INDUSTRIAL TRAINING REPORT

AT MARUTI SUZUKI INDIA LIMITED

SUBMTTED FOR PARTIAL FULFILLMENT OF REQUIRE MENT FOR THE

AWARD OF DIPLOMA IN MECHANICAL ENGINEERING

PUSA INSTITUTE OF TECHNOLOGY

NEW DELHI -110012
DEPARTMENT OF MECHANICAL ENGINEERING

SUBMITTED BY SUBMITTED TO
NITIN SH. L.P SINHA
1708131230 ( SR. LECTURER MECH.
MECH – 5th SEM (EVENING ) ENGG. DEPARTMENT )
Certificate
ACKNOWLEDGEMENT

The four-week industrial training is indeed the most important and integral part of our curriculum at the
Mechanical Engineering Department at PUSA Institute of Engineering and Technology, New Delhi

This industrial training gives us an ample opportunity to develop a veritable and first hand industrial
experience not only towards technical but all round development also. Being able to see and learn
about the actual implementation of the subjects we study is indeed a valuable experience.

The work culture of the leading industrial establishment of the country enhances the person ’s overall
technical aptitude and provides him with an ample opportunity to interact with senior engineers and
learn from their experience and technical insight.

Training at MARUTI SUZUKI INDIA LIMITED has not only been beneficial in the technical aspects
(as it has given an unprecedented opportunity to exercise and put into practice, some of the theoretical
aspects of engineering), but also contributed immensely and actively towards growth in the personal
capacity, as a more thinking, efficient , organized and aware individual.

My sincere and heartfelt thanks to all the people at MARUTI SUZUKI INDIA LIMITED who helped
to make my training a success. I would like to convey my gratitude to Mr. PRABHANJAN (general
manegar) for his support and active interest in my training. My sincere thanks to my Training
coordinator Mr. AMANDEEP (DM, ASSEMBLY-3)

NITIN
1708131230
Mechanical Engineering
Pusa Institute of Technology
INDEX

Chapter 1 INTRODUCTION OF COMPANY

Chapter 2 LAYOUT OF THE COMPANY

Chapter 3 PRODUCT SERVICES DETAILS WITH PROPER PHOTO AND DIAGRAM

Chapter 4 DETAILS OF DIFFERENT DEPARTMENTS

Chapter 5 CONCLUSION OF THE TRAINING

Chapter 6 FUTURE PLANS OF THE COMPANY

Chapter 7 REFFRENCES
 Chapter 1 Introduction to the Company

The Maruti Suzuki India Limited When Maruti entered the Indian car market, it sought to fill what it, formely
known as Maruti Udyog Limited, is an automobile manufacturer in India. It is a 56.21% owned subsidiary of
the japnese car and motorcycle manufacturer Suzuki Motor Corporation. As of January 2017, it had a market
share of 51% of the Indian passenger car market. Maruti Suzuki manufactures and sells popular cars such as the
Ciaz, Ertiga, Wagon R, Alto, Swift, Celerio, Swift Dzire, Baleno, and Baleno RS, Omni, Alto 800, SX4, Eeco,
Ignis. The company is headquartered at new Delhi. In February 2012, the company sold its ten million vehicles
in India.

1.1 A Brief History of the Company

Maruti Suzuki India Limited was incorporated as a Public sector company on February 24, 1981 with the
following objectives: -
1. Modernization of Indian automobile industry.
2. Production of fuel-efficient vehicles to conserve scarce resources.
3. Production of large number of vehicles, which was necessary for economic growth.
Maruti was established in February 1981 though the actual production commenced only in 1983. It started with
the Maruti 800, based on the Suzuki Alto kei car. As of May 2007, the Government of India, through Ministry
of Disinvestment, sold its complete share to Indian financial institutions and no longer has any stake in Maruti
Udyog. Originally, 18.28% of the company was owned by the Indian government, and 54.2% by Suzuki of
Japan. The BJP-led government held an initial public offering of 25% of the company in June 2003. As of May
2007, the government of India sold its complete share to Indian financial institutions and no longer has any
stake in Maruti Udyog.

