ACKNOWLEDGEMENT

Industrial training is an indispensable part of any curriculum. It provides

the students with an opportunity to gain experience on the practical
application of our knowledge.

I express my gratitude to all the people at Maruti Suzuki India Limited who
helped me during the past six weeks. The exposure and experience
gained at Maruti has been uniue.
I would like to thank Mr. Sanjeev Bhatnaagar. !"#M $ssembly Shop%&'
for giving me this opportunity to work in their departments and guiding me
through the pro(ects for his constant guidance and support.
I would also like to express my sincere gratitude to Mr. Mahinder Vikram
Singh ) Training Incharges their able guidance and keen interest in my
training.
.

RO!T
G!TM G"RGAON
GITM GURGAON
Page 1

ABSTRACT
In order to get faster result over a particular period, maximum utilization of is very much
required. So if the proper utilization of time will be done then the maximum efficiency will be
produced with in the industry. My topic Time study of ETSA & Rear axle sub assembly and
design layout of line no.1 (assembely-1!at Maruti is very much related with above fact.
here are many reasons for wanting to !now the amount of time a particular tas! should ta!e to
be completed. It may simply be for reasons of curiosity. "ut realistically, it is for any of three
reasons# (1) to accomplish planning, (2) determine performance and (3) establish costs.
In this pro$ect I have calculated the total time that the each wor!er at each station too! to
complete its tas! in %S&'%ngine ransmission Sub &ssembly of (agon)* and rear axle sub
assembly of line no+, '%eco - )itz* and I also design the layout of line no.1'.mni - )itz*.I
have calculated time at different station with the help of stop watch and for layout design I visit
all the station of line no.1 to find how many wor!ers are engaged there and note all the wor!ers
wor!ing in different sections of line no.1 and !now its category'category such as permanent, .,
casual, apprentice, repairmen - reliever. &fter finding various details of / sections 0trim, chasis
and final of line no.1, I designed the layout of line no.1.
GITM GURGAON
Page 1

CONTENTS:
Introduction to MSIL
Organisational structure of MSIL
Production overview
Milestones reached by MSIL
ow a car is !ade in reality
"ifferent sho#s in MSIL
Pro$ect re#ort on Plant I!#rove!ent
Conclusion
GITM GURGAON
Page /

COMPANYS VISION:
TERMS OF PRODUCTION VOLUME, COSTS AND PROFITS. WE
MUST NOT ONLY MAINTAIN LE2TO BECOME AN
INTERNATIONALLY COMPETETIVE COMPANY IN ADERSHIP IN
INDIA BUT SHOULD ASPIRE TO BE AMONGST THE GLOBAL
PLAYERS. THE CULTURE, THINKING AND ACTIONS HAVE ALL TO
BE CONSISTENT WITH THIS VISION

GITM GURGAON
Page ,

!NTROD"CT!ON
$n aerial view of the MSIL )*urgaon.
#LANT LA$O"T O%
GITM GURGAON
Page 3

MAR"T! S"&"K! !ND!A L!M!TED

MAR"T! S"&"K! !ND!A L!M!TED
GITM GURGAON
Page 4

ABO"T MAR"T! S"&"K! !ND!A L!M!TED
TE START O% A NEW ERA'
Maruti Suzuki India Limited !MSIL' was established in +eb &,-& through an $ct of
#arliament) to meet the growing demand of a personal mode of transport caused by the lack
of an efficient public transport system.
Suzuki Motor .ompany was chosen from seven prospective partners worldwide. This was
done not only due to their undisputed leadership in small cars but also due to their
commitment to actively bring to MSIL contemporary technology and /apanese management
practices !which had catapulted /apan over 0S$ to the status of the top auto manufacturing
country in the world'.
$ license and a /oint 1enture agreement were signed between *ovt. of India and Suzuki
Motor .ompany !now Suzuki Motor .orporation of /apan' in 2ct &,-3.
The ob(ectives of MSIL then were4
&. Modernization of the Indian $utomobile Industry.
3. #roduction of fuel%efficient vehicles to conserve scarce resources.
5. #roduction of large number of motor vehicles) which was necessary for economic
growth.
TE REVOL"T!ON'
Maruti created history by going into production in a record time of &5 months. 2n &6
"ecember &,-5) the then #rime Minister of India) Mrs. Indira *andhi) handed over the keys
of the first car to Mr. 7arpal Singh of "elhi. 1olume targets were routinely exceeded) and in
March &,,6) Maruti became the first Indian company to produce over one million vehicles.
Maruti is one of the most successful automobile (oint ventures) and has made profits every
year since inception till 3888%8&. In 3888%8&) although Maruti generated operating profits on
an income of 9s. ,3.: billion) high depreciation on new model launches resulted in a book
loss. Maruti revolutionized the way Indians looked at cars. (N) )ther *ar *)m+an, -)
*)m+.ete., d)minate- it- h)me market( / 0The E*)n)mi-t1. "espite there being more
than &8 companies now in the passenger car market) Maruti holds about :6.:; of the total
market share. MSIL 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 /" #ower .ustomer Satisfaction study.
GITM GURGAON
Page 5

