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car available in India, its' only competitors- the Hindustan Ambassador and Premier Padmini were both around 25 years out of date at that point.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.

Its manufacturing facilities are located at two facilities Gurgaon and Manesar south of New Delhi. Marutis 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. Suzukis 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 Marutis mission to motorize India.

PRODUCT RANGE

MODELS MARUTI 800 (FIRST MODEL) OMNI GYPSY MARUTI 800 (MODIFIED) MARUTI 1000 ZEN ESTEEM 1.3L LX ESTEEM 1.3L VX ESTEEM 1.3L AX ZEN AX (AUTOMATIC) GYPSY KING OMNI (E) GYPSY (E) MARUTI 800 (NEW MODEL) ESTEEM 98 NEW OMNI & OMNI-E ZEN VX & ZEN VX AUTOMATIC ZEN D MARUTI 800 EX ZEN LX

SPECIFICATIONS 796CC, HATCHBACK 796CC, MUV 992CC, 4WD 796CC, HATCHBACK 996CC, SEDAN 996CC, HATCHBACK 1296CC, SEDAN 1296CC, SEDAN 1296CC, SEDAN 996CC, HATCHBACK 1296CC, 4WD 796CC, MUV 1296CC, 4WD 796CC, HATCHBACK 1296CC, SEDAN 796CC, MUV 996CC, HATCHBACK 1200CC, HATCHBACK 796CC, HATCHBACK 996CC, HATCHBACK

YEAR OF LAUNCH DECEMBER 1983 NOVEMBER 1984 DECEMBER 1985 APRIL 1986 OCTOBER 1990 OCTOBER 1993 NOVEMBER 994 NOVEMBER1995 JUNE 1996 OCTOBER 1996 NOVEMBER1996 DECEMBER 1996 DECEMBER 1996 SEPTEMBER 997 OCTOBER 1997 FEBRUARY 1998 JULY 1998

AUGUST 1998 JANUARY 1999 JANUARY 1999

ZEN CLASSIC ZEN VXI OMNI XL BALENO WAGON R

996CC, HATCHBACK 996CC, HATCHBACK 796CC, MUV 1586CC, SEDAN 1096CC, HATCHBACK 1586CC, HATCHBACK (BALENO) 796CC, HATCHBACK 1296CC, MUV 1296CC, HATCHBACK 1096CC, HATCHBACK 1296CC, HATCHBACK

AUGUST 1999 OCTOBER 1999 OCTOBER 1999 DECEMBER 1999 JANUARY 2000

ALTURA ALTO LX, LXI VERSA SWIFT ZEN ESTILO SWIFT DIESEL SWIFT DIESEL GRAND VITARA SX4 SWIFT DZIRE A- STAR RITZ

MARCH 2000 SEPTEMBER 000 DECEMBER 2001 MAY 2005 DECEMBER 2006 FEBRUARY 2007 FEBRUARY 2007 MARCH 2007

1.600CC

MAY 2007 MARCH 2008 NOVEMBER 2008 MAY 2009

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)

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 ) of 60 Capacity of 55,000 strokes / day from 400 tons of steel coils SPM

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

Yield Improvement

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.

ED DIP

WR I

WR II

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+/5C.

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)