Maruti Udyog Limited was established in February 1981, though the actual production commenced only in
1983. It started with Maruti 800, based on the Suzuki Alto kei car which at the time was the only modern car
available in India. Its only competitors were Hindustan Ambassador and Premier Padmini. Originally, 74% of
the company was owned by the Indian government, and 26% by Suzuki of Japan. As of May 2007, the
government of India sold its complete share to Indian financial institutions and no longer has any stake in
Maruti Udyog.The company exports more than 50,000 cars annually and has domestic sales of 730,000 cars
annually. Its manufacturing facilities are located at two facilities Gurgaon and Manesar in Haryana, south of
Delhi. Maruti Suzuki’s Gurgaon facility has an installed capacity of 900,000 units per annum. The Manesar
facilities, launched in February 2007 comprise a vehicle assembly plant with a capacity of 550,000 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 14, 50,000 units annually.

1.2 Suzuki enters

In 1982, a license & Joint Venture Agreement (JVA) is signed between Maruti Udyog Ltd. and Suzuki of Japan.
At first, Maruti Suzuki was mainly an importer of cars. In India's closed market, Maruti received the right to
import 40,000 fully built-up Suzuki’s in the first two years, and even after that the early goal was to use only
33% indigenous parts. This upset the local manufacturers considerably. There were also some concerns that
the Indian market was too small to absorb the comparatively large production planned by Maruti Suzuki, with
the government even considering adjusting the petrol tax and lowering the excise duty in order to boost sales.
Finally, in 1983, the Maruti800 is released. This 796 cc hatchback is based on the SS80 Suzuki Alto and is
India’s first affordable car. Initial product plan is 40% saloons, and 60% Maruti Van. Local production
commences in December 1983. In 1984 the Maruti Van, with the same three-cylinder engine as the 800, is
released. Installed capacity of the plant in Gurgaon, reaches 40,000 units.In 1985 the Suzuki SJ410-based
Gypsy, a 970 cc 4WD off-road vehicle, is launched. In 1986 the original 800 is replaced by an all-new model
of the 796 cc hatchback Suzuki Alto/Fronte. This is also when the 100,000th vehicle is produced by the
company. In 1987 follows the company's first export to the West, when a lot of 500 cars were sent to Hungary.
Maruti products had been exported to certain neighboring countries already. By 1988, the capacity of the
Gurgaon plant is increased to 100,000 units per annum.

1.3 Company mission

When Maruti entered the Indian car market, it sought to fill what it perceived as two very glaring needs. One,
was to provide fuel efficient, low-cost vehicles, which were reliable and of high quality. Two, was to offer
customers friendly sales and after sales service, total automobile value and customer satisfaction. Additionally,
the absence of an efficient public transportation system was leading to a growing demand for passenger cars. A
burgeoning work force and growing middle class population meant that personal transport had become a
necessity. To attract good managerial talent, the corporate world had started to offer cars even to junior
executives. Since the cars that Maruti manufactured were mainly entry-level cars, the company successfully
fulfilled this demand in the market. The main objective of setting up the Maruti plant was to fulfill the following
objectives: -
Modernization and upliftment of Indian Automobile Industry from its current disheveled shape.
Production of fuel-efficient vehicles to conserve the scarce resources of petroleum.
Production of large number of motor vehicles, which are necessary for the economic growth of any country.

1.4 Manifacturing facilities

Maruti Suzuki has three manufacturing facilities in India. All manufacturing facilities have
a combined production capacity of 1,700,000 vehicles annually. The Gurgaon
manufacturing facility has three fully integrated manufacturing plants and is spread over
300 acres (1.2 km ).The Gurgaon facilities also manufacture 240,000 K-Series engines
2
annually. The Gurgaon Facilities manufactures the Alto 800, WagonR, Ertiga, S-Cross,
Vitara Brezza, Ignis and Eeco.
The Manesar manufacturing plant was inaugurated in February 2007 and is spread over
600 acres (2.4 km ).Initially it had a production capacity of 100,000 vehicles annually but
2

this was increased to 300,000 vehicles annually in October 2008. The production
capacity was further increased by 250,000 vehicles taking total production capacity to
800,000 vehicles annually. The Manesar Plant produces the Alto 800, Alto K10, Swift,
Ciaz, Baleno, Baleno RS and Celerio. On 25 June 2012, Haryana State Industries and
Infrastructure Development Corporation demanded Maruti Suzuki to pay an additional Rs
235 crore for enhanced land acquisition for its Haryana plant expansion. The agency
reminded Maruti that failure to pay the amount would lead to further proceedings and
vacating the enhanced land acquisition.The launch of the Dzire happened in the month
of May 2017 and the variant is said to have good mileage

Type Public
Traded as BSE: 532500
NSE: MARUTI
BSE SENSEX Constituent
Industry Automotive
Founded 1981; 38 years ago[1]
Headquarters New Delhi, India[2]
Area served India
Key people R. C. Bhargava[3] (Chairman)
Kenichi Ayukawa[3] (Managing Director & CEO)