TRANS%ER O% TECNOLOG$'
<very 3= seconds a vehicle rolls out of the Maruti plant. It is therefore imperative that the
transfer of contemporary technology from its partner S0>0?I is a smooth process. *reat
stresses are laid on training and motivating the people who man and maintain the euipment)
since the best euipment alone can@t guarantee high uality and productivity. +rom the
beginning it was a conscious decision to send people to S0>0?I Motor .orporation for on
the (ob training for line technician supervisors and engineers. These help them to imbibe the
culture in a way that merely transferring technology through documents can never replicate.
$t present 38; of its workforce has been trained under this program.
ETOS O% MAR"T!'
<mployees are Maruti@s greatest strength and asset. It is this underlying philosophy that has
moulded its workforce into a team with common goals and ob(ectives. The employee%
management relationship is therefore characterized by4
.ustomer obsession
+ast) flexible and first mover
Innovation and creativity
Aetworking and partnership
2penness and learning
#articipative management
Team work and kaizen
.ommunication and information sharing
2pen office culture for easy accessibility
To implement this philosophy) Maruti has taken several measures like a flat organizational
structure. There are only three levels of responsibilities ranging from the Board of "irectors)
"ivision to 7ead of departments. 2ther visible features of this philosophy are an open office)
common uniforms at all levels) and a common canteen to all.
The structure ensures better communication and speedy decision making process. It also
creates an environment that builds trust) transparency and a sense of belonging amongst
employees.
GITM GURGAON
Page 6

SAREOLD!NG'
Maruti Suzuki India Limited was set up as a deemed public limited company in &,-& by an
$ct of #arliament. MSIL was classified in the #ublic Sector as long as the euity of
*overnment of India remained over :&;. $ License and /oint 1enture $greement was
signed in &,-3) with Suzuki Motor .orporation !SM.' acuiring 3=; of the euity. SM.
increased its euity to 68; in &,-,. In &,,3) Maruti ceased to be a government company) as
SM.Cs euity holding went up to :8;.
In 3883) SM.Cs share went up to :6.3;) making MSIL a subsidiary of SM.. The *ovt. of
India held 6=.=;) and employees trust holds the balance 8.3;.
$s of Sept 388=) Suzuki holds :6.3&; shares) *ovt. of India hold &8.3D;) rest of the shares
are distributed between the public) Insurance companies) +IIs) Mutual funds etc.
V!S!ON O% MAR"T!4
To be The leader in the Indian automobile industry
.reating customer delight and shareholder@s wealth
Be $ pride of India
GITM GURGAON
Page 7

MAR"T! S"&"K! !ND!A C"LT"RE
Building a distinctive organizational culture is one of the most challenging tasks faced by
any company. By organizational culture) is meant an organizational philosophy) which
guides the actions and behavioral pattern of the members. It also defines implicitly how
the external agents perceive the organization. 7ence the necessity of a work culture
which) while appealing to those within) also satisfies the expectations of those outside
the organizational environment. There is no use for a work ethic that creates highly
efficient pseudo%robots out of the employees. Such an approach might look like giving
dividend in the short term but will definitely lead to stagnation and frustration in the long
term.
$ harmony between the work culture and organizational ob(ectives is hence very
essential. It is the duty of every employee to work towards sustaining the EMAR"T!
C"LT"RE, which is built over the years.
2 S O% MS!L
S<I9I % #92#<9 S<L<.TI2A
S<IT2A % $99$A*<M<AT
S<IS2 % .L<$AIA*
S<I?<TS0 % .L<$ALIA<SS
S7ITS0?< % "IS.I#LIA<
3M O% MS!L
In factory various problems occur which hamper production and adversely affect the
uality of products. Most of these problems occur due to 5M4 %
M09I % IA.2A1<AI<A.<
M0"$ % F$ST$*<
M09$ % IA.2ASIST<A.G
GITM GURGAON
Page 18

3G O% MS!L
5* means) EIn case of an abnormality) all concerned members should actually go to the
place where the problem has occurred) see the actual thing and take 9ealistic action to
solve the problemH. In the /apanese language this point is compiled in 5 words4 %
*<A.7I % $.T0$L #L$.<
*<AB0TS0 % $.T0$L T7IA*
*<A/ITS0 % $.T0$LLG
3K O% MS!L

?IM<9$$9<T$ ?2T2 *$4 Fhat has been decided
?I72A "29I4 $s per the standard
?I.7IA T2 M$M2904 Must be followed
COMM"N!CAT!ON CANNELS
$s a part of open culture) all managers strive to facilitate both top%down as well as
bottom%up communications. $t all levels) throughout the company employees can
communicate on any business) organizational or personal concern) without having to
cross many channels. The organizational structure has deliberately been kept very flat
to facilitate communication.
GITM GURGAON
Page 11

ORGAN!SAT!ONAL STR"CT"RE AT MS!L
MSIL is a functional organization. The .ompany is divided into different divisions
according to the various functional areas. $ "ivisional Manager heads each "ivision.
"ivisions are further divided into "epartments) which are headed by "epartment
Managers who report to the respective divisional managers. "esignations in the
.ompany are based on the functional responsibility in terms of the .ompanyCs
philosophy of de linking designations and functional responsibility from the salary levels.
The total operations of the .ompany are divided into "ivisions like Marketing I Sales)
Spares) <ngineering) J.$. I Services) #roduction) #roduction <ngineering) Materials)
Information Services) +inance) #ersonnel I $dministration) etc. <ach "ivision is further
divided into "epartments.
+or example4 %
In Marketing I Sales "ivision) the departments are <xports) Marketing) Sales #lanning)
Sales I "ispatch) 92%<ast) % Fest) % South) % Aorth%I) Aorth%II I MSS%A. In Information
Services "ivision) the departments are Marketing I Sales Information) #roduction
Management Information) Materials Management information I 9esource Management
Information.
Maruti Suzuki india Limited has a total of 55:6 employees !not including trainees or
/apanese experts'.
GITM GURGAON
Page 11

