Data Collection for Maruti Suzuki Process

DATA COLLECTION FOR W.I.C.S.
&
WELD SPOT CHECKING PROCESS STANDARDIZATION
CHAPTER 1
MARUTI SUZUKI INDIA LIMITED PROFILE
1.1 Introduction
Maruti Suzuki is one of India's leading automobile manufacturers and the market leader in
the car segment, both in terms of volume of vehicles sold and revenue earned. The Indian
government held an initial public offering of 25% of the company in June 2003. As of May
10, 2007, Govt. of India sold its complete share to Indian financial institutions. With this,
Govt. of India no longer has stake in Maruti Udyog.
Maruti Udyog Limited (MUL) was established in February 1981, though the actual
production commenced in 1983 with the Maruti 800, based on the Suzuki Alto kei car which
at the time was the only modern car available in India, its' only competitors- the Hindustan
Ambassador and Premier Padmini were both around 25 years out of date at that point. Maruti
are sold in India and various several other countries, depending upon export orders. Cars
similar to Maruti (but not manufactured by Maruti Udyog) are sold by Suzuki and
manufactured in Pakistan and other South Asian countries.
The company annually exports more than 50,000 cars and has an extremely large domestic
market in India selling over 730,000 cars annually. Maruti 800, till 2004, was the India's
largest selling compact car ever since it was launched in 1983. More than a million units of
this car have been sold worldwide. Currently, Maruti Alto tops the sales charts and Maruti
Swift is the largest selling in A2 segment.
Due to the large number of Maruti 800s sold in the Indian market, the term "Maruti" is
commonly used to refer to this compact car model. Till recently the term "Maruti", in popular
Indian culture, was associated to the Maruti 800 model.
Its manufacturing facilities are located at two facilities Gurgaon and Manesar, south of New
Delhi. Marutis Gurgaon facility has an installed capacity of 350,000 units per annum. The
Manesar facilities, launched in February 2007 comprise a vehicle assembly plant with a
capacity of 100,000 units per year and a Diesel Engine plant with an annual capacity of
100,000 engines and transmissions. Manesar and Gurgaon facilities have a combined
capability to produce over 700,000 units annually.
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WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT
DATA COLLECTION FOR W.I.C.S. &
1.2 BACKGROUND OF THE INDIAN AUTO INDUSTRY
Although the Indian car industry was established in the late forties, there was little growth or
technical progress, as passenger cars were given very low priority in the scheme of
Centralized Economic Planning. In the 1980s, the car industry was undergoing technological
stagnation and was characterized by low production volumes, high cost and low productivity.
The consumer had very little choice and the market was selling just around 30,000 cars per
year.
There was a clear need to provide a cost effective, reliable and quality car to the customers.
Maruti Suzuki India Limited was incorporated in such a scenario as a fully owned
Government Company on February 24, 1981 with a resolve to bring about expansion and
technological modernization, of the automobile sector. Thus MSIL, when started was
entrusted with the task of achieving the following policy objectives:
Modernization of Indian Automobile Industry.

Production of Vehicles in large volumes, which was necessary for economic growth.
Production of Fuel-efficient vehicles to conserve scarce resources.
1.3 Choice of product and collaborator
To achieve the above objectives, one of the foremost tasks before, Maruti Suzuki
India Limited was to determine the most suitable product mix and to select the most
suitable foreign partner who would be willing to accept MSILs requirements in terms
of product mix, technology transfer, and equality participation and had the required
technological expertise and experience in producing high quality, reliable and fuel
efficient vehicles.
After extensive discussion with several major European and Japanese car
manufacturers, MUL chose Suzuki Motor Corporation (SMC) further increased its
equity holding to 50% in the year 1992, converting . Maruti Suzuki India Limited,
into a Non-Government Company with a total Equity base of Rs. 1322.92 million.
2
1.4 COMPANY MISSION
A leader in the Indian Automobile Industry.

Creating Customer Delight and Shareholders wealth.
A pride of India!
1.5 LEADERSHIP
By Market share and brand equity

By operational practices
By people strategy
1.6 CUSTOMER DELIGHT
Values for money

Quality
Service
1.7 SHARE HOLDERS WEALTH
High Profitability & Image
1.8 A PRIDE OF INDIA
As a corporate citizen
Products
People
Practices
Customers
3
1.9 VALUES
Customer Obsession
Fast, Flexible, First Mover
Innovation and creativity
Networking and partnership
Openness and learning
1.10 QUALITY POLICY
To increase consumer satisfaction through continuous improvement of products and

services, this is achieved by following PDCA functions and levels of Maruti
Organizations.
PLAN DO
QUALITY
POLICY
ACT CHECK
Fig. 1.1- Maruti Suzuki India Limited Company Policy
4
1.11 QUALITY TOOLS
5S
SEIRI PROPER SELECTION

SEITION ARRANGEMENT
SEISO CLEANING
SEIKETSO CLEANLINESS
SHITSUKE DISCIPLINE
4M
MAN
MACHINE
MATERIAL
METHODS
3M
MURI INCONVENIENCE
MUDA WASTAGE
MURA INCONSISTENCY
3G
GENCHI GO TO ACTUAL PLACE

GENBUTSU SEE THE ACTUAL THING
GENJITSU TAKE APPROPRIATE ACTION
5
1.12 The hierarchy diagram of MSIL
6
1.13 DIVISIONS AND DEPARTMENTS
Corporate Services Division
Legal & Secretarial Department

