A REPORT

ON

6 WEEKS INDUSTRIAL
TRAINING
AT

JAY BHARAT MARUTI LIMITED

( A Joint Venture with Maruti Suzuki India Limited)
PLOT NO. 15 & 22, MARUTI SUPPLIER PARK, SECTOR-3A,
IMT MANESAR, GURGAON 122051 ( HARYANA )
E.MAIL WWW.JBM-GROUP.COM
TEL : +91 9999190423, +91 9899079952
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Submitted By :
GAGANDEEP
ITM UNIVERSITY, GURGAON

HISTORY OF THE COMPANY

Jay Bharat Maruti Limited set up in 1987 is one of the largest joint ventures of Maruti
Udyog Limited. This is a unique combination of modern Press Shop and Weld Shop
capable of supplying components in Just in Sequence (JIS) meeting customers quality
and quantity requirements. Manufacturing facilities at JBML also include die
maintenance, dedicated facilities for manufacturing exhaust systems and in house
modern tool room. JBML is rising to meet new challenges with modern equipment and
higher goals of manufacturing and quality control.
The period from 1988 to 1995 was a steep rise in the demand of passenger car in
India. To meet this rising demand, JBML had to continually expand its manufacturing
facilities. Because of space constraints a new plant (Plant-2) was set us for the
manufacturing of sheet Metal parts with latest technologies like fully automatic
tandem line from Rovetta of Italy, 5-axis laser cutting machine from Prima of Italy.
This new plant is located approximately 14 kms from Plant-1. Space crated extra
because of this new plant was being utilized by additional business of weld assemblies
like front under body, rear under body for car & exhaust systems for various models of
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Maruti. The net sales of the company has increased from 262.86 crores in the year
2002-03 to 414.85 crores in the year 2004-05.
Driven buy a commitment to customer satisfaction and international standards of
quality, JBML has not only won customer confidence but also industry recognition
through several awards and accolades viz. National Productivity Award Best
Performing Vendor Award, Quality Trophy etc.

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GUIDING PRINCIPLES AT JBML

MISSION
To make JBML a synonym for world class organization excelling in sheet metal
technologies.

VISION
Expanding leadership in our business through people, keeping pace with market trends
and technology.

HR POLICY
JBML will always keep on striving for the deployment of competent and efficient
employees at all levels to create inculcate and foster excellent
Working and learning environment; because it believes in nurturing strength of
individuals for developing mutual trust, support and positive attitude for achieving
organization goals to create a world class manufacturing organization and to remain
the market leader in sheet metal components not only today but for all the tomorrows
to come.

QUALITY POLICY
The policy of JBML is to achieve total customer satisfaction by delivering products
and providing services that meet or exceed their exacting requirements and
expectations and to do so on time and at most competitive prices in domestic and
export market for our entire product range.

ENVIRONMENT, HEALTH AND SAFETY POLICY

Jay Bharat Maruti Limited, as a responsible manufacturer of sheet metal components,
welded sub assemblies and exhaust systems for automotive applications, re-affirms its
commitment to minimize the adverse impacts of its operations, products and services
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on the environment, health and safety. To this end, the company endeavor to:
1

Develop and maintain an Environment, Health and Safety Management System

and continually monitor, set and review the environmental, health and safety
objectives and targets.

Meet all applicable legislations, regulations and customers requirements.

Conserve natural resources and energy by constantly seeking to reduce their

consumption by reducing wastages and maximizing recycle/reuse.

Minimize/Prevent air, water, noise and land pollution generation. Maintain a

system for hazard waste management.

Establish health and safety programmes to continually reduce health and safety
risks.

This policy shall be communicated to all the employees of JBML and be made
available to public and interested Parties on demand.