Products Automobiles
Production output 1,568,603 units (2019)[4]

Revenue ₹886,301 million (US$13 billion) (2019)[4]

Operating income ₹106,238 million (US$1.5 billion) (2019)[4]

Net income ₹76,506 million (US$1.1 billion) (2019)[4]

Total assets ₹639,687 million (US$9.3 billion) (2019)[4]

Total equity ₹471,097 million (US$6.8 billion) (2019)[4]

Number of employees 40,000 (2019)[5]

Parent Suzuki Motor Corporation (56.21%)

Public (43.79%)[6][7]
 TABLE-1

The Gujarat manufacturing plant became operational in February 2017. The plant current
capacity is about 250,000 units per year. But with new investments Maruti Suzuki has
plan to take it to 450,000 units per year.
In 2012, the company decided to merge Suzuki Powertrain India Limited (SPIL) with itself.
SPIL was started as a JV by Suzuki Motor Corp. along with Maruti Suzuki. It has the
facilities available for manufacturing diesel engines and transmissions. The demand for
transmissions for all Maruti Suzuki cars is met by the production from SPIL.
1.3 Market liberalization
In 1989, the Maruti 1000 was introduced and the 970 cc, three-box was India's first contemporary sedan. By
1991, 65 per cent of the components, for all vehicles produced, were indigenized. After liberalization of the
Indian economy in 1991, Suzuki increased its stake in Maruti to 50 per cent, making the company a 50-50 Joint
Venture with the Government of India the other stake holder.
In 1993, the Zen, a 993 cc, hatchback was launched and in 1994 the 1298 cc Esteem was introduced. Maruti
produced its 1 millionth vehicle since the commencement of production in 1994. Maruti's second plant was
opened with annual capacity reaching 200,000 units. Maruti launched a 24-hour emergency on-road vehicle
service. In 1998, the new Maruti 800 was released, the first change in design since 1986. Zen D, a 1527 cc
diesel hatchback, and Maruti's first diesel vehicle, and a redesigned Omni were introduced. In 1999, the 1.6 litre
Maruti Baleno three-box saloon and Wagon R were also launched. In 2006 Suzuki and Maruti set up
another joint venture, "Maruti Suzuki Automobiles India", to build two new manufacturing
plants, one for vehicles and one for engines. Cleaner cars were also introduced, with
several new models meeting the new "Bharat Stage III" standards. In February 2012,
Maruti Suzuki sold its ten millionth vehicle in India.

AN AERIAL VIEW OF MSIL, GURUGRAM fig 1

1.5 MARUTI VISION & VALUES

COMPANY VISION
Our Vision for the future is to be:
“The Leader in the Indian Automobile Industry,
Creating Customer delight and Shareholders wealth;
A pride of India”.
The above vision is based on -
1. LEADERSHIP
(i) By Market Share (ii) By Brand Equity
(iii) By Operational Practices (iv) By People Strategy
2. CUSTOMER DELIGHT
(i) Value for Money (ii) Quality (iii) Service
3. SHARE HOLDERS WEALTH
(i) High Profitability & Image (ii) As a corporate Citizen
(iii) Our products (iv) Our People
(v) Our Practices (vi) Our Customer

VALUES
The Five Values identified are as follows:
I. Customer Obsession
II. Fast, Flexible & First mover
III. Innovation & Creativity
IV. Networking & Partnership
V. Openness & Learning

1.6 Role of Honor

I. Productivity Award by National Productivity Council (1988)
II. ETHBSAI Awards.
III. CII Awards for Quality & Reliability.
IV. Trading House status in view of its export performance since 1990
 CHAPTER-2

2.1 LAYOUT OF ORGANISATION

Maruti Suzuki is situated at Plot No 504, Phase III, Udyog Vihar, Sector 20, Gurugram, Haryana 122001.
This was the first plant made in 1983 by MARUTI SUZUKI INDIA LTD. For the production of automobiles.
Firstly in the starting stages there used to be 4 plants under it but nowadays there is only two plants working no.
2 and no 3. The plant layout is been made by considering the proper division of land between work area and
green belt. The plant has a lot of space especially for the greenery so that there would be very less pollution
caused by the plant and it matches the environmental guidelines.
 PLANT LAYOUT OF
MARUTI SUZUKI INDIA LIMITED(fig 2)
2.2 Divisions and Departments
1) Corporate Services
This division is comprised of the following Departments;
 Legal & secretarial Department
 Public Relations
 Corporate Planning
 Corporate Personnel

2) Personnel and Administration

This division is comprised of the following Departments:
  Recruitment and IR department
 Establishment and Time Office
 Factory Administration department
 Training department.