S$STEM O% DES!GNAT!ON
There will be a dual set of designations. Internally) only the designations linked to
functional responsibility will be used. +or external dealings a different set of
designations may be followed.
The following system of designations would be practiced without any exception within
the .ompany. +or the purposes of defining explicit responsibility centers)
The .ompany has been divided into three layers of management.
"ivision
"epartment
Section
$n official of the .ompany) who will be designated as "ivisional Manager) "epartment
Manager) Section Manager respectively would head each of these responsibility
centers. 9emaining employees of the .ompany will have no specific designation and
would simply use the name of the "ivisionK"epartmentKSection to which they belong) to
identify their location in the .ompany.
The M" would make appointment to positions of "ivisional Managers and "epartment
Managers only. The "ivisional Managers would appoint section Managers.
GITM GURGAON
Page 1/

De-ignati)n %.)4*hart
GITM GURGAON
Page 1,
T e c h n i c i a n
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OVERV!EW O% #ROD"CT!ON AT MAR"T!
The plants were setup with an initial collective capacity of : lakh cars per year. But over
the years as the demand has increased Maruti has risen to the task and responded
tremendously to the market. By introducing automation at various levels) streamlining
and refinement of material handling systems and operator motivation and incentives)
Maruti is now churning out close to &8 lakh vehicles from the plants that were planned
only for : lakh.
GITM GURGAON
Page 13

M!LESTONES REACED B$ MAR"T!
6==<
Launch of SL6
6==:
Fagon9 Lx I Lxi L#*ew car plant and the diesel engine facility commenced
operations during 388=%388D at Manesar) 7aryana
6==2
The fiftieth lakh car rolls out in $pril) 388:
6==7
$lto becomes IndiaCs new best selling car
L#* variant of C2mni .argoC
1ersa :%seater) a new variant
Baleno LLi) a new variant
Maruti closed the financial year 3885%86 with an annual sale of 6D3&33 units) the
highest ever since the company began operations 38 years ago
6==3
Aew Suzuki *rand 1itara LL%D
<nters into partnership with State Bank of India
#roduction of 6 millionth vehicle. Listed on BS< and AS< after a public issue
oversubscribed &8 times
6==6
Fagon9 #ride
<steem "iesel. $ll other variants upgraded
Maruti Insurance. Two new subsidiaries started4 Maruti Insurance "istributor
Services and Maruti Insurance Brokers Limited
$lto Spin LLi) with electronic power steering
Special edition of Maruti -88) India@s first colour%coordinated car
GITM GURGAON
Page 14

Maruti +inance in Mumbai with &8 finance companies
6==>
&en L?i
Maruti True 1alue launched in Bangalore and "elhi
Maruti 1ersa) India@s first luxury M#1
$lto 1xi
6===
+irst car company in India to launch a .all .enter
Aew $lto
$ltura) a luxury estate car
>999
Maruti -88 <L !D,=cc) hatchback car'
>en 1Li !,,5cc) hatchback car with power steering'
2mni LL ! D,=cc) M01) high roof'
Baleno !&=88cc) 5 Box .ar'
Fagon 9
>99;
>en " !&:3D cc diesel) hatchback car'
Aew !2mni I 2mni <' !D,=cc) M01'
Launch of website as part of .9M initiatives
>99<
&,,- <steem !&3,,cc) 5 box car' LL) 1L and $L
Aew Maruti -88 !D,=cc)hatchback .ar' Standard and "eluxe
#roduced the 3 millionth vehicle since the commencement of production
GITM GURGAON
Page 15

>99:
*ypsy ?ing !&3,-cc) 6F") off road vehicle'
>en $utomatic !,,5cc) hatchback car'
Launch of 36%hour emergency on%road vehicle service
>992
Fith the launch of second plant) installed capacity reached 388)888 units
>997
<steem&.5L !&3,-cc) 5 box car'LL
#roduced the & millionth vehicle since the commencement of production
>993
>en!,,5cc) hatchback .ar') which was later exported in <urope and elsewhere
as the $lto
>99>
9eaches cumsilative indigenisation of =: percent for all vehicles produced
>99=
Maruti &888!,D8cc) 5 box') India@s first contemporary sedan
>9;;
Installed capacity increased to &88)888 units
>9;<
<xported first lot of :88 cars to 7ungary
>9;:
Maruti -88 ! Aew Model%D,=cc) hatchback .ar'
#roduced &88)888 vehicles !cumsilative production'
GITM GURGAON
Page 16

>9;2
Launch of Maruti *ypsy !,D8cc) 6F" off%road vehicle'
>9;7
2mni) a D,=cc M01
Installed capacity reached 68)888 units
>9;3
Maruti -88) a D,= cc hatchback) India@s first affordable car.
#roduction was started under /1$
>9;6
License and /1 agreement signed between Maruti Suzuki india Ltd. and SM. of
/apan
>9;>
Maruti Suzuki india Ltd was incorporated under the provisions of the Indian
.ompanies $ct) &,:=.
GITM GURGAON
Page 17

