Final Report Maruti

Summer Training Project Report

Session 2010-2014

Repairman Training Module Submitted By Final Year Mechanical Engineering

NIT Jalandhar

Maruti Suzuki

ACKNOWLEDGEMENT I acknowledge my gratitude to my mentor , Mr. Vikram Wadhawan (ASSY-3, L12) Gurgaon plant. The supervision and support that he gave truly help the progression and smoothness of the internship program. The co-operation is much indeed appreciated. My grateful thanks also go to Mr. Sunil Gupta (ASSY-3, DPM) Gurgaon plant. A big contribution and hard worked from both of you during the six week is very great indeed. All projects during the program would be nothing without the enthusiasm and imagination from both of you. Besides, this internship program makes me realized the value of working together as a team and as a new experience in working environment, which challenges us every minute. Not forget, great appreciation go to the rest of MSIL staffs that help me from time to time during the project.

My grateful thanks also go to Dr. R.K.Garg ,Head of the Training & Placement and Dr. Subhash Chander, HOD Mechanical for giving me chance to be part of MSIL for the industrial training. Last but not least I would like to thank my friend Plash Monga who worked together as an intern at Maruti Suzuki India Limited for the wise ideas and help throughout the project that encouraged, supported and helped me in completing this program successfully.

Vishal Badyal 10109090 NIT Jalandhar

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TABLE OF CONTENTS 1. Introduction about the company 1.1. 1.2. 1.3. 1.4. 1.5. 1.6. 1.7.

Historical background Shareholding Maruti’s quality policy Quality system Employee quality measures Performance of MSIL Exports

2. Different shops in MSIL 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8.

Press shop Weld shop Paint shop Engine assembly shop Assembly shop Machine shop Vehicle inspection Vehicle flow in MSIL

3. About the project 3.1. Need for the Project 3.2. Objective 3.3. Research methodology 3.4. Work done 4. Conclusion 5. References

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INTRODUCTION 1.1 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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1.2 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.

1.3 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.

1.4 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. 4 | Summer Training Report 2013 10109090

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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.

1.5 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.

1.6 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

Exports

600000

Domestic

Total

400000

200000

0 1999-00

2000-01

2001-02

2002-03

2003-04

2004-05

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 200304. 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 200405.

1.7 EXPORTS In 2004-05, company exported 48,899 vehicles to 50 countries. of 4.5 per cent in the export sale compared to 2003-04.

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There was a marginal decline

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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.

MARUTI INSTALLED CAPACITY I. PLANT 1 - 200,000 units II. PLANT 2 - 150,000 units 7 | Summer Training Report 2013

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IV. PLANT 4 - 100,000 units

QUALITY TOOLS I.

5S

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

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 8 | Summer Training Report 2013

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NIT Jalandhar accordingly.    

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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

DIFFERENT SHOPS IN MSIL 2.1 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 to 9 | Summer Training Report 2013

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NIT Jalandhar Maruti Suzuki design 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:

2.1.1 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.

2.1.2 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. 2. 3. 4. 5. 6.

Uncoiling Cleaning Leveling Measuring Shearing/ cutting Piling/ stacking

2.1.3 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.

2.2 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

2.2.1 Process Outline

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

2.2.1.1 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.

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

2.2.1.3 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.

2.3 Paint Shop In the paint shop following processes is carried out

2.3.1 Pre-treatment The body is thoroughly washed to remove the dirt and oil scales.

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

2.3.3 Intermediate coat 11 | Summer Training Report 2013

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

2.3.4 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.

2.4. 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)

2.4.1 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.

2.4.1.1 Cylinder head line: 12 | Summer Training Report 2013

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NIT Jalandhar Maruti Suzuki A sub assembly integrating the throttle body, inlet and exhaust manifold and fuel injectors cater to this line. Main 1. 2. 3. 4. 5. 6.

parts: Inlet and exhaust valves Cotter valves Retainer springs Rocker arm assembly Throttle body Inlet and exhaust manifold

2.4.1.2 Block line: Main 1. 2. 3. 4. 5. 6. 7.

parts on the block line are: Crankshaft Pistons Oil pan Alternator/generator Starter motor Flywheel Clutch

2.4.1.3 Transmission line Several sub-assemblies involved in making the input shaft, countershaft etc. supply to the T/M line.

Main 1. 2. 3.

parts are: Clutch release shaft Gear box assembly Transmission oil pan

2.4.1.4 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 13 | Summer Training Report 2013

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NIT Jalandhar 3. 4 A.C Compressors 4. Water pump 5. Air filter

Maruti Suzuki

2.5 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

2.6 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

2.6.1 Major activities performed in Machine Shop

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NIT Jalandhar Maruti Suzuki 1. Process design/development and equipment planning for new engine components to be machined in machine shop. 2. Procurement, installation and commissioning of new machining lines / Modification of existing machining lines for new variants 3. Indigenization of machines for reduction in project cost 4. Development (Indigenization) of raw material for machine shop 5. Designing of Jigs, Fixtures and procurement of wear parts, inspection gauges 6. Development / Indigenization of cutting tools, holders and wear parts. 7. Preparation of standards related to Machine shop. 8. Support to shops for trouble shooting in operation and quality related problems

2.7 VEHICLE INSPECTION Vehicle inspection has the following testing stations: a. Toe in test b. Slip test c. Headlamp test d. Appearance test e. Drum test f. Brake test g. Shower test h. Road test i. Final check

2.7.1 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

2.7 VEHICLE FLOW IN M.S.I.L

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CASTING

PRESS SHOP

ENGINE ASSY.

WELD SHOP

M/C SHOP

PAINT SHOP ASSY. SHOP VEHICLE INSPECTION

STORAGE

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About The Project 17 | Summer Training Report 2013

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3.1 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.

3.2 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.

3.3 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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NIT Jalandhar Maruti Suzuki 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.

3.4 WORK DONE Repairman Training Module 3.4.1 GENERAL REPAIR

3.4.1.1 APPEARANCE RELATED DEFECTS 19 | Summer Training Report 2013

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3.4.1.2 ELECTRICAL DEFECTS 20 | Summer Training Report 2013

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3.4.1.3 LOOSE PART RELATED DEFECTS

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3.4.1.4 SECONDARY DEFECTS

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3.4.1.5 GENERAL DEFECTS

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3.4.1.6 SYSTEM RELATED DEFECTS-1

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SYSTEM RELATED DEFECTS-2

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3.4.2 SPECIFIC REPAIR Specific repair sub group is defined as inspection Check points to be and repair methodology used for repairing specific vital part in vehicle i.e. column repair, knuckle repair, brake fail repair, drive shaft repair etc. The prepared contains the checkpoints to be checked before repair, the repair method checkpoints to be checked after repair including the relevant photographs.

checked steering module and the

Specific repair can be subdivided into the following repair areas: 1. 2. 3. 4. 5. 6. 7.

Brake fail repair Steering column repair Knuckle repair Door change and door hinge bolt repair Drive shaft repair Bumper repair Instrument panel repair

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3.4.2.1 BRAKE FAIL REPAIR

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3.4.2.2 STEERING COLUMN CHANGE AND REPAIR METHOD

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3.4.2.3 KNUCKLE REPAIR METHOD

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3.4.2.4 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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3.4.2.6 BUMPER CHANGE AND REPAIR METHOD

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3.4.2.7 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.

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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