1) Production
This division is comprised of the following Departments:
 Press Shop & Blanking Line
 Weld Shop
 Paint Shop
 Engine Assembly Shop
 Assembly Shop (1, 2 & 3)
 Machine Shop
 Materials-X (1&2)
 MX-Engineering
 PQC
 Maintenance and Maintenance Plant Common
 PKC (Productivity and Kaizen Control)
 Welfare & Safety

4) Production Engineering Division

Product Engineering and Production Engineering are two main supports for production activities in any
manufacturing industry. In Maruti the production Engineering activities are organized to provide ‘total service’
to all manufacturing shops i.e. Press Shop, Weld Shop, Paint Shop, Assembly Shop & Machine Shop. These
activities are which span from conception to commissioning, are performed by the corresponding PE
departments and are listed below:
 Process planning
 Shop Layout Planning
 Equipment specification
 Tendering & Procurement
 Equipment installation and trial
 Process Standards, & Inspection Standards.
 Trouble Shooting
 Raw Material Development
 Consumable Development
 Vendor Assistance
 Market Feedback
 Future Growth Plan
 Development of New Products
 Tool Room
 Civil Construction and Maintenance
 Budgeting and monitoring
 Support to JV Companies

5) Quality Assurance and Service Division

This department mainly consists of:
a) QA & Service Department:
 Quality Assurance Department
 Service Department
 Vehicle Inspection Department (I & II)
 MSS workshop- in Naraina, Delhi
 Quality Systems
b) Parts Inspection Division (1, 2, 3 & 4)

6) Engineering Division
Objective of the Engineering Division is to
 Cater to the problems in production line relating to component fitment of quality mainly design
conformance.
 Communization of parts and their indigenization thereby controlling cost.
 Export vehicle homologation as per country requirement
 Modification of products relating to functional was well as aesthetic parts based on market feedback.
 Introduction of new models.
7) Materials Division
The departments in this division are:
 New projects department
 Vendor Consultancy Cell
 Materials 1 & 2
The main functions of the VDD (Vendor Development Department) are indigenization of components,
procurements of components/ sub-assemblies, and cost control and vendor up gradation.
Materials 3
 Imports and Raw materials
 Materials Control
 Consumables and Excise
 Shipping and Transport

8) Marketing and Sales Division

The departments in this division are:
 Sales Planning Department
 Market Planning Department
 Dealer Development Department
 Marketing Department
 Regional Offices
 Sales and Dispatch Department
 Export
 Spare parts division
 Vigilance Division

9) Information Technology Division (ITD)

The departments in this division are:
 Financial & Personnel Systems(FPS) – for salary/inventory processing
 Plant Material System(PMS) – Materials supply
 Marketing and Sales Information(MSI) – Sales and Marketing
 Systems Management(SMD)- maintenance of computer systems

10) Finance Division

The departments in this division are:
 Payments
 Internal audit
 Corporate Finance Budget,
 Costs and Accounts
 Works and Imports
 Income Accounting