OW !S 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. +rom the press shop) the parts are send to the weld
shop) where they are welded to make the frame of the car. +rom the weld shop) these
frames are transferred via conveyors to the paint shop) where these are coated and
glazed. +rom 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 <ngine 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 1.I deptt.
conducts various tests to ensure that no defects remain before the car is dispatched via
trucks to various parts of the country.
GITM GURGAON
Page 18

The @.)4 *hart @)r a t,+i*a. *ar A)d, 4e.d .ine .))k- a- @)..)4-'
GITM GURGAON
Page 11

The Aa-i* .a,)5t )@ a +aint -h)+ i- a- @)..)4-'
%r)m 4e.d -h)+
GITM GURGAON
Page 11

The @eat5re- )@ an a--emA., -h)+ i- -h)4n a- @)..)4- '
Trim line4 The car body moves over the conveyor on mounts) as shown below4

.hassis Line4 7ere) the car is loaded on overhead (igs as shown below4


+inal Line4 7ere) as both the engine and wheels have been fitted) the car once again
moves over the conveyor belt.


GITM GURGAON
Page 1/

D!%%ERENT SO#S !N MAR"T! S"&"K! !ND!A L!M!TED

>. #RESS SO#
The press shop can be regarded as the starting point of the car manufacturing process.
.entrally located between weld &) weld 3 and weld 5 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 reuirements picks the finished body parts from the press shop.
These may be divided as $) B and .. M$@ 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 reuirements. MB@ and M.@
components are manufactured by (oint ventures or bought from vendors. The press
shop can be explained under following headings4
0a1 Ra4 materia.
0A1 B.anking .ine
0*1 Stam+ing .ine
'a* Ra4 materia.: The raw material is in the form of cold rolled steel coils. It is specified
in terms of steel grade and width of coil reuired. The coils weigh about &:888 kg.
'b* B.anking .ine' There are two blanking linesN 92SL !9otary 2scillatory shear line'
for rectangular shapes and the others employing die cutting for irregular shapes.
'c* Stam+ing .ine' there are six presses of capacity varying from &:88 Ton to 6888
Ton) out of which five are transfer presses and one is semi%automatic press. The die
can be changed to obtain different body components.
GITM GURGAON
Page 1,

6. WELD SO#
The body panels produced in the press shop and the other small components are (oined
here to give the Ewhite bodyH or EshellH. In a typical car body &688 different components
are welded together. The weld shops have the following facilities.
Felding (igs
Spot welding guns
?awasaki welding robots
7emming machines
#unching machines
#ROCESS O"TL!NE' The shop has different lines for different models) each of) which
is further divided into three parts4
"NDER BOD$' 7ere 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.
MA!N BOD$4 $s the body moves on) the conveyor roof and side body panels !prepared
on the sub lines' are welded to it to give the main body. The chassis number is punched
on the cowl top and it is welded to the front engine room panel.
W!TE BOD$' The doors) hood and back door are attached on the main body with the
help of bolts and screws to make it a Ewhite bodyH. The body is checked for dent) burr
and spatter and these defects are repaired. $fter inspection and repairs the body is
called FB2?. It is sent to the paint shop thereafter.
GITM GURGAON
Page 13

3. #A!NT SO#
In the paint shop following processes are carried out4 %
There are five plantsKunits 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 are4 %
'a* #re/treatment 0#T1' The body is thoroughly washed to remove the dirt and oil
scales. Then the body is treated with >n#26 !phosphating' to prevent corroding of
the body.
'b* ED *)at' This is done by electric deposition method) at 3681%dc supply. $fter
applying the <" coat the body is baked in oven.
'c* S)./-ea.er and 5nder *)at' 7ere the left in the body !due to welding' are filled with
sol%sealer to provide waterproofing. 0nder coat is done on the surface above wheels
to prevent damage of body in that portion.
'd* !ntermediate *)at' This is done by spray%painting method using &8 ?awasaki
9obots. $fter applying the coat) the body is dried in the oven. #ainting done is
basically an intermediate coating to provide base for the final coat.
'e* T)+*)at4 This is done by spray%painting method using 38 ?awasaki 9obots. +or
metallic coating) double coats are applied and aluminum flakes are provided to
shine the metallic paints.
$fter inspection and touch up) the #BOK8 i.e. the paint body ok is sent to the assembly
shop.
GITM GURGAON
Page 14

MAC!NE SO#
The machine shop is the source of all ma(or components for the <ngine $ssy. Shop.
The unmachined crankshaft and camshaft forgings) transmission case) cylinder head
and cylinder block castings are brought in as raw material from vendors. The cylinder
head and transmission case are aluminum castings while crankshaft and camshaft are
steel forgings.
It has the following lines
Transmission .ase Line
.ylinder 7ead Line
.ylinder Block Line
.rankshaft Line
.amshaft Line
ENG!NE ASSEMBL$
<ngine assembly 5 is currently used to assemble the &8=&cc engine for Fagon9) +-"
engine !:%speed transmission) D,=cc M#+I' for .ar-88 and $lto. <ngine assembly is
divided into 5 main Sub%$ssemblies) one Main Line and a +iring Test. The sub
assemblies are4
.ylinder Block Line
.ylinder 7ead Line
Transmission Line
The cylinder block) cylinder head) transmission case) camshaft and crankshaft are
received here from the machine shop.
GITM GURGAON
Page 15

