1 millionth vehicle since the commencement of

1994 production.
 Second plant launched, the installed capacity reached

1995 200,000 units.
 Launch of 24-hour emergency on-road vehicle service.

1996
 Produced the 2 millionth vehicle since the commencement of

1997 production.
 Launch of website as part of CRM initiatives.

1998
 Launch of Maruti - Suzuki innovative traffic beat in Delhi and

Chennai as social initiatives.
1999
 IDTR (Institute of Driving Training and Research) launched

2000 jointly with Delhi government to promote safe driving habits.
2001  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
2002 Mumbai.
 Start of Maruti True value in Mumbai.
 Production of 4 millionth vehicle.

2003
Listed on BSE and NSE after a public issue oversubscribed 10
times.
 Maruti closed the financial year 2003-04 with an annual sale

of 472122 units, the highest ever since the company began
2004
operations 20 years ago.
 The fiftieth lakh car rolls out in April, 2005.

2005.
 Maruti tops jd power csi survey for record seventh time in a

2006. row
 Govt of India awarded O SUZUKI with coveted padma bhusan

 Board of directors give approval to new name MUL to become
2007
maruti Suzuki India limited.
 M-800 crosses 25 lakh mark

 MSIL celebrates SILVER JUBILEE
2008.
 MSIL launches national road safety program.
 Capacity to manufacture expanded from 800,000 to a million

units(Gurgaon plus Manesar) annually
2009  All India engineering export promotion council(EEPC) award.
 MSIL achieved highest sales ever in Dec’2009
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 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 to design secrecy and huge investment requirements. ‘B’ and ‘C’
components are manufactured by joint ventures or bought from vendors.
Process flow of Press Shop activity :-
Steel coil Blank Panel
1. Currently Press Shop is producing sheet metal components for 8 running

models of Maruti Suzuki and one model of GM India - Tavera
2. The Blanking and stamping shop processes 10000 metric ton of steel / month
i.e. 400 tons a day
Machine :
 Five Transfer Press ( 4000 ton , 3500 ton , 2400 ton -1 2400 ton -2 ,
2000 ton in terms of total capacity i.e. draw+trim+pierce+bend+restrike ) &
1 Tandem line( 1500 ton draw capacity )
 Two Coil processing lines ( ROSL – Shear line & Blanking line ) SPM
of 60
 Capacity of 55,000 strokes / day from 400 tons of steel coils
4000 Ton
transfer
press
Pressed panels
come out from
this side
Press Machine : Mass production presses are continuous flow transfer presses. Set
of 4 to 5 dies are mounted on single press & complete panel comes out from press after
going through stamping, trimming & piercing.
 189 die sets (including 15 die sets of GMI) – 1 die set has avg 4 upper +
lower dies
SMED : “Single Minute Exchange of Dies” new concept being adopted . This concept
helps in changing of die set up within single digit minute (below 9 minutes) This helps us
in improving machine utilization & operating efficiency. Since press machines are very
high cost investment & any idle time lost due to die exchange will be a cost to company.
Upper die Lower die

Yield improvement (Ratio of output panel to input coil in weight) is Best amongst
the SMC group Companies. ( Presently at 63.2% )
Modifications to improve yield are continuously done & till Oct-09 Press Shop has saved
Rs. 7.786 millions of material in current year
120
105
Yield Improvement
100
77.86
80
56.94
50.12
LACS
46.2
60
29.6
40
21.0
13.0
20
0
Apr 09 May 09 Jun 09 Jul 09 Aug 09 Sep 09 Oct 09 Nov 09 Dec 09 Jan 10 Feb 10 Mar 10 Target
(09-10)
Yield is improved by
1. Reducing the blank size
2. Utilization of scrap for making smaller sheet metal parts

Steel Coils
 Steel coil is raw material used to make body sheet metal parts. These are
CRS coils made of mild steel having thickness from 0.65 mm to 0.8 mm &
weight from 1 ton to 4 tons.
 Steel coils are received in bulk quantities from indigenous as well as