CHAPTER-3

3.1-Models offered by Maruti Suzuki India Limited

Model Launched Category Image

Omni 1984 Minivan

Gypsy King 1985 SUV

WagonR 1999 Hatchback

Swift 2005 Hatchback

DZire 2008 Sedan

Eeco 2009 Minivan

K10 2010 Hatchback

Ertiga 2012 Mini MPV

Alto 800 2012 Hatchback

Celerio 2014 Hatchback

 Ciaz 2014 Sedan

Baleno 2015 Hatchback

S-Cross 2015 Mini SUV

Vitara Brezza 2016 Mini SUV

Ignis 2017 Hatchback

Baleno RS 2017 Hatchback

3.2-Discontinued Models

Model Launched Discontinued Category Image

800 1983 2012 Hatchback

Gypsy E 1985 2000 SUV

 1000 1990 2000 Sedan

Zen 1993 2006 Hatchback

Esteem 1994 2008 Sedan

Baleno 1999 2007 Sedan

Alto 2000 2012 Hatchback

Versa 2001 2010 Minivan

Grand Vitara XL7 2003 2007 Mini SUV

Grand Vitara 2007 2015 Mini SUV

Zen Estilo 2007 2013 Hatchback

A-star 2008 2014 Hatchback

SX4 2008 2014 Sedan

 Ritz 2009 2016 Hatchback

Kizashi 2011 2014 Sedan

3.3-HOW IS A CAR MADE

The making of a car starts from the press shop, where the raw material is obtained in the form of cold-
rolled sheets. From the press shop, the parts are send to the weld shop, where they are welded to make
the frame of the car. From the weld shop, these frames are transferred via conveyors to the paint shop,
where these are coated and glazed. From the paint shop, these are send to the assembly shop, where
through a conveyor system, various parts are fitted at various canopies or stations. The machine shop and
the Engine assembly shops are located close to the respective assemblies, and the car engine and other
transmission parts are also fitted in the assembly shop itself. Then, the V.I deptt. conducts various tests to
ensure that no defects remain before the car is dispatched via trucks to various parts of the country.
3.4-OPERATIONS PERFORMED IN MSIL
3.4.1 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 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:
3.4.2 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.

3.4.3 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. Uncoiling
2. Cleaning
3. Leveling
4. Measuring
5. Shearing/ cutting

3.4.4 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.

3.4.5 Hydraulic Presses

Hydraulic presses are a powerful class of machine tools, they derive the energy they deliver through hydraulic
pressure. Fluid pressure, in a particular chamber, can be increased or decreased by the use of pumps, and valves.
Sometimes devices and systems may be used to increase the capacity of the pumps in more powerful presses.
These presses can operate over a long distance and at a constant speed. Hydraulic presses are generally slower
relative to other press machine types. This involves longer contact with the work, therefore the cooling of the
work can be an issue when hot forming a part with hydraulic force. Hydraulic presses are capable of being the
most powerful class of presses. Some may be as large as buildings, and can deliver awesome pressure. The
largest hydraulic presses are capable of applying 75,000 tons, (150,000,000 lbs), of force. The hydraulic press
shown is being used to manufacture a metal forging. Extrusion is also a very common use for such a press,
although extrusion is often performed horizontally. The basic working principles of the hydraulic press are
simple, and rely on differences in fluid pressure. Fluid is pumped into the cylinder below the piston, this causes
the fluid pressure under the piston to increase. Simultaneously, fluid is pumped out of the top channel, causing
the fluid pressure above the piston to decrease. A higher pressure of the fluid below the piston than the fluid
above it causes the piston to rise. In the next step, fluid is pumped out from below the piston, causing the
pressure under the piston to decrease. Simultaneously, fluid is pumped into the cylinder from the top, this
increases the fluid pressure above the piston. A higher pressure of the fluid above the piston, than the fluid
below it, moves the piston downward. Press machines are also the primary machine tool used in metal extrusion
and sheet metal fabrication processes. Hydraulic and mechanical presses are employed during sheet metal
forming to the extent that sheet metal processes, in general, are often referred to as press working. Presses may
be used in the manufacture of plastic parts. Machining operations, such as broaching, may also require presses.
3.4.5.1 Mechanical Presses
Mechanical presses belong to a class of machine tools that encompass a wide range of different machine types.
Primarily, the mechanical press transforms the rotational force of a motor into a translational force vector that
performs the pressing action. Therefore, the energy in a mechanical press comes from the motor. These types of
presses are generally faster than hydraulic or screw presses, (actually the screw press may also be classified as a
mechanical press). Unlike some presses, in a mechanical press, the application of force varies in both speed and
magnitude throughout the distance of the stroke. When performing a manufacturing operation using a
mechanical press, the correct range of the stroke is essential.

Presses are chosen based on the characteristics of the manufacturing process. Mechanical press machine tools
are commonly used in metal forging manufacture, and sheet metal working. The desired application of force will
dictate the type of machine required. Extrusion will often necessitate a more consistent force over a longer
distance. However, a mechanical press may often be a good choice for impact extrusion, since a fast, quickly
repeatable application of force over a limited distance is what is needed for that type of manufacturing process.
The most powerful mechanical presses in modern manufacturing industry will have a press capacity of about
12,000 tons, (24,000,000 lbs).
3.5 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

3.5.1 Process Outline

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

3.5.2 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.
3.5.3 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.

The flow chart for a typical car body weld line looks as follows:
3.6 Paint Shop
In the paint shop following processes is carried out

3.6.1 Pre-treatment

The body is thoroughly washed to remove the dirt and oil scales.

3.6.2 ED coat

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

3.6.3 Intermediate coat

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

3.6.4 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 From weld shop

3.7 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 - Currently not working. (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)
3.7.1 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

3.7.1.1 Cylinder head line:

A sub assembly integrating the throttle body, inlet and exhaust manifold and fuel injectors cater to this
line.