ASSEMBL$ SO# /!
There are 5 assembly shops in MSIL which produce on an average &D:8 cars daily.
The assembly shop receives #B%2? i.e. paint body 2? from the paint shop. 7ere the
body is loaded on an over head conveyor. $s the conveyor moves the body) fitments
are made at various stations.
$ssembly I mainly produces MAR"T! ;== 0D)me-ti* B EC+)rt Main.,18 &EN EST!LO
0D)me-ti*B EC+)rt18 OMN!0#a--enger B Carg)18 EECO8R!T& B WAGON R0ne4
m)de.1.
The Fhole process of assembling undergoes through different number of stations.
There are about 5D: employees in two shifts. The $sssembly shop can be further
subdivided as following
Trim
.hassis
+inal
TR!M L!NE
Trim can be further subdivided as following4
Trim >
This is the beginning of the assembly line conveyor. 7ere amongst the first tasks done
is attaching the hydraulic supporters for the boot. The assembly line check sheet is put
inside the body. "oor is removed here and sent to final line .The various fitments made
here are doorKfloor 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 later.
Trim 6
GITM GURGAON
Page 16

It starts with 9ear combination light fitment. 2ther operations done here are vacuum
boosterK brake master cylinder fitment) seat belts) fuse box) wiper sprayer and motor)
accelerator) clutch) brake pedals) door glasses and aKc panel fitment. Trim 3 ends with
the fitment of the instrument panel) which is received from an instrument panel sub%
assembly. This sub assembly involves the fitting of the speedometer console) ashtray
and stereo system. .
Trim 3
The fittings done here are rear inside cover for boot) back door glass and windshield)
uarter glasses and connecting pipe between fuel lid and fuel tank. Steering gear is
mounted. +or cemendine application on the windshield) Motoman robots are employed.
7ere a process check is done
CASS!S
The chassis receives a trim up body. 7ere underbody fitments are made) hence body is
loaded on overhead (igs. .hassis is subdivided as following4
Cha--i- >
1arious 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. #rocess check is done at the end of .hassis &.
Cha--i- 6
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 I" plate fixation. $ process check is done at the end of
chassis 3.
GITM GURGAON
Page 17