QUALITY IS COMPONENT NO. 1

More than anything else, the driving force at JBML is Quality. Stringent quality
control maintained at every stage of the designing and manufacturing processes
translates into zero-defects, international standard products. Rooted on the policy to
achieve total customer satisfaction by delivering products and services that meet and
exceed their expectations, on time and at competitive cost, JBML has developed a
tradition of quality. Every personnel is positively attuned and committed to excellence.
It is a corporate motto at JBM to accomplish tasks right the first time, every time. And
ongoing improvement on manufacturing processes and advanced quality planning play
a critical role in ensuring high standards. No wonder, globally JBML became the first
company to achieve ISO/TS-16949-2002 certification. Also, concern for environment
protection has brought JBML ISO 14000 certification.

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MARCHING AHEAD WITH PEOPLE, THROUGH PEOPLE

JBML has an image, which is transparent, fair, and customer caring. The vision of the
Company and its goals are well appreciated by all our stakeholders viz. employees,
suppliers, customers, shareholders and society at large. Our basic value simplicity,
Teamwork, trust in people, customer focus and meeting commitment are well
embodied in each and every employee of the organization
Jay Bharat Maruti Ltd. honours the dignity of labor and that is the reason that one can
see all JBML Employees in the same uniform right from the lowest worker to the top
level of Managing Director. People from different states with different religious
leanings, different lifestyle, and speaking different languages make JBML a well-knit
close family. All the policies/practices are, therefore, fair do allow the principle of
equal opportunities. There is absolutely no discrimination on account of age, sex,
caste, creed, religion or region.
Environment, health and safety are considered imperative for physical health of JBML.
Besides fulfilling the legal requirements it generates a feeling of care and healthy well
being towards the employees. The Company understands its responsibility towards
protective, environment and is already an ISO 14001 Organization and has received
OHSAS 18001 Certification. It is ensured that all processes and work are designed to
take account of health and safety and are properly supervise at all times.

Business Environment
With entry of worlds leading automotive manufacturers in India the passenger car
manufacturing segment found them in fierce competitive environment. The utilization
of manufacturing facilities added by OEM s in anticipation of further demand,
declined. Market share of Maruti dropped from 83% to 65%. JBM then started looking
for other business avenues. JBML, for expanding its manufacturing scope for higher
market share shifted its approach from MUL as component supplier to system supplier.
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JBML believed that, for survival growth and prosperity change is must. The policies
need to be reassessed and changed as needed. As a result business development was
added as a key business process and a separate function and department was created
for the same. This decline in profitability is due to tough competition and heavy
discounts being asked by customers on regular basis.

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Customer Management
Customer focus is one of the basic values adopted by the company. Quality policy
revolves around the customer satisfaction. There is emphasis on understanding the
unspoken and meeting the implied needs expectations of the customer also. Customer
satisfaction has been identified as one of the CSF. It is one of the business performance
measures of long term plan and its improvement. Over the years based on periodic
reviews various forms have been established for regular interaction with customer. Top
management apart from personal meetings of middle managers regularly visits
customers. The process of satisfaction surveys also provides the voice of customer for
policy and strategy making. All customer complaints, customer ends nonconformances, performance of delivery, result of customer satisfaction surveys and
any other need and expectation of customer is reviewed on weekly basis. Major
customers are Maruti Udyog Limited, Eicher Motors Ltd. M&M Ltd., and HMSI.