Main parts:
1. Inlet and exhaust valves
2. Cotter valves
3. Retainer springs
4. Rocker arm assembly
5. Throttle body
6. Inlet and exhaust manifold

3.7.1.2 Block line:

Main parts on the block line are:
1. Crankshaft
2. Pistons
3. Oil pan
4. Alternator/generator
5. Starter motor
6. Flywheel
7. Clutch

3.7.1.3 Transmission line

Several sub-assemblies involved in making the input shaft, countershaft etc. supply to the T/M line.
Main parts are:
1. Clutch release shaft
2. Gear box assembly
3. Transmission oil pan

3.7.1.4 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
3. 4 A.C Compressors
4. Water pump
5. Air filter

3.8 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

3.9 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

3.9.1 Major activities performed in Machine Shop

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

3.10 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

3.10.1 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
3.11-DEPARTMENT ALLOCATED DURING TRAINING- ASSEMBLY
DEPARTMENT-3
ASSEMBLY SHOP -3
There are 2 assembly shops in MSIL which produce on an average 1750 cars daily. The assembly
shop receives PB-OK i.e. paint body OK from the paint shop. Here the body is loaded on an over
head conveyor. As the conveyor moves the body, fitments are made at various stations.
Assembly I mainly produces CIAZ (Domestic& Export),), EECO,RITZ & WAGON R(new
model),BREZZA ,IGNIS,CARRY,BALENO ETC
The Whole process of assembling undergoes through different number of stations. There are about
10,000 employees in two shifts. The Asssembly shop can be further subdivided as following
 Trim
 Chassis
 Final

3.11.1TRIM LINE-Trim can be further subdivided as following Trim 1

This is the beginning of the assembly line conveyor. Here amongst the first tasks done is attaching
the hydraulic supporters for the boot. The assembly line check sheet is put inside the body. Door is
removed here and sent to final line .The various fitments made here are door/floor grommets,
electric wiring, and door trims parking brake cable, inner and outer door openers, model stickers
and emblems, roof silencer and cabin lamp.
Steering gear case is put inside to be fixed

3.11.2 Trim 2
It starts with Rear combination light fitment. Other operations done here are vacuum booster/
brake master cylinder fitment, seat belts, fuse box, wiper sprayer and motor, accelerator, clutch,
brake pedals, door glasses and a/c panel fitment. Trim 2 ends with the fitment of the instrument
panel, which is received from an instrument panel subassembly. This sub assembly involves the
fitting of the speedometer console, ashtray and stereo system. .

3.11.3 Trim 3
The fittings done here are rear inside cover for boot, back door glass and windshield, quarter
glasses and connecting pipe between fuel lid and fuel tank. Steering gear is mounted. For
cemendine application on the windshield, Motoman robots are employed. Here a process check is
done
3.11.4 CHASSIS
The chassis receives a trim up body. Here underbody fitments are made, hence body is loaded on
overhead jigs. Chassis is subdivided as following:

3.11.5 Chassis 1
Various fitments made here are rear shock absorbers, brake pipes, front coil spring with knuckle,
steering wheel, tie rods, rear suspension, fuel pipes, fuel tank and rear brake drum. There is a
knuckle sub assembly that feeds the line with knuckles for the front suspension system. Process
check is done at the end of Chassis 1.

3.11.6 Chassis 2
The fitments made here the exhaust system (silencer and catalytic converter), engine cum
transmission case assembly, gearshift rod, front and rear bumpers, stabilizer bars and tyres. The tie
rod and drive shafts are connected to the knuckle to complete the front suspension system and ID
plate fixation. A process check is done at the end of chassis 2.

3.11.7 FINAL
Since all the fitments have been made, the body is referred as vehicle from now onwards. The
vehicle is loaded on the final conveyor. Final area is further subdivided as: -The fitments made
here are Spare wheel cover, scuff, seats, roof trim and carpet, boot carpet, battery and air cleaner.
Clutch cable and parking brake connections are made.