%!NAL
Since all the fitments have been made) the body is referred as vehicle from now
onwards. The vehicle is loaded on the final conveyor. +inal area is further subdivided
as4 %
%ina. >
The fitments made here are Spare wheel cover) scuff) seats) roof trim and carpet) boot
carpet) battery and air cleaner. .lutch cable and parking brake connections are made.
Brakes are evacuated and brake oil is filled. .oolant is also filled.
%ina. 6
+ive liters of petrol is filled in the vehicle. $K. vaccum and charging is also done here)
the refrigerant used here is 9&56a !688 gm O% :8'."oor $ssembly is also done here.
%ina. 3
There is a process check at the end of this line. The vehicle is said to be $B%2? now. It
is handed over to the vehicle inspection department.
GITM GURGAON
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VE!CLE !NS#ECT!ON / !
The 1<7I.L< IAS#<.TI2A II having the following stations 4
Toe%in test
Slip tester
7ead lamp test
$ppearance test
"rum test
Brake test
<ngine room and #it inspection
Shower test
9oad test
+inal check
Genera. #r)*ed5re
In 1I a vehicle is checked at checkpoints in the above mentioned order. $t each
checkpoint different parameters are checked. <ach vehicle is issued a check%sheet in
which the operator at the check points marks down the defects if any) otherwise he
marks an 2? stamp. $fter the road test if the vehicle has 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 on the type of defect4
$ssembly repair
Feld repair
#aint repair
<ngine $ssembly repair
GITM GURGAON
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$fter repairs the vehicle is then sent to the final check conveyor where the repair work is
checked and if satisfactory then the vehicle is given final clearance.
T)e/!n Te-t
This is the first inspection point for a vehicle once it comes off the assembly line
conveyor. Before the vehicle is accepted for this test it is checked for external damages)
feel of the brakes and floor carpet. The ob(ectives of doing the toe%in test are as follows4
Minimum tyre wear
Steering position 2?
Minimum side slip
Toe%In refers to the alignment of the wheels. It is not possible to have a wheel alignment
such that the wheels are perfectly straight !ideally this leads to minimum tyre wear'. The
wheels are either pointing slightly inwards !toe%in' or outwards !toe%out'. $lso when a
car is in motion then the wheels tend to align outwards so vehicles are generally set with
a toe%in condition. Statistical analysis and experiments has given a value of toe%in 3 and
toe%out & for front wheels in .ar-88) Fagon9 and Baleno. Baleno has rear wheel
allowance of toe%in 5.: and toe%out 8.:.
$nother point checked here is the steering position. .orrect steering position refers to
that setting of the steering wheel that would allow the car to move in a straight line and
which is the natural position of the wheel i.e. the driver isn@t holding the steering wheel.
+igure no. : shows the toe%in tester machine.
GITM GURGAON
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SL!# TESTER
This machine checks vehicle slipping after the toe in ad(ustment. The machine is
calibrated for 3 unit toe%in and & unit toe%out. If the vehicle slipping falls in between the
calibration limits) the vehicle is 2? in slipping otherwise A2T 2?.
EAD LAM# TESTER
2ften the car driver faces the problem) the headlight beam ad(ustment. Because of the
malad(ustment the light beam falls on unwanted ob(ects. $t the headlamp tester) a
yellow cross represents the position of the headlamp whereas the point where it should
ideally be is shown as green rectangle. The operator manning the test tries to get the
yellow cross inside the green rectangle by ad(usting screws for horizontal and vertical
alignment of the lamp.
$part from checking the headlamp) turning radius and other things are also checked at
this checkpoint.
A++earan*e Te-t
This test involves evaluating a vehicle on a large number of parameters ranging mainly
from external appearance of the vehicle to the internal trim fittings to checking for
coolant level and braking fluid level. The vehicle is loaded on a conveyor. The vehicle is
visually inspected for weld) paint and assembly defects and the same are marked on the
diagrammatic representation given on the checksheet. The appearance check points
are I." plate) emblems) bumper) doors) fuel lid) front hood) routing and clamping) seats)
interiors) seat belts) weather strips) tyres and glasses.
1arious paint defects are paint peel off) scratches) paint miss) overflow) orange peel)
shade mismatch) pin holes sealer application and sanding marks. 1arious weld defects
are level difference) dents) door gap and fouling.
The vehicle is driven in all the gears and the various parameters checked are as follows4
GITM GURGAON
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Steering wheel 4 positionKvibration
.lutch 4 free play 38%58 mmKnoiseKengagementKdisengagement
$ccelerator #edal4 free play 3%D mmKoperation
*ear shifting4 hardKnoiseKslippage
Speedometer4 needle vibrationKerrorKreading at 68 kmKh
7orn4 volumeKtone
FiperKwasher !frontKrear'4 auto stop positionKwipingKspraying position
Farning lamps and indications4 parking brakeKbattery changingKoil
pressureKhazard lampKturn signalKpilot lampKroom lampKpanel lightKpre heatKbrake
oil indication.
9ear view mirror4 blurred imageK distortion
+uelKTemperature gauge4 function
Lamps4 #arking) head lamp highKlow) side turn signal) cabin lampKdoor switchKfog
lamp) brake light) hazard lamp) reverse light
Blower4 2peration of switch at different speeds) air direction control) freshKre%
circulating air control) fins
7eater4 functioning) switch operation
$K.4 functioning) switch operation
.hoke4 operationK function
$bnormal noise of any kind from wheelsKbodyKengine should not be there.
Brake Te-ter
The front and rear brake forces are measured here. 7ere the brake pedal is checked
for hardness) sponginess) play and noise. #arking brake force is also checked here.
The vehicle is moved onto the drums) vehicle brakes are employed and the
corresponding resistance force is measured with the help of computerized machine. The
measured force is displayed on the screen and must lie between the values prescribed
by the company.
GITM GURGAON
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Engine R))m
7ere the engine is inspected for various kinds of defects such as tappet noise) clutch
lever play !.ar-88') exhaust emissions as per the standards laid down) idling rpm with
and without $K. switched on. In case of M#I cars) a "L. !"ata Link .onnector' cable
is used to detect the working of <lectronic .ontrol Module and various sensors. The
"L. cable is connected to a computer which shows not ok if there is any malfunctioning
in the engine. The defects are noted on the checksheet to be repaired in assembly or
engine assembly.
#it !n-+e*ti)n
The underbody of the vehicle is checked for4
Brake fluidKcoolantKfuelKengine oil leakage
9ed and yellow paint on nuts) bolts and fuel and brake pipes !the paint indicates that the
nuts and bolts have been properly assembled and checked for torue'Muffler mounting
bolt 9ear suspension coil or leaf spring
Sh)4er Te-ter
The vehicle is moved on the shower tester conveyor belt where it passes through a
series of shower (ets aligned at different angles and locations. Fhile passing through)
the vehicle is sealed i.e. all window glasses are rolled up and doors closed. Fhen the
vehicle exits from other side of the shower tester an inspector checks the cabin for
water seepage. If water is found) then the particular leak defect is repaired in the shower
repair section following which the vehicle is sent for the road test.
R)ad Te-t
GITM GURGAON
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9oad test of a vehicle consists of a track on which the vehicle is run at predetermined
speed. The track is designed so as to check the various aspects of the vehicle such as
braking) acceleration) handling) performance etc. "istance traveled after application of
brakes) reverse braking and Steering positioning is also checked. $fter driving the car at
a fast speed it is made to take a 0%turn to try and find for any loose part in the panel.
2ther parameters checked in the road test are4
Steering stability4 positionKplayKvibration
.lutchKaccelerator pedal4 playKnoise
Brake4 noiseKsponginessKbrake pulling
9ear view mirror4 blurred imageKdistortion
*ear shifting4 gear slipKengagementKhard disengagementKnoise
"efogger4 functioning
Speedometer4 needle vibration
$bnormal noise of any kind from panels) doors) wheels ) engine) hood etc is noted
down
%ina. Che*k
This is the last of the vehicle inspection checks. $fter the vehicle has gone through the
other tests and if there are no repairs to be done then it is sent to final check. 7ere the
overall appearance of the vehicle is checked again.
Scratches) dents) cleanliness and .emedine!windscreen sealer' leftovers are checked
for. $lso secondary defects i.e. defects that may creep in while repairing the primary
defects are also checked for. Inspection stamps for all the previous check stations are
checked to see that there is no inspection miss. +inally the chassis and engine number
on the I.". plate are verified and the +inal .heck 2? ! +.2?' sticker is put on the car
and it is sent to the final check parking area. +. 2?@ed vehicles are later picked by the
Sales and "ispatch drivers.
GITM GURGAON
Page /4