Supplier Management
The definition of customer in the company is not limited to buyers of the product. The
company treats all its associates as customers in one way or the other way. Various
form set-ups for regular meeting, understanding, and responding to the suppliers need
are maintained. Major vendors are connected through emails. The information on
vendors and suppliers expectations and needs gathered through these forms are
analyzed and considered by formulating policies and strategies. Day to day
expectations and needs are responded through the normal communication channel of
materials division, purchase department, supply chain cell as part of MX dept. Vendors
and suppliers are rated and communicated the performances with respect to quality and
delivery. These are reviewed for continual improvements on weekly basis. Major
suppliers for bought out parts are group companies whereas raw material is arranged
from leading Indian steel manufacturers and through imports.
Finance Management:
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Financial management system and policies are directed towards optimum utilization of
financial resources. The approach has been to use the financial resources for
minimizing returns to the company, and in return to the stakeholder. There is clear-cut
laid down rules and regulation for its transparent monitoring and inflows and outflows
of funds. There is transparent pricing system avinashshankar29@gmail.combetween
the company and all major customers, so that prices are continuously reviewed and
rationalized in view of any KAIZEN/Cost reduction/VA-VE exercise as the case may
be. It is all that because of this transparent price reviewing system in existence we
have passed on around 20% discounts to MUL since last five years. The other
important stakeholders are banks and Finance Institutions. The financial policies are
in line with the expectations and high level of commitment to them. The company
ensures the timely payment to entire supply chain partners in time. The company has
been rated as P1 by CRISIL(one of the best credit rating agency in India) various
currency movements are monitored and accordingly risks are hedged by forward
coverage. The company has been constantly working on the various financial strategies
for reducing the cost of funds. Conversion of term loan to lease Transactions, Foreign
currency, short term unsecured loans, inter changeability of limits etc are negotiated
from time to time which has helped in bringing down its weighted average cost of
funds from 13.25% in 2001 to 10% in 2002. By negotiating the L.C. charges and
bank charges have been brought down to half of normal rates. No commitment charges
are paid to the bank. Due to these measures, the other income on account of cash
discount and interest earned has been to the tune of 221 Lac in 2004. The company
has been able to manage its working capital in efficient manner. The company is
continuously improving its financial system. Baan ERP System has been implemented.
Decisions on all new investment are based on IRR at the pre-project analysis stage.
Management of building, equipment and materials
Main thrust area regarding utilization of assets has been on achieving high capacity
utilization and productivity, through continual improvement in the production
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processes, technological up-gradation and higher levels of productivity. Other thrust

areas has been improvement in space utilization. This has been achieved by systematic
review of all layouts and production flow sequence, balancing of production lines,
improvement in method of material storage, inventory reductions and internal
logistics. The materials constitute 70% of the sale value. Therefore material utilization
has been another thrust area. The material yield, which is ratio of weight of finish
product to the weight of total weight of raw material consumed, has been continually
improved by reducing the material going to scrap. A committee called as VA/VE has
been reviewing this exercise in a planned and systematic manner. The various
approaches adopted in VA/VE are blank size reductions, using off cuts changes in
blanking layouts. Raw material inventories have been reduced drastically. Predictive
maintenance and TPM concepts are applied to maintain the equipments. Detailed
checklist developed one for each process equipment is used for preventive
maintenance as per the maintenance dept plan developed yearly and reviewed monthly.
Minimum and minimum levels of spares have been defined for keeping low
inventories and to avoid stockpot. History cards are maintained for each equipment
and tooling. Uninterrupted electric power is supplied through own D.G. sets to save
any damage to delicate electronic parts and mechanism of equipment.
Technology Management
In line with vision the company is continually upgrading the technology to world-class
level. Visiting collaborators plants, visiting exhibitions and regular interaction with
customer and different forums gather the information of new technology. The company
has one fully automated tandem press line, fully automatic laser cutting machine etc.
Latest IT technologies are being used like Baan ERP is used for managing companies
business. Integrated communication system is developed. Knowledge management
system has been developed to share improvements and good practices adopted in the
organization.

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Shareholders Management
Annual shareholder s meeting and board meetings provide useful information on needs
and expectation on them. A shareholders grievance committee has been formed at
director s level. Grievances are reviewed in board meetings. Shareholders views are
captured in one to one communications, letters also. The company has been giving
dividend to share holders continuously.