foreign suppliers in the ratio of 60 to 40 & stored at a centralized storage &
supplied to blank cutting areas as per plan
 Steel coils are fed to Blanking & ROSL lines by overhead EOT cranes.
Sheet is first de-coiled , cleaned, oiled & fed to cutting or shearing areas of
blanking or ROSL lines.
Blank
 Coils are fed to blanking line & continuous supply of sheet to cutting dies
result in shaping of coils to plan blanks.
 Blanks are cut by stamping or shearing process & are stacked one by one to
form large mass of blanks
 These stacks of blanks are further sent to press machines for forming into
shape of body panels
Stack of blanks
Panel
Blanks are supplied to press lines for pressing. Blanks are converted to body panels
by this process. Panels are stored in pallets which are supplied to Weld Shops for
making White Bodies.
Panels re
stacked in
pallet
trolleys
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.
 Welding jigs
 Spot welding guns
 Kawasaki welding robots
 Hemming machines
 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 comprise
of rear underbody, central underbody, front engine room panel. These underbodies are
put on the conveyor and welded together to give the underbody.
MAIN BODY: As the body moves on, 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.
WHITE BODY: The doors, hood and back door are attached on the main body with the
help of bolts and screws 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 are carried out: -
There are five plants/units that provide a uniform painting over the white body coming
from the weld shop. In paint shop all the models are painted on the same line. The five
units are: -
 Pre-treatment (PT): The body is thoroughly washed to remove the dirt and oil
scales. Then the body is treated with ZnPO4 (phosphating) to prevent corroding
of the body.
 ED coat: This is done by electric deposition method, at 240V-DC supply. After
applying the ED coat the body is baked in oven.
 Sol-sealer and under coat: Here the left in the body (due to welding) are filled
with sol-sealer to provide water proofing. Under coat is done on the surface
above wheels to prevent damage of body in that portion.
 Intermediate coat: This is done by spray-painting method using 10 Kawasaki
Robots. After applying the coat, the body is dried in the oven. Painting done is
basically an intermediate coating to provide base for the final coat.
 Top coat: This is done by spray-painting method using 20 Kawasaki Robots. For
metallic coating, double coats are applied and aluminum flakes are provided to
shine the metallic paints.
After inspection and touch up, the PBOK, i.e. the paint body ok is sent to the assembly
shop.
In paint shop II, only ZEN and ALTO are painted. Paint used is Nerolac. There are 4
coatings of paint.
1] Phosphate coating
2] ED coating
3] IC coating
4] TOP coating
Inside portion of vehicle is painted manually and outside is by Robots.

PRE TREATMENT:
Before sending vehicle to painting process pretreatment is done to
WBS
Hot water rinse Spray degreasing Dip de
SURFACE CONTROL WR III WR II WR I
PHOSPHATING WR IV WR V WR VI WR VII
ED PROCESS DI WATER MIST
ED PAINTING:
ED is electro deposition. Vehicle is dipped in the ED solution. In this around 300V is
passed to make paint to be attached. ED is 17% of paint rest is water and some
additives (EDD, M).

PROCESS:
The whole solution of ED acts as electrolytic solution. Vehicle before coming to ED dip,
it undergoes pre treatment. In that phosphating is done, in which Zn phosphate is made
to attach vehicle body which help in electro deposition, in this, vehicle acts as cathode
and paint as positive ions. When current is passed paint will be attracted by vehicle till
its thickness will be covered. ED is very accurate to apply. This is about whole process.
Rinsing is done after to remove excessive color. In rinsing industrial water is used which
will not be left go waste. That will be filtered and used again.
WR I WR II
ED DIP
WR IV WR III RINSING BY DIPPING
WR V DI WATER OVEN
ULTRA FILTRATION:
Ultra filtration is the process in which all the rinse pipes and dip tanks will be filtered and
cleaned, by this way water is recycled. Here Osmosis process is used to filter water.
IC painting:
IC is intermediate coating in which 3 colors are used. They are white, blue and red.
Outside portion of vehicle is painted by robots and inside is done manually. Paint
thickness is taken care, after that vehicle is sent to IC oven. Oven temperature is 198+/-
5’C.
TOP COAT Painting:
Top coating is done after checking in Dry sanding II. There are 2 sub coatings Base coat
and Clear coat. Here 11 colors are used; 8 metallic and 3 solid. Only metallic colors are
coated with clear coating. Here also outside portion of vehicle is painted by robots and
inside is done manually.
Next vehicle will move to final inspection and will be sent to assembly.
DRY SANDING
 Following repairs are done:
1. Roof sanding
2. Side repair if any.
 Following checking is done:
1. Dosing mark
2. Sanding mark
SOL SEALING LINE:
 Sealer appearance is given the preference.
 3 types of guns are used.
1. Pencil gun
2. Flat gun
3. Blind gun
4. Moti gun
 In this line followings are checked;
1. Powder dust
2. Extra sealer
3. Pin hole in lamp area
4. Sealer appearance
PROCESS THROUGH PICTURES:

PB ON(WHITE BODY) PRE TREATEMENT
ELECTRO DEPOSITION PROCESS
DRY SANDING I SOL SEALING LINE PVC COATING
IC OVEN IC COATING
DRY SANDING II
TC OVEN TC COATING
FINAL INSPECTION TO ASSEMBLY SHO