"EE# $%R T&E 'R%(ECT
he need of the pro$ect is to increase the productivity of the wor!ers both in terms of quality and
quantity. his can be achieved by doing the time study of the various wor!ing stations of line.
he main purpose of implementing time study in %S& - )ear &xle Sub &ssembly and layout
design is to+
Identify and Eliminate hidden waste of time+ 9idden waste refers to those waste which
are not visible during the process but still exist.
To calculate standard time of each process+ Standard time of each action performed by
the wor!er is calculated by using M.S, thus standard time of each process can be
found.
ine balancing+ he goal in balancing an assembly line is to assign tas!s to stations such
that equal amount of wor! is performed at each station.
!an power reduction+ o optimize the :ine by calculating the required Man power -
removing the extra wor!ers from the line.
GITM GURGAON
Page /5

)ntrodu*tion to Time Study
In business efficiency studies, Time Study 'an Industrial %ngineering term* is the time required
for a person to complete a tas! or operation at a defined rate of wor!ing. It includes appropriate
allowances to allow the person to recover from fatigue and, where necessary, an additional
allowance to cover contingent elements which may occur but have not been observed. he
Standard ime is the product of three factors#
1. %bser+ed Time + he time required to complete the tas!.
1. Rating $a*tor + he pace the person is wor!ing at. 78; is wor!ing slower than normal,
118; is wor!ing faster than normal, 188; is normal. his factor is calculated by an Industrial
%ngineer trained to observe and determine the rating.
1. '$# Allo,an*e + <ersonal, =atigue, and >elay &llowances. hese include factors such
as# &re the wor!ers standing all day? &re they wor!ing in a cold environment? >o they
have to wear safety equipment?
-et.od to Cal*ulate Time/
In this pro$ect I have calculated time at different stations by using stop watch. "efore calculating
the time at each, first we have saw that how many operator at each station has and what is their
method of doing the wor!. If we analyze all the relevant details of station and accurately !new
the amount of component that each operator fit in the ob$ect then only accurate time is measured
with the stop watch.
GITM GURGAON
Page /6

Rear Axle Sub Assembly 0ine "o.1
In rear axle sub assembly of line no., rear axle of %eco - )itz are made. In this section there are
/ stations in which different operation performed by each operator. In this various components
attached to the axle frame. he components such as bra!e sub assembly, drum head, trailing
arm, par!ing cable, brea! pipe, % rings, clamps, spindle rear, stic!er, oil filling in %eco, hose
pipe, plug, bump stopper, helical springs etc.
In this section there are two stations on conveyor belt and one station for engine mounting.
Stations of Rear Axle Sub Assembly
Station no.1
Station no.2R
Station no.20
Station no.3
#ESCR)'T)%" %$ STAT)%"S AT REAR A40E S5B ASSE-B06/
STAT)%" "%.1/
GITM GURGAON
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In this station the axle of %eco - )itz first transfer from trolleys to the station no1 with the help
of crane and then component such as bra!e sub assembly, hose pipe, oil filing etc. done on axle
frame. In this station only one wor!er is engaged.
STAT)%" "%.2/
In this station 1 wor!ers are engaged on left and right side. &t station no.1 ')-:* the component
such as trailing arms, bra!e pipes, hose pipes, clamps, par!ing cable and drum head attach on the
axle body.
STAT)%" "%.3/
In this station the axle is moved from conveyer belt to lift and from lift it is attached to car body
with the help of bolts and lateral rod, helical springs also attach at the same time.
Time Cal*ulation/
ime at each station is calculated / times with the stop watch, so that standard time can be
obtained. Standard time of both cars of line no., %eco - )itz at each station is shown below in
the table.
GITM GURGAON
Page ,8

.perator wor!ing at rear axle sub assembly
Time Study #ata S.eet
AC.e S5A A--emA.,

Stati)n n). t)ta. time taken!in seconds'

station no.&
<eco &.:&P=-total'
loading from trolley &DP&-sec


9itz &P38P5-min !total'
loading &3.33sec
fetching of component 3.8-sec


station no.3
<cco &P&:.=3min
9itz &P66.63min


station no.5

9itz &.:5P&=
<cco &.:5P&=
<cco!lining front fender' -.-=!seconds'
GITM GURGAON
Page ,1



E"7)"E -%5"T)"7 STAT)%"
&t this station an engine is fited to the car by using an automatin lift.
wo operators wor! on this station below the lift.

he time observed is as follow#
'ERS%" 1
'ERS%" 2
GITM GURGAON
Page ,1
%'ERAR)%"S
T)-E(EEC% T)-E(R)T8
Total time 9:.:;se* <=.=9se*

0ine 0ayout of 0ine no.=
)"TR%#5CT)%"/
A line layout study is an engineering study used to analy>e
different ?.ysi*al *onfigurations for an industrial ?lant.
#efinition/
Definition of Line Lay out
0ine 0ayout is the physical arrangement of equipment, facilities - man power within a line. he
0ine 0ayout can be indicated on a floor plan showing the distances between different features of
the line. .ptimizing the :ayout of a line can improve productivity, safety and quality of
<roducts. @nnecessary efforts of materials handling can be avoided when the :ine :ayout is
optimized. his is valid for#
+ >istances Material has to move
+ >istances %quipment has to move
+ >istances .perators have to move
+ ypes of 9andling %quipments needed
+ %nergy required to move items against resistance 'i.e. gravity*
GITM GURGAON
Page ,/
%'ERAR)%"S
T)-E(EEC% T)-E(R)T8
Total time 9@.=1se* 1;2.:@se*