Regulator Management
All the laws and regulations applicable to the operations are taken care off. The
company has been consciously and proactively ensuring compliance to all such
applicable laws and regulations. There has never been any challan from authorities
concerned with respect to labor laws and factories act. The company has been rated
"good" during the audits conducted by central excise department during the year 1999
to 2003. The sales tax and income tax returns have always been satisfactorily assessed
and no penalty was imposed. Company is actively involved in various industries and
association, which interact with government agencies.
Society Management
The environmental policy has been prominently displayed at the entrance of the
company. Company s policies and practices ensure equal opportunities to all. It does
not discriminate on the basis of caste, creed and religion, sex language and province
etc, during recruitment, supply and service contracts, employing casual labor, allowing
visitors inside the plant. Company is continually generating directly and indirectly
higher employment opportunities. Preferences are given to local residents. Large no of
local suppliers, vendors, contractors are developed thus boosting the local economy.
MX DEPARTMENT
MX Material transaction department deals with supply chain. This department is a
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combination of raw material & consumable store, PPC, and Dispatch. JBM P2 supply
materials to JBM Plant 1, Maruti Udyog Ltd., Eicher Motor Ltd., Mahindra &
Mahindra, Honda Motorcycle & Scooters Pvt. Ltd. along-with job work for JBM Auto
components Ltd. There are two types of components supplied by JBM P2, one is in
house production and other is job work by subcontractors to fulfill the requirement of
customers. The components manufactured by subcontractors the raw material is
supplied by JBM P2. MX department monitor & control the whole supply chain of
subcontractors, raw material for production at JBM P2. The customers of JBM P1 are
JBM P2, MUL, EML, M&M, HMSI and JBM Auto. All customers have given their
production plan and schedule for dispatch of material. MUL communicate daily
schedule on their WEB SITE for vendors. In the MUL daily schedule and time of
deliveries is also indicated. This is to control inventories at MUL. All other customers
give their schedule on weekly basis. App. 70% of the total components manufactured
by JBM P1 is of Maruti Vehicles and remaining 30% are for other customers. For the
purpose of raw material planning JBM P1 consider the production of vehicles per day
at customer end and the requirement of our components for manufacturing these
vehicles MUL communicate their production plan in advance so every vendor should
plan production and purchase of raw material. To bring the planning on one plate form
a Daily Status Report (Annexure No.1) is generated by PPC department. On the basis
of DSR raw material planning is done by raw material store and a schedule is raised to
suppliers. Daily consumption of steel at JBM P1 is app. 70-100 tons and for feed the
lines of JBM P1we have to purchase the same quantity of material per day. Therefore
to avoid criticalities we should have the material, which is required in next 3 days. In
making schedule for raw material (Annexure No.02) first we check the status of the
material, secondly requirement of material in the week for which schedule is generated
and third, material requirement date and forth, minimum loading plan. First, status of
material, status tells us about the finished goods inventory and seconds the coverage.
Coverage means the material in finished goods cover the requirement of number of
days. It is counted on the basis of production levels of our customers. For example, If
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we take a component no. PPC58120 it is used in manufacturing of Maruti 800, on any

day its finished goods is 800 nos. and Maruti 800 production per day is 600 nos.
PPC58120 is required one component per vehicle so the coverage is 800/600 = 1.3
days. To feed the line of MUL we have to take loading of this material of the same day
or next day. Second, when we get the per-day requirement of material and status of
raw material then we can calculate requirement of material per week. Third, on which
date of the week material will be required for take loading, it is calculated by the
coverage of material and schedule for dispatch. For example: If any day, coverage of
PPC58120 is zero and there is no schedule in next two days then this material required
today because of coverage is zero. Fourth, and very important, to control the loss time
in die changing, minimum loading for every component is standardized.

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ACCOLADES AND RECOGNITIONS

v MERIT CERTIFICATE FOR PRODUCTIVITY BY NPC

1993-94

v AWARD FOR PRODUCTIVITY BY ACMA

1993-94

v BEST VENDOR AWARD BY CUSTOMER (MUL)

1994-94

v BEST VENDOR AWARD BY CUSTOMER (MUL)

1994-95

v ISO 9002 ACCREDITATION BY RWTUV (GERMANY)

1994-95

v MERIT CERTIFICATION FOR PRODUCTIVITY BY ACMA

1996-97

v BEST VENDOR AWARD BY CUSTOMER (MUL)