Brakes are evacuated and brake oil is filled. Coolant is also filled.
3.11.8 Final 2
Five liters of petrol is filled in the vehicle. A/C vaccum and charging is also done here, the
refrigerant used here is R134a (400 gm +- 50).Door Assembly is also done here.
CHAPTER-4 DIFFERENT DEPARTMENTS IN MSIL

4.1 ORGANISATIONAL STRUCTURE AT MSIL

MSIL is a functional organization. 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, which are headed by Department
Managers who report to the respective divisional managers. Designations in the Company are
based on the functional responsibility in terms of the Company's philosophy of de linking
designations and functional responsibility 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 further divided into
Departments.For example In Marketing & Sales Division, the departments are Exports, Marketing,
Sales Planning, Sales & Dispatch, RO-East, - West, - South, - North-I, North-II & MSS-N. In
Information Services Division, the departments are Marketing & Sales Information, Production
Management Information, Materials Management information & Resource Management
Information.Maruti Suzuki india Limited has a total of 40000 employees (not including trainees or
Japanese experts).

4.2 SYSTEM OF DESIGNATION

There will be a dual set of designations. Internally, only the designations linked to functional
responsibility will be used. For external dealings a different set of designations may be followed.
The following system of designations would be practiced without any exception within the
Company. For the purposes of defining explicit responsibility centers, The Company has been
divided into three layers of management.
 Division
 Department
 Section
An official of the Company, who will be designated as Divisional Manager, Department Manager,
Section Manager respectively would head each of these responsibility centers. Remaining
employees of the Company will have no specific designation and would simply use the name of
the Division/Department/Section to which they belong, to identify their location in the Company.
The MD would make appointment to positions of Divisional Managers and Department Managers
only. The Divisional Managers would appoint section Managers.

4.3 PRODUCTION AND ANALYSIS DEPARTMENT

A production department is a group of functions within a business that is responsible for the
manufacture of goods. This can include just a few specialized functions with all other work outsourced, or a
fully functioning department that converts raw materials, assembles components into finished goods, and
packages them. The production department can be the largest organization within a business. It may employee
mechanics, machine setup specialists, maintenance personnel, and machine operators. A key focus of the
production department is efficiency. To that end, the bottleneck operation within the facility is closely
monitored and supported so that throughput (revenue minus variable costs) is maximized.

4.4 PERT CHART

A PERT chart gives a visual representation of the critical path of a project. This critical path is the sequence of
interdependent activities that will require the longest time period to complete. Each task on the chart is labeled
with high and low estimated start and finish times, which can be used to determine where there is slack in the
system and where to focus attention on compressing the schedule. In addition, the chart contains all tasks that
must be addressed before a project can be completed, the sequence in which they must be completed, and the
time requirements for each one. A PERT chart is especially useful for the management of more complex
projects that would overwhelm a Gantt chart.

4.5QUALITY DEPARTMENT
This department has very crucial as well as very important role in company’s development. A small defect in
product can cause bis loss economically.
The whole system work as suppose company get an order of 1 lakh pieces of patch pieces then the first product
from the machine is verified by engineers by “ panel checker” and if found accurate then all other product are
only visually checked by workers. Engineers have all the basic data about product dimensions, distance between
holes etc, which help then in verifying the product on panel checker.

4.6STORAGE DEPARTMENT
Most manufacturing concerns spend more than 60% of the money they take in, for materials, i.e., materials
soak up a substantial portion of the capital invested in an industrial concern. This emphasizes the need for
adequate materials management and control because even a small saving in materials can reduce the production
cost to a fair extent and thus add to the profits.
Materials Management may be thought of as an integrated functioning of the different sections of a company
dealing with the supply of materials and other related activities so as to obtain maximum co-ordination and
optimum minimum expenditure on materials. Materials Management involves controlling the type, amount,
location, movement, timings of purchase of various materials etc., used in an industrial concern.

4.6.1 Functions of Materials Management:

1. Materials planning.
2. Procurement or purchasing of materials.
3. Receiving and warehousing.
4. Storage and store-administration.
5. Inventory control.
6. Standardization, Simplification and Value-analysis.
7. External transportation (i.e., traffic, shipping, etc.) and materials handling (i.e., internal transportation).
8. Disposal of scrap, surplus and obsolete materials.