0ine 0ay out of line no.=(AA7%"-R
:ine no.3 mainly contains three most important sections. he sections are#
Trim
C.assis
$inal
Trim/
rim of line no.3 has 1/ stations on its right side and 1/ stations on its left side. In trim sections
/, wor!ers are engaged at its different stations and all are of different categories. he categories
such as casual, permanent, ., apprentice, reliver and repairmen. he category of each wor!er
at each station is shown in table /.
C.assis/
Ahassis of line no.3 has 1, stations on its right side and 1, stations on its left side. In chassis
sections 14 wor!ers are engaged at its different stations and all are of different categories. he
categories such as casual, permanent, ., apprentice, reliver and repairmen. he category of
each wor!er at each station is shown in table ,.
$inal/
=inal of line no.3 has 17 stations on its right side and 17 stations on its left side. In final sections
,5 wor!ers are engaged at its different stations and all are of different categories. he categories
such as casual, permanent, ., apprentice, reliver and repairmen. he category of each wor!er
at each station is shown in table 3.
GITM GURGAON
Page ,,

Table "otations#
C-CAS5A0 '-'ER-A"E"T
T.T-TRA)"EE A-A''RE"T)CE
Trim #ata/ 0eft Station (table no.1
Station Category of ,orBer
10 C
20 C
30 C
10 C
=0 T.T C R
90 C
<0 C
@0 C
110 T.T
120 C
110 C
1=01 C
1=02 C
190 C
1@0 C
2;0 T.T
210 '
230 '
.
GITM GURGAON
Page ,3

Trim #ata/ Rig.t Station
Station Category of ,orBer
1R C
2R C
3R C
1R C
=R C
9R C
<R C
@R T.T
:R C
11R C
12R C
11R C
1@R '
2;R C
21R C
23R '
)'SA 2'
=C
ETSA 1'
1T.T
=C
RE0)EDER-3
C.assis #ata/ 0eft Station
Station Category of ,orBer
210 C
2=0 C
290 A''.
2<0 C
2@0 C
2:0 C
GITM GURGAON
Page ,4

330 C
310 C
3=0 C
390 C
3<0 '
REAR A40E ASSE-B06
CE"TRE C
0E$T C C C
C.assis #ata/ Rig.t Station
Station Category of ,orBer
21R C
2=R C
29R A''.
2<R C
2@R C
2:R C
31R C
31R C
3=R C
39R C
3<R '
REAR A40E ASSE-B06
GITM GURGAON
Page ,5

R)7&T C C C
RE0)DER-3

$inal #ata/ 0eft Station
Station Category of ,orBer
3@0 C
3:0 C
110 ' C A''.
120 A''.
130 C
190 C
1<0 '
1@0 '
1:0 C
=;0 T.T
=20 C
=30 A
==0 '
=90 C C C(underbody-')T
=<0 C
=@0 '
=:0 '
9;0 '
GITM GURGAON
Page ,6

910 '
920 '
930 '
9=0 '

$inal #ata/ Rig.t Station
Station Category of ,orBer
3@R C
3:R C
11R C
12R T.T
13R '
11R C
1<R C
1@R C
1:R C
=;R C
=1R C
=2R A
=3R C
==R C
=9R C
=<R C
=@R '
=:R '
9;R C
91R '
GITM GURGAON
Page ,7

92R '
91R '
99R '
RE0)EDER-2 A%REERS AT C"7 STAT)%" -=
#R)DER-2 RE'A)R-A"-1; (%$$0)"E-2 C %"0)"E-2

:IB% :&C .@
:ine layout is made on white board in which 1 tapes of blue and red color stic! on it borders.
"lue tape is stic! on white showing the trim, chassis - final sections and also showing all the
wor!ing stations that / section of line no.1 has. %very stations on white board is shown with the
of mar!er and all wor!ers on each station are then implement with the of above tables. In this
line layout each wor!er assigned different color of magnets and then each magnet are put on
mar! station in white board according to its category. &fter doing all the above stated tas! line
layout is made on white board.
GITM GURGAON
Page 38



C%"C05S)%"
he 4 wee!s Industrial raining is indeed the most important part of our curriculum at the
Mechanical %ngineering >epartment of 7)T- 75R7A%". It provides me an opportunity to
gain experience on the practical application our technical !nowledge.
I have done my industrial training in the ASSE-B06 S&%'-1 of -AR5T) S585E) )"#)A
0)-)TE#. In my training I have leaned 3 topics IM% ST5#6 TEC&")F5E A"# 0)"E
0A6 %5T #ES)7". ime Study is a very useful tool which can be employed in manufacturing
companies li!e Maruti which have to constantly cater to ever increasing demand from the mar!et
with very small lead times. he overall experience that I have gained at Maruti helped me a lot in
my future. In the end I would li!e to than! my Mentor at Maruti and all staff members of
assembly shop +1 who have encouraged and inspired me to achieve higher goals.
GITM GURGAON
Page 31


RES50T
&. Standard time for ea*. o?eration in E"7)"E
-%5"T)"7C 0)"E "%.1 is Bno,n.
2. Standard time for ea*. o?eration in REAR A40E S5B
ASSE-B06 is Bno,n.
5. 0)"E 0A6 %5T %$ 0)"E "%.= is made.
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GITM GURGAON
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