Presentation on Summer Industrial Training

At
Jay-Bharat Maruti Limited




Submitted by:- Submitted to:-
Shahill Dev Singh Mr. Upendra Yadav
M.E, 4
th
year- 7
th
sem Deptt. of Mech. Engg.
DIT, Dehradun

Introduction to JBM Company:
JAY BHARAT MARUTI
LIMITED, set up in 1987, is the largest joint venture of MARUTI UDYOG
LIMITED, in collaboration with SUZUKI MOTOR CORPORATION of JAPAN.
JBML is rising to meet new challenges with modern equipment and higher goals
of manufacturing and quality control.
COMPANY PROFILE
Name: JAY BHARAT MARUTI LTD.
Head Quarters: DELHI
Established: 1987
Turnover: Rs.4500 Crores(overall)
Employees (No.): AROUND 15,000

MISSION
TO MAKE JBM A SYNONYM FOR WORLD CLASS ORGNISATION
EXCELLENCE IN SHEET METAL TECHNOLOGIES

VISION
EXPANDING LEADERSHIP IN OUR BUSINESS THROUGH PEOPLE,
KEEPING PACE WITH MARKET TRENDS AND TECHNOLOGY



Working Environment:
The working environment at JBML is based on
Japanese systems of manufacturing. 2000 trained and highly motivated personnel
are the companys greatest asset. The core group works closely with its staff and
workers to provide solution and create new goals for JBML. The major
manufacturing facilities include:
1) Kaizen principle, use of 5-s
2) Five axis Laser Cutting Machine
3) Standard and Special Purpose Stationary/Portable/MIG/
MAG/Resistance/Welding Machines
4) Six axis Articulated type Arc Welding Robot
5) Special Purpose Machines for manufacturing of Exhaust Systems
Product Manufactured:
Following parts are manufactured as given
below:-
Body in White parts
Exhaust System
Rear axle
Painting of parts

Body in White:
As the name suggests, body parts which are put in the body as
it is without being painted.
Most of these parts are formed by spot welding which produces negligible spatter
and hence can be applied without any type of rework or finishing.
Some of these parts includes- apron fender, cowel upper, cowel lower, dash panel,
bumper and many more. The models for which skin panels and body parts include
Wagon R , Alto K10,Alto 800,Ertiga,Omni,Ritz,Estilo and some others as well.

Process Used in Fabrication of BIW:
Resistance Welding:
Resistance welding is a welding process which join the metals with the heat
obtained from resistance offered by the work to the flow of electrical current
through the parts being joined.
A pair of copper alloy electrodes conducts electrical current through the two
sheets pressed between the interface.
The two sheets offer maximum resistance to the flow of current, this generates
heat, the interface melts and consequently solidifies under the pressures of the two
electrodes, thereby joining the two sheets at the spot that was under the two
electrodes.

Working of Resistance Welding:
Spot welding is one form of resistance welding, which is a method of welding two
or more metal sheets together without using any filler material by applying pressure
and heat to the area to be welded.
The process is used for joining sheet materials and uses shaped copper alloy
electrodes to apply pressure and convey the electrical current through the
workpieces.
In all forms of resistance welding, the parts are locally heated. The material between
the electrodes yields and is squeezed together. It then melts, destroying the interface
between the parts.
SPOT WELDING - ELECTRODE TIP
WATER
TEFLON TUBE
6 mm
2~3 mm
0.5 mm
TIP DIA BE CHECKED AFTER DRESSING WITH GO / NOGO GAUGE
ELECTRODE
GO NOGO
6~8 mm < 8mm
GAUGE FOR TIP DIA
USED
NEW
WEAR LINE
SPOT WELDING - ALIGNMENT OF
TIPS:
BEST SPOT
TIP ALIGNMENT
OK
100 % Matching
90 % Matching < 90 % Matching
NOT OK ACCEPTABLE
Rear Axle Manufacturing Process:
Rear Axle:
It is the part of vehicle which supports the super structure of the vehicle.
In Rear Axle Department assembles are made with the help of MAG
(Metal Active Gas) Welding.
Types of Rear Axle Manufactured:
Wagon-R (YR-9)
ALTO
ALTO-CD (YG-4)
CAR (MARUTI 800)
SWIFT (YN-4)
RITZ (YV-4)

Method Used for Fabrication Process:
Metal Inert Gas Welding (MIG):
POWER SOURCE
WIRE FEEDER
HEATER
REGULATER
CO 2 CYLUNDER
WELDING TORCH
GAS NOZZLE
CONTACT TIP
NOZZLE / SOCKET
Working:
Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert
gas (MIG) welding or metal active gas (MAG)welding, is a welding process in
which an electric arc forms between a consumable wire electrode and the workpiece
metal(s), which heats the workpiece metal(s), causing them to melt, and join.
Along with the wire electrode, a shielding gas feeds through the welding gun,
which shields the process from contaminants in the air.
Equipment used for Welding:
We are using automatic welding process for
fast production and accuracy. For this purpose we are using six axis robot as
described below.
Exhaust System:
An exhaust system is piping used to guide reaction exhaust gases away from a
controlled combustion inside an engine. The entire system conveys burnt gases from
the engine and includes one or more exhaust gases.

Major Component Used :
The major components of the exhaust systems include:
Muffler (silencer)
Turbocharger (to increase power)
Catalytic converter ( to reduce air pollution)
Cylinder head and exhaust manifold

In JBM, exhaust systems of only two Maruti models i.e. alto 800 and Omni are
manufactured. MAG welding, spot welding and other type of simple sheet metal
operations are used in manufacturing of exhaust systems.
Some Miscellaneous Techniques Used:
5-S:
5S is a set of techniques providing a standard approach to housekeeping within
Lean Manufacturing.
It is often promoted as being far more than simply housekeeping and some of the
elements described below certainly have broader implications.
It originated, as did most of the elements of JIT, within Toyota.
A cornerstone of 5S is that untidy, cluttered work areas are not productive

1S-SEIRI- Sort Out Unnecessary Items In The Workplace
2S-SEITON- Arrange Necessary Items In Order
3S-SEISO- Clean your work place completely
4S-SEIKETSU-Maintain high standard of housekeeping
5S-SHITSUKE-Train people to follow good housekeeping


Benefits of 5-S:
1) Improve safety
2)Decrease down time
3)Raise employee morale
4)Identify problems more quickly
5)Develop control through visibility and increase product and process quality
6)Strengthen employees pride in their work
7)Promote stronger communication among staff
8)Empower employees to sustain their work area





THANK YOU