A Seminar on

PRACTICAL TRAINING
AT
Maruti Suzuki
Gurgaon Plant

2018-2019
SUBMITTED TO : SUBMITTED BY :
Mr. B L Gupta Sir Hemant Singh
4TH YEAR M.E. DEPARTMENT
HEAD OF M.E. DEPARTMENT

DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT ENGINNERING COLLEGE
BHARATPUR, RAJASTHAN
PROJECT - SHOP FLOOR HEALTH CHECK
UP FOR IMPROVEMENT IN MACHINE
SHOPS

Head of project –

Mrs. ALPANA PANDEY

Assistant Manager(OPC)
Introduction-
Shop floor health check up refers
to a systematic process which
helps to keep the operations lean
for cost savings, healthier and
more agile operation.
Various systems used to carry out
during health check of shops:

1. MOS-K

2. LINE REJECTION

3. SKILL MATRIX
1. MOS-K –
 Here MOS stands for “Maruti
Operation Standard” and S refers to
it is to be filled by the supervisor.

 To maintain manufacturing process

and control operating conditions,
supervisor needs to confirm these
conditions.
MOS-K SHEET:
2. LINE REJECTION-

The objective of this Procedure is to

stipulate guidelines to deal with the
parts/ subassemblies/ spare parts/
direct raw material which are
deemed unusable owing to
abnormalities, noticed during various
stages of processing.
3. SKILL MATRIX-

 Objective of this procedure is to

measure and evaluate the skill
level of the employees
periodically and to utilize them
effectively based on skill sets
available for flexibility in line
management.
SKILL MATRIX SHEET:
• Skill Evaluation-
Skill levels are measured and evaluated in four
levels:
 Level 1: Basic training completed
 Level 2: Can complete the task to the
required standard
 Level 3: Can complete the task to the
required standard in the required amount
of time
 Level 4: Can do all the above and train
others
RESULT-
 After analysing these systems we were able
to suggest improvements which helped to
improve tracking of root cause of any defect
or problem which arises from customer
side.
 Tracking of root cause of any defect or
problem is utmost important to any industry
in order to fix the issue from ground level
and avoid such problems in future.
 COMPANY PROFILE

 Type of industry– Automotive: company designs and

manufacture motor cars.
 Key representative – Mr. Kenichi Ayukawa (CEO).
 Revenue – 79606 crores rupees (US $12 Billion) (2017).
 Employees – 40000 (2018).
 Company Shares – 1) Suzuki Motor corp. – 56.21%
2) public – 43.79%
 Market Share – 51% of Indian passenger car market.
MANUFACTURING FACILITIES
Manufacturing Production of Model
facility

Gurgaon Alto 800(YE3), WagonR and WagonR Stingray(YR9),

Omni(Y88), Gypsy(E19), Ertiga(YL8), Ignis(YJC),
Eeco(YG8), S-cross(YAD), Super Carry(Y9T) and
Vitara Brezza(YBA)

Manesar Alto K10(YE3), Dzire(YSD), Swift Dzire Tour(YN8),

Ciaz(YL1), Baleno(YRA), Baleno RS(YRC) and
Celerio(YL7)

Gujarat Swift(YP8) and Baleno( YRA & YRC)

Besides this Maruti Suzuki also has one R & D facility in Rohtak.
 Engine Series
Petrol engine series – There are five types of engine series F, G, J, M and K out of
which J and M do not have any currently running models.
Series F G K
Current  Omni • Eeco • Swift • Ciaz
Models • Alto 800 • Gypsy • Dzire • Alto K 10
• WagonR • Baleno
• Stingray • Ignis
• Ertiga • Swift Dzire
• Celerio tour
Diesel engine series- There are three diesel engine series out of which Z doesn't
have any currently running models.
Series D E
Current Models • Swift • Celerio
• Dzire • Super Carry
• Ertiga
• Ciaz
• Baleno
• S-Cross
• Vitara Brezza
• Ignis
THANK YOU
 PRESS SHOP
Steel coil Blank Panel

 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.
 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. Cutting
6. Piling/ stacking
 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.
 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.