ASSEMBLY SHOP
In the assembly shop the body is loaded on an overhead conveyor. As the conveyor
moves the body, fitments are made at various stations. There are three Assembly
Shops named ASSY-1, ASSY-2 and ASSY-3. Plant 2 and Plant 3 have similar setup but
in Plant-1 there are separate assembly lines for separate models. The assembly shop
has a continuous production system. The assembly line can be subdivided into the
followings: -
(a) Trim line
The vehicle proceeds through a series of Trim workstations where team members begin
by installing weather stripping, moldings and pads. Then they put in wiring, vents and
lights. After an instrument panel, windows, steering column and bumper supports are
added, it starts to look less like a shell and more like a car.
(b) Chassis Line
This is where many safety-related items are installed. Things like brake lines, torque,
gas tanks and power steering are double-checked. The engine is installed, along with
the starter and alternator. Then come suspension and exhaust systems. Then wheel is
mounted with the help of wheel nut fastening machine.

(c) Final Line
From there the vehicle enters Final 1, which covers many interior items such as the
console, seats, carpet, glove box and steering wheel. This is also where bumpers, tires
and the battery are added, as well as finishing touches like covers and vents. Then,
Coolant, Brake oil, Power steering oil are filled and also the A/C gas are charged.
Features
Different assembly shop layouts are followed to reduce material handling operations &
to facilitate material flow between workstations.
a) Straight-line layout – Car & omni line (Assy shop-1): Simplest layout in which
material enters at 1 end & leaves at the other end.
b) U shape layout – Assy shop 2 & 3: Receiving & shipping ends of line are at
same end of plant, due to material handling considerations (same forklift for both
needs) or external needs.
c) S shape layout – Esteem line (AS-1): Serpentine layout to fit longer assy line in
square shop.
Separate door Assy line: - Doors are taken out from the vehicle at the first station of the
trim line. Doors fitted in the final line make working easier.
OTHER SHOPS/DEPARTMENTS
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 are aluminum castings while crankshaft and
camshaft are steel forgings.
It has the following lines:
(a) Transmission case line
(b) Cylinder head line
(c) Cylinder block line
(d) Crankshaft line
(e) Camshaft line.
ENGINE ASSEMBLY
There are four types of engines which are assembled in the Engine Plant
1. FC Engine – Engine with cast iron block
a. M-800
b. Omni
c. Alto
d. Wagon-R
e. Zen Estillo
2. Aluminum Engine – Engine with aluminum block
a. Gypsy
b. SX4
c. Swift (Petrol)
d. Dezire (Petrol)
3. KB Engine (New series of engines with aluminum block)
a. A-Star
b. Ritz
4. Diesel Engine
a. Swift (Diesel)
b. Dezire (Diesel)
c. Ritz (Diesel)
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Maruti - Vehicle Manufactering Process - Electrical Engg. (EE) Summer Industrial Trianing Project

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PROJECT REPORT

 Study of vehicle manufacturing processes from raw material

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BACKGROUND OF THE INDIAN AUTO INDUSTRY

 Modernization of Indian Automobile Industry.

Choice of product and collaborator

 required technological expertise and experience in producing high quality, reliable

SUZUKI was founded in 1909 as Suzuki Loom Manufacturing Company. It started

SUZUKI AND MARUTI’S WORLD-CLASS MANUFACTURING

On February 06,2007 Mr. Bhupendera Singh Hooda , Chief Minister of Haryana

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The facilities inaugurated were as follows:

 MSIL’s fourth car Assembly plant.

 SMC’s two-wheeler plant in Gurgaon, Suzuki Motorcycle India Private Limited

INTRODUCTION TO MARUTI SUZUKI INDIA LIMITED

 A License and a Joint Venture Agreement was signed with Suzuki

 Market leader with over 54% Share in Domestic Car Market

 Maruti has revolutionized the Indian Automobile and Component

MARUTI INSTALLED CAPACITY

 PLANT 1 200,000 units

 PLANT 2 150,000 units

 PALNT 3 150,000 units

 PLANT 4 100,000 units

 A leader in the Indian Automobile Industry.

 Creating Customer Delight and Shareholders wealth.

 By Market share and brand equity

 Values for money

SHARE HOLDERS WEALTH

 High Profitability & Image

 Fast, Flexible, First Mover

 Innovation and creativity

 Networking and partnership

 Openness and learning

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To increase consumer satisfaction through continuous improvement of products and

SEIRI – PROPER SELECTION

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