1996-97

v MERIT CERTIFICATION FOR PRODUCTIVITY BY NPC

1996-97

v AWARD FOR QUALITY BY ACMA

1997-98

v QS 9000 ACCREDITATION BY UL

1997-98

v AWARD FOR QUALITY BY ACMA

1998-99

v SAFETY & WELFARE AWARD BY GOVT. OF HARYANA

1999-00

v MERIT CERTIFICATE FOR QUALITY BY ACMA

1999-00

v AWARD FOR PRODUCTIVITY BY ACMA

2000-01

v ISO 14000 ACCREDITATION BY UL

2001-02

v ISO/TS 16949:2002 ACCREDITATION BY UL

2002-03

v OHSAS 18001 ACCREDITATION BY UL

2003-04

v OUTSTANDING OVERALL PERFORMANCE TROPHY

2003-04

BY MUL
v CERTIFICATE BY MUL FOR COST REDUCTION THROUGH
(1) VA / VE

2003-04

(2) YIELD IMPROVEMENTS

2003-04

(3) KAIZENS

2003-04

v CII-EXIM BANK AWARD FOR BUSINEES EXELLENCE

2003-04

&
STRONG COMMITMENT TO EXCEL

2004-05

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JBM MILESTONE BRICK BY BRICK

COMPANY INCORPORATED

19-03-87

COMMERCIAL PRODUCTION COMMENCED

01-

03-89

EQUITY HOLDING
MUL
S.K. ARYA & ASSOCIATES

29.30%
29.30%

PUBLIC

41.40%

PLANT 2 COMMISSIONED WITH

95-96

UPGRATION OF PRODUTION TECHNOLOGY

FORAY INTO EXHAUST SYSTEM SUPPLIES

96-97

FOR MUL VEHICLES

SYSTEM SUPPLIER CONCEPT STARTED

97-98

FOR MUL FENDER ASSEMBLY

BAAN IV SOFTWARE SYSTEM

98-99

IMPLIMENTED

EXHAUST SYSTEM OF ALTO AND

99-00

WAGON-R WITH EMMISSION NORMS

COMPLIANCE COMMENCED

SYSTEM SUPPLIES FOR CAR UNDER

00-01

BODIES STARTED

VERSA LINE COMMISSIONED

01-02

5-AXIS LASER CUTTING MACHINE

03-04

COMMISIONED

REAR AXLE LINE COMMISIONED

04-05

PROPOSED PT-CED PAINT SHOP

04-05
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AXLE LINE OF MODEL YN4 COMMISSIONED 04-05

COMMENCEMENT OF COMMERCIAL
PRODUCTION OF MODEL YN4

05-06

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COMPANY PROFILE
JBM group began its engineering activity in 1983 with the establishment of Gurera
gas cylinder limited and entered the auto component industries in 1985 with the
inception of SUZUKI AUTO INDIA. JBML is a multi- unit, multi-product group with
extensive and diversified interest in engineering and precision tooling, dies and
facilities spread over different parts of the country. The JBML engineering groups
deals in brand range of sheet metal assemblies, die casting components and forging for
the domestic and export markets.

Jay Bharat Maruti Ltd.

An ISO/ITS 16949:2002/iso- 14001/ohsas-18001-

company setup in 1987 is the largest joint venture of Maruti Udyog ltd. In
collaboration with Suzuki motors company of Japan. The plant worth Rs.1210 million,
and is equipped with state of art technology, in metal forming and welding. This is a
unique combination of modern press shop and weld shop capable of supplying
components in JUST-IN-TIME (JIT) meeting customers quality and quantity meeting
customers quality and quantity. The working at JBML is based on Japanese system of
manufacturing. Flawless on quality and reliability, these products have won the
confidence of industry leaders. Manufacturing facility at JBML includes die
maintenance, dedicated facilities for manufacturing exhaust systems, in house modern
tool room and a talented design team. JBML is rising to meet new challenges with
modern equipments and higher goals of manufacturing and quality controls.