Under Body - Here different underbody panels are welded

together. These comprises of rear underbody, central
underbody, front engine room panel.

Main Body - The chassis no. is punched on the cowl top

and it is welded to the front engine room panel.

White Body - The doors, hood and back door are

attached on the main body with the help of bolts and
screws to make it a “white body”. The body is checked for
dent, burr and spatter and these defects are repaired
 PAINT SHOP
Pre-treatment - The body is thoroughly washed to remove
the dirt and oil scales. Then body is treated with Znpo4 to
prevent corrosion.

ED coat - This is done by electric deposition method. After

applying the ED coat the body is baked in oven.

Intermediate coat - This is done by spray painting

method. After applying the coat, the body is dried in the
oven.

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.
 ASSEMBLY SHOP
 Trim line - The vehicle proceeds through a series of Trim workstations
where team members begin by installing weather stripping, moldings
and pads. Then they put in wiring, vents and lights. After an instrument
panel, windows, steering column and bumper supports are added, it
starts to look less like a shell and more like a car.

 Chassis Line - This is where many safety-related items are installed.

Things like brake lines, torque, gas tanks and power steering are
double-checked. The engine is installed, along with the starter and
alternator. Then come suspension and exhaust systems. Then wheel is
mounted with the help of wheel nut fastening machine.

 Final Line - From there the vehicle enters Final 1, which covers many
interior items such as the console, seats, carpet, glove box and
steering wheel. This is also where bumpers, tires and the battery are
added, as well as finishing touches like covers and vents. Then,
Coolant, Brake oil, Power steering oil are filled and also the A/C gas
are charged.
 VEHICLE INSPECTION
Vehicle inspection has the following testing stations:
 Toe in test
 Slip test
 Headlamp test
 Appearance test
 Drum test
 Brake test
 Shower test
 Road test
 Final check
 Process Outline Of Diesel Engine Crankshaft
The crank line manufacturing process of D13A diesel engine which is used in various
models in Diesel Machine Shop. Where we learned every step of manufacturing
process. This line is highly automated, here all the process that are being carried out
is done by CNC Machines.

Rear end

Front end

Crankpins
Step 1 - In this step firstly the centering of the crankshaft takes place so that
other operation can be carried out easily by the CNC machine, after that by
the same machine the facing of the rear and front end takes place then the
reference pad milling is done because all the radial measurements are taken
from this reference pad then the drilling of mfg. holes is done.
 Step 2 - In this step turning of front and rear end
takes place and the dimensions after the turning and
step turning are shown below:

Part Name Dimensions in mm.

Flange dia. 78.45±.10
Rear end step dia. 41.5±.1
Front end dia. 1 28.5±.1
Front end dia. 2 29.5±.1
Front end dia. 3 38.1±.1
Front end dia. 4 39.5±.1
Step 3 - In this step rough milling of all five journals and eight counter-
weights takes place. The final dimension of the part is shown below:
Part Name Dimensions(mm.)
Dia. Of all journals 52.2 ± .2

Width of all journals 22.65 ± .15

Step 4 - In this step 'finish turning' of journals takes place where their dia.
is reduced to 51.45±.1, journal J2, J3, J4 width is reduced to 23.45+.15 and
journal J5 width is reduced to 23.40±.15.
Step 5 - In this step semi finish milling and undercutting of crankpins takes
place and width of web is also reduced in this step. Dimension (mm) of the
final part is shown below:

Part Name Dimensions (mm.)

All pins dia. 43.3 ± .1
All pins undercut dia. 41.8 ± .1
All pin width 23.95 ± .10
Web width 25.45 ± .15
Step 6 - In this step oil hole drilling and chamfering of journals & pins takes
place. Here the holes are drilled from pins to journals are shown as below:

Part Name Dimensions(mm

)
Journal oil hole dia. 1 5.55± .10
Journal oil hole dia. 2 6.0 ± .1
Angular oil hole dia. 1 5.55± .10
Angular oil hole dia. 2 5.6 ± .1
Angular oil hole dia. 3 5.8± .1
Step 7 - In this step washing of crankshaft and air blowing of holes at
specified pressure range (2-4 bar) is done to remove chips and other
particles that might remain inside the oil holes which might result in engine
seizure.