4.6.2 Objectives of Materials Management:

1. To minimize materials cost.
2. To procure and provide materials of desired quality when required, at the lowest possible overall cost of the
concern.
3. To reduce investment tied in inventories for use in other productive purposes and to develop high inventory
turnover ratios.
4. To purchase, receive, transport (i.e., handle) and store materials efficiently and to reduce the related costs.
5. To trace new sources of supply and to develop cordial relations with them in order to ensure continuous
material supply at reasonable rates.
6. To cut down costs through simplification, standardization, value analysis, import substitution, etc.
7. To report changes in market conditions and other factors affecting the concern, to the concern.
8. To modify paper work procedure in order to minimize delays in procuring materials.
9. To conduct studies in areas such as quality, consumption and cost of materials so as to minimize cost of
production.
10. To train personnel in the field of materials management in order to increase operational efficiency.
4.7 SAFETY DEPARTMENT
Industrial safety refers to the management of all operations and events within an industry in order to
protect its employees and assets by minimizing hazards, risks, accidents, and near misses.
Industrial safety is overseen by federal, state, and local laws and regulations. The Occupational Safety and
Health Association (OSHA) is the primary regulatory body in the United States dedicated to ensuring industrial
safety
Industrial safety covers a number of issues and topics affecting safety of personnel and the integrity of
equipment in a particular industry.
The following topics are generally discussed:
1. General Safety – General aspects of safety which are common to all industries
2. Occupational Safety and Health – Particularly associated with the occupation
3. Process and Production Safety
4. Material Safety
5. Workplace Safety – Safety issues directly related to the workplace setting
6. Fire Safety
7. Electrical Safety – Arising from the equipment used
8. Building and Structural Safety – Including installations as per existing building code
9. Environmental Safety – Concerns the direct and indirect environmental impact of the industry

4.8MARKETING DEPARTMENT
A marketing department promotes your business and drives sales of its products or services. It provides
the necessary research to identify your target customers and other audiences. Depending on the company’s
hierarchical organization, a marketing director, manager or vice president of marketing might be at the helm. In
some businesses, a vice president of sales and marketing oversees both the marketing and sales departments
with a strong manager leading each department. It’s important to keep a strong marketing department intact
regardless of the economy so you remain visible and keep sales strong.
 CHAPTER 6
During my industrial training, there are many changes from the point of learning environments and discussion
among colleagues. It can directly increase the dedication and rational attitude toward myself there are a lot of
new knowledge that can be learned and I get to understand altogether on how this firm plays an important role
in industrial field, especially in Quantity Surveying. Exposure that have been given to me by ESQUEL Sdn Bhd
staff about the working and technical aspect is a very meaningful knowledge to me in order to prepare myself
before stepping into the real work environment on the upcoming days. I hope with the implication of the
Industrial Training, there will be no more anomalous feelings when the students started working after they have
finished their course later. The staff at ESQUEL SDN. BHD are very helpful and friendly. They gave me a lot of
exposure on the terms of reference and procedures related to the process of my work. Other than that, the
exposure visiting the other EGM SDN BHD, meeting atmosphere and so on also give a useful knowledge to
me.Exposure that were given to me at this firm can provide the picture on a real-life situation, the task and
responsibility that would be carried by some people on the field. Lastly, students involvement in industrial
training like this can prove and further strengthen student's identity in undergoing training in technical field, in
the same time making Polytechnic as practical platform of education. Apart from that, the format report that
needs to be done by students after undergoing industrial training also can train each of the student in preparing
technical report that is complete, compact and in a right order that can be made as an important knowledge
when they face a real situation later. This is fit with the Polytechnic objective that is to produce a workforce that
are high in quality and partially professional in this country Besides, I also can train myself to be good in
attitude while doing my work. In addition, the knowledge and research skills can be improved as when I was
doing project of analysis food content. This is important things for our chemist or science student that working
on laboratory. After my industrial training at the SAWM. I already know and learn the working depth. As a
result I am very proud of what I have learned and I am grateful for ending the practice of this industry with very
useful experience for the future. This experience not only introduced me to something new, but it was an early
exposure to nature before I had a real job. In addition, I also wanted to prove that what you learn in class is
useful for putting yourself in the real job someday. Students will also be more aware of the importance of the
subject being studied as a stake in continuing ambition to be required even if the theory learned is not
necessarily the same as those carried out during the period of industrial training but passion and enthusiasm are
very important before venturing into the working environment. Many knowledge that I gained during their
training program this industry. All the knowledge learned during the training to apply and I will use my best to
step up to the job later. This training guide many students are not aware of the additional costs to be taken and
studied at Polytechnic. In conclusion, the industrial training program is very good and can create the potential
for students to better quality in the field they want to operate in the present. During the training, I had a taste of
how the real atmosphere in the workplace, as well as a good relationship of mutual help - help and cooperation
during my industrial training.
 Chapter 7 References

1) Hand written notes given by Sh. Amandeep (DM of Assembly Shop)

2) https://en.wikipedia.org/wiki/Maruti_Suzuki
3) Maruti Udyog Ltd. Company Profile
4) Marutisuzuki.com
5) General knowledge searches about different topis