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JBMS PRODUCT RANGE:

JBM nicely diversified their business by starting manufacturing not only sheet metal
components but also started manufacturing other automobile components and tools.
PRESENT MANUFACTURING RANGE:
Skin panels (unpainted) for driver cabin of LCV and MCV.
Underbody parts / assemblies (unpainted) for passenger cars, e.g.,

Front and rear underbodies

Fenders

Aprons

Cross members

Floor tunnel

Rear axle (painted) for passenger cars.

Fuel neck pipe (electroplated)
Exhaust systems for

Passenger cars in SS / coated steel, and

Two wheelers in painted condition

JBMS MAIN PRODUCTS:

1

Sheet Metal Stamping.

Welded Sub Assemblies.

Chassis and Suspension System.

Jigs and Fixtures.

Exhaust System.

JBM manufactures a range of specialized components for front ranking OEMs.

Flawless on quality and reliability these products have won the confidence of industry
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leaders.

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Production Volume:(Approximate)
Products per day
32,000 assemblies of 203 types
Made up of about
2,00,000 pressed parts
20,00,000 spots
1,20,000 hardware

JBMS QUALITY GOALS:

1

Zero defects.

First time right, every time right.

No quality control, only quality assurance.

Reduced process variance.

100% customer satisfaction.

Reduction in the cost of product.

Not only functional quality but also competitive commonly expected and
attractive quality.

To stick to these goals, the company has successfully implemented the Enterprises
Resource Planning (ERP) software i.e. Baan-IV a system application to support
the manufacturing, finance and sales & distribution functions.

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TODAY, JBM ENJOYS A COMPETITIVE EDGE IN THE

MARKET. SOME OF THE REASONS FOR THIS ARE:
1

A unique combination of modern press shop and weld shop.

The capacity of supplying components on a just in time (JIT) basis.

Indigenisation and system engineering to manufacture complex automobile

exhaust systems.

Flexible manufacturing systems.

Support of modern tool room facilities available within the group.

FEATHERS ADDED IN THE CAP JBML:

National productivity councils Certificate of merit 1993-94&1996-97.

ACMA productivity award 1993-94.

Best performing vendor award in the technology group largest sheet metal
components-category A from MUL for four consecutive years, 1993-97.

Certificate of recommendation from Haryana state pollution control board in

recognition of environment friendly industry 1994-95

Certificate of merit for excellence in products of automotive components from

ACMA 1996-97

Award for quality ACMA1997-98

QS 9000 accreditation by UL 1997-98

Award for quality ACMA 1998-99

Safety and welfare award by Government of Haryana 1999-2000

Merit certificate for quality by ACMA 1999-2000

Award for productivity by ACMA 2000-01

ISO 14000 Accreditation by UL 2001-02

Recommendation by UL for ISO/TS

-- 16949 certificate
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The prestigious QS-9000 CERTIFICATE by KPMG Peat-Marvic, the Quality

Register of India, representing Peat- Marvic, USA, has also awarded the
company.

CRISIL, (in famed credit rating agency) has assigned P-1 rating to company for
its commercial paper program.

JBM, under the guidance of Prof. Y. Tsuda of Japan, Quality M management

Adviser, is working in close conjunction with a cluster of companies. Together
they will march towards TQM.

ION has initiated a major drive to improve the production process by the
implementation of KAIZEN (continuous improvement in small steps) in the
various areas of operations, resulting in a phenomenal improvement in JBML.

OHSAS 18001 Accreditation By UL 03-04.

Outstanding overall performance trophy by MUL

Commendation certificate for strong commitment to TQM by CII EXIM

BANK 03-04.