Step 8 - In this step to increase the strength induction hardening of crankpins

and journals with the help of heating coils is done. The hardness required is
in the range of <=50-70 HRC. If hardening depth is not proper, it may result
in crack or component breakage during engine or vehicle operation, here
cooling is done by water.
Step 9 - In this step tempering of the crankshaft takes place wherein the
temperature should be in the range of 180±10 °C. If temperature is not within
the defined range, hardening stresses may not be relieved which may result
in crack or component breakage during engine working and the hardness in
this step should be in the range of 48-70 HPC, because if hardness is not
proper, it may result in crack or component breakage during engine or
vehicle operation, here cooling is done by air blowers.
Step 10 - In this step deep rolling of the journal and crank pin takes place
which is required to increase the fatigue strength which combines the
generation of compressive stresses, removing the micro notches and
therefore significantly increasing the service life of the component.

Step 11 - In this step machining of both ends takes place which includes
lapping, drilling, threading and reaming by a single machine. In this step
drilling of 8 holes (M8-6H) on flange and drilling of holes at both ends with
tapping takes place.
Step 12 - In this step turning of thrust face and front end dia. takes place in
which final dimension of thrust width is 24±.025.
Step 13 - In this step grinding of crankpins takes place hence the dia. is
reduced to 42.597±.007 mm. If dia. of pin is not proper, bearing may not be
properly mounted in engine or bearing may foul with crankshaft during
engine operation resulting in abnormal noise or damage to crank shaft. If
burning or chatter marks are present on dia., it may damage the bearing in
engine.
Step 14 - In this step finish grinding of all journals and front end takes place. If dia. of
journal is not proper, bearing may not be properly mounted in engine or bearing
may foul with crankshaft during engine operation resulting in abnormal noise or
damage to crankshaft. If burning or chatter mark present on dia., it may damage the
bearing in engine. Their dimensions are given below:

Part Name Dimensions (mm)

All journal dia. 50.997±.007
Front end dia. 1 28(0.0/-.030)

Front end dia. 3 29(0.01-.030)

Step 15 - In this step finish grinding of flywheel side takes place which
includes spigot, oil seal and flange. If dia. of oil seal and spigot is not proper,
flywheel may not be properly mounted in engine or flywheel may remain
loose resulting in loss of engine power and degradation of engine
performance. If burning or chatter mark present on dia., it may damage the
bearing in engine.

Part Name Dimensions (mm)

Flange dia. 78.007±.015
Rear end step dia. 41.0(0.0/-.03)

Length from J3 to front of 192.5±.2

flange
Step 16 - In this step dynamic balancing of crankshaft takes place by making
holes on counterweight, here maximum allowed unbalance for each
compensation level is 100g-mm.

Step 17 - In this step washing of crankshaft takes place so that chips and other
particles remain inside the holes can be removed and measuring of various
dimensions to check if they are within desired limits then marking of the serial no.
and printing of barcodes takes place.
Step 19 - Non-destructive test using Rockwell hardness tester is carried out on
various parts of crankshaft and the hardness measured should be in the specified
range.

Step 20 – In this step deburring of all the holes by deburring file and deburring of
counterweight by flat file takes place. In this process if scratches are produced on
journals and pins, then it may cause bearing wear and bearing seizure after that
burrs are checked with the help of endoscope if there is any burr then the component
is sent to be reworked by putting a yellow tag on it.
Final Dimensions -

Part Name Dimension in

mm.
Flange dia. 78.007±.15
All journal dia. 50.997±.007
Length 407.8±.2
Crankpin dia. 42.597±.007
Holes on flange(M8X1.25-6H) 6.8±.2
Front side hole dia.(M14X1.25-6H) 14.8±.2