The company has also been awarded by the prestigious QS-9000 certificate by KPMG
Peat-Marvic, the Quality Register of India, representing Peat- Marvic, USA.
CRISIL, (in famed credit rating agency) has assigned P-1 rating to company for its
commercial paper program.
JBM, under the guidance of Prof. Y. Tsuda of Japan, Quality Management Advisor, is
working in close conjunction with a cluster of companies. Together they will march
towards TQM.
Furthermore, SUZUKI MOTOR CORPORATION has initiated a major drive to
improve the production process by the implementation of KAIZEN (continuous
improvement in small steps) in the various areas of operations, resulting in a
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phenomenal improvement ISO 14000 Accreditation by UL 2001-02nt in JBML.

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WORK CULTURE AT JBML:

1

COMMON UNIFORM.

ATTENDANCE BONUS.

TRAINING (EXTERNAL AND INTERNAL).

OPEN AND TRANSPARENT APPRAISAL.

JBMS MAJOR CUSTOMERS:

5

MARUTI UDYOG LIMITED.

ASHOKA LEYLAND.

DEFENCE.

DELPHI.

EICHER.

10 ESCORTS.
11 HINDUSTAN MOTORS.
12 HONDA SCOOTERS.
13 MAHINDRA & MAHINDRA.
14 YAMAHA MOTORS INDIA L.T.D.

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JBML`s GROUP COMPANIES

15 JAI BHARAT MARUTI LTD-PLANT -2
16 JBM AUTO COMPONENT LTD
17 NEEL METAL PRODUCT LIMITED
18 JBM INDUSTRIES LIMITED
19 JAI BHARAT BREEDS LIMITED
20 NEEL INDUTRIES PRIVATE LIMITED
21 JAY BHARAT EXHAUST SYSTEM LTD
22 THYSSENKRUPP JBM PRIVATE LTD
23 NEEL ENGINEERING SOLUTIONS
24 JAICO STEEL FASTENERS LTD

JBMS GLOBAL ALLIANCES:

25 BELLSONICA COMPANY, JAPAN.
26 MARUTI UDYOG LIMITED.
27 SUZUKI MOTORS COMPANY.
28 NAGATA AUTOPARTS CO. LTD., JAPAN.
29 HAMAMATSU PIPE COMPANY LTD., JAPAN.

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WELDING DEPARTMENT
INTRODUCTION
Welding is the process of permanently joining two or more metal parts, by
melting both materials. The molten materials quickly cool, and the two metals
are permanently bonded.

TYPES OF WELDING DONE IN THIS PLANT

1
2

SPOT WELDING.
MIG WELDING.

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SPOT WELDING
Spot welding is primarily used for joining parts that normally upto 3 mm
(0.125 in) thickness.
Spot-weld diameters range from 3 mm to 12.5 mm (0.125 to 0.5 in) in
diameter.

MATERIALS
1

Low carbon steel is most suitable for spot welding. Higher carbon
content or alloy steels tend to form hard welds that are brittle and
could crack. This tendency can be reduced by tempering

Low carbon steel is most suitable for spot welding. Higher carbon
content or alloy steels tend to form hard welds that are brittle and
could crack. This tendency can be reduced by tempering.

Aluminums can be welded using high power and very clean oxide free
surfaces. Cleaning the surface to be oxide-free, adds extra costs (that
can be avoided with low carbon steel).
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Dissimilar materials cannot be spot welded due to different melt

properties and thermal conductivities. Plated steel welding takes on
the characteristics of the coating.

MANUFACTURING
CONSIDERATIONS
1

Thickness of the parts to be welded should be equal or the ratio of

thick nesses should be less than 3:1.

Spacing of welds
Min. Weld to weld spacing = 10 x Stock
Center of weld to edge distance = 2 x weld
Weld to form distance = Bend Radius + 1 weld diameter, minimum.

Flat surfaces are easier to spot weld due to easy access. Multiple
bends impose access restrictions, and special fixtures may have to
be designed to handle the parts, if access is not a problem.

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WELD SPACING GUIDELINES

Prior to finishing, the spot welds have to be sanded or ground to blend

the welds with the rest of the surface.

It is best to choose the same spot weld size, to minimize setups and
increase throughput.

Plating of spot welded assemblies can cause problems when the

sheet metal is overlapped. This can cause plating salts to be trappedrequiring special cleaning, or potential long-term corrosion problems.
By carefully designing the assembly to allow easy draining of plating
solutions this can be avoided.
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The mating parts can be self-jigged for easy location prior to welding. This
can be done by lancing one part and locating in a corresponding slot in the
other part; or by boss type extrusion, weld buttons, in part locating to a slot in
the other. This type of design can often eliminate the need for external
fixtures.

MACHINE DESCRIPTION
MACHINE DESCRIPTION Integrated Transformer spot welding
Machine.
PROCESS

- Spot Welding

PART NAME

- Body parts of various Maruti models.

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INTEGRATED TRANSFORMER GUN AND CONTROLLER DIAGRAM

MIG WELDING

Gas Metal Arc Welding (GMAW) is frequently referred to as MIG welding.

MIG welding is a commonly used high deposition rate welding process. Wire
is continuously fed from a spool. MIG welding is therefore referred to as a
semiautomatic welding process.

MIG WELDING BENEFITS

1
2

All position capability

Higher deposition rates than SMAW
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3
4
5

Less operator skill required

Long welds can be made without starts and stops
Minimal post weld cleaning is required

MIG WELDING SHIELDING GAS

The shielding gas, forms the arc plasma, stabilizes the arc on the metal
being welded, shields the arc and molten weld pool, and allows smooth
transfer of metal from the weld wire to the molten weld pool
The primary shielding gasses used are:
1 Argon
2 Argon - 1 to 5% Oxygen
3 Argon - 3 to 25% CO2
4 Argon/Helium
CO2 is also used in its pure form in some MIG welding processes. However,
in some applications the presence of CO2 in the shielding gas may adversely
affect the mechanical properties of the weld.
WELD DISCONTINUITIES
1 Undercutting
2 Excessive melt-through
3 Incomplete fusion
4 Incomplete joint penetration
5 Porosity
6 Weld metal cracks
7 Heat affected zone cracks

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MIG WELDING PROBLEMS

1 Heavily oxidized weld deposit
2 Irregular wire feed
3 Porosity
4 Unstable arc
5 Difficult arc starting

MIG WELDING MACHINE

DESCRIPTION

1.

MACHINE DESCRIPTION - MIG Welding Set

PROCESS

- MIG Welding

PART NAME

CONDITION
Voltage
Current
Gas Flow
Wire

22-24 Volt
160-180 Amp
As Required
As Required
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OPERATION
1.
2.
3.

Set part 1 & 2 on welding jig

Weld as per Sequence i.e. no blowholes, holes porosity etc.
After Welding Declaiming the part

PRESS SHOP
INTRODUCTION:
PRESS SHOP LAYOUT:

PA

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MACHINE DESCRIPTION
1.

MACHINE NAME - 200 Tons Hydraulic Press

PROCESS NAME - Trimming
PART NAME

- As Per die (Fuel Tank)

SPECIFICATION OF MACHINE
1
2
3

Max Load Pressure

Set Pressure
Brake Pressure

178 Kg / Cm2
178- 198 Kg / Cm2
2-2.8 Kg / Cm2

OPERATION
1
2
3
4
5
6
7

Set Die with last component in die

Adjust the stroke accordingly to limit collar (Yellow Pads)
Run 3-5 Idle strokes
Trim the component and observe
Check component for any deformation burr and smooth disposal of
scrap.
Compare the trim component with limit sample
Any Arability on tool maintance help and cleaning is required

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2.

MACHINE NAME -

400 T Mechanical Press

PROCESS NAME - Parting

3.

PART NAME -

Chain Case

DRIVEN TYPE -

V-Belt Driven

MACHINE NAME

- 400 T Mechanical press

PROCESS NAME - Inner Panel Piercing

PART NAME

4.

- Chain Case

MACHINE NAME - 200 T Press K3

PROCESS NAME Pressing
PART NAME -

Chain Case

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THANK YOU

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