Corporate Communication Cell
Protocol
Strategic Initiative Group
Recruitment & Management Compensation
Human Resource Division
Employee Relations Department

Establishment & Time Office
Factory Administration Department
Organizational Development Department
Production Engineering
Production Engineering Division

Production Service Division
Engineering Directorate
QAIN Division
Service Division
Service- 1-5
MSS(D)
Parts Inspection Division
Engineering Division
7
Supply Chain division
Supply Chain- 1,2,3 Division

Shipping & transport Department
Imports Department
Consumables Department
Information Technology Division
Application Group1 (AG1)

Information Technology Strategies(ITS)
IT Operation and Services(ITOS)
Marketing & Sales Secretariat
Marketing Strategy & Development

Marketing
Sales
Exports
Web-IT, E-Commerce
Spare Parts Division
Spare Parts Procurement

Warehousing & Dispatch
Spare Parts Sales
Accessories
8
Vigilance Division
Security Wing
Vigilance Wing
Finance Division
Budget, Cost & Accounts Department Income Accounting
Production Division of Maruti Suzuki India Limited
Production Division in Maruti Suzuki India Limited has been renamed as Production
Business Vertical (PBV) after inclusion of Projects, Production Engineering, Vehicle
Inspection & Supplier Quality Assurance divisions in it.
Major components of PBV
Press Shop and Blanking Line

Weld Shop (1,2 & 3)
Paint Shop (1,2,& 3)
Engine Assembly (1,2,& 3)
Assembly Shop (1,2,& 3)
Machine Shop (1,2,& 3)
Materials X (1,2,& 3)
Plant maintenance
KB Casting
KB Engine
KB Machine Shop
Production facility at Manesar Plant
SQA (Supplier Quality Assurance)
Production Engineering & Projects
Vehicle Inspection (VI)
9
1.14 LAYOUT OF PROCESS FLOW
Fig. 1.2- Process flow of Maruti Suzuki India Limited
10
1.15 INTRODUCTION TO VARIOUS MODELS
PRODUCT RANGE
MODELS SPECIFICATIONS YEAR OF LAUNCH
MARUTI 800 (FIRST

796CC, HATCHBACK DECEMBER 1983
MODEL)
OMNI 796CC, MUV NOVEMBER 1984
GYPSY 992CC, 4WD DECEMBER 1985
MARUTI 800 (MODIFIED) 796CC, HATCHBACK APRIL 1986
MARUTI 1000 996CC, SEDAN OCTOBER 1990
ZEN 996CC, HATCHBACK OCTOBER 1993
ESTEEM 1.3L LX 1296CC, SEDAN NOVEMBER 994
ESTEEM 1.3L VX 1296CC, SEDAN NOVEMBER1995
ESTEEM 1.3L AX 1296CC, SEDAN JUNE 1996
ZEN AX (AUTOMATIC) 996CC, HATCHBACK OCTOBER 1996
GYPSY KING 1296CC, 4WD NOVEMBER1996
OMNI (E) 796CC, MUV DECEMBER 1996
GYPSY (E) 1296CC, 4WD DECEMBER 1996
MARUTI 800 (NEW

796CC, HATCHBACK SEPTEMBER 997
MODEL)
ESTEEM 98 1296CC, SEDAN OCTOBER 1997
NEWOMNI&OMNI-E 796CC, MUV FEBRUARY 1998
ZEN VX & ZEN VX JULY 1998

996CC, HATCHBACK
AUTOMATIC
11
ZEN D 1200CC, HATCHBACK AUGUST 1998
MARUTI 800 EX 796CC, HATCHBACK JANUARY 1999
ZEN LX 996CC, HATCHBACK JANUARY 1999
ZEN CLASSIC 996CC, HATCHBACK AUGUST 1999
ZEN VXI 996CC, HATCHBACK OCTOBER 1999
OMNI XL 796CC, MUV OCTOBER 1999
BALENO 1586CC, SEDAN DECEMBER 1999
WAGON R 1096CC, HATCHBACK JANUARY 2000
1586CC, HATCHBACK
ALTURA MARCH 2000
(BALENO)
ALTO LX, LXI 796CC, HATCHBACK SEPTEMBER 000
VERSA 1296CC, MUV DECEMBER 2001
SWIFT 1296CC, HATCHBACK MAY 2005
ZEN ESTILO 1096CC, HATCHBACK DECEMBER 2006
SWIFT DIESEL 1296CC, HATCHBACK FEBRUARY 2007
SWIFT DIESEL FEBRUARY 2007
GRAND VITARA MARCH 2007
SX4 1.600CC MAY 2007
SWIFT DZIRE MARCH 2008
A- STAR NOVEMBER 2008

RITZ MAY 2009
STINGRAY OCTOBER 2013
CELLARIO MARCH 2014
12
1.16 MILESTONES
1981 Maruti Udyog Ltd. was incorporated.
1982 Stepped into a JV with SMC of Japan.
Maruti 800, a 796 cc hatchback, India's first affordable car was

1983 produced.
Installed capacity reached 40,000 units. Omni, a 796 cc MUV

1984 was in production.
1985 Launch of Maruti Gypsy (970cc, 4WD off-road vehicle).
1986 Produced 100,000 vehicles (cumulative production).
1987 Exported first lot of 500 cars to Hungary.
1988 Installed capacity increased to 100,000 units.
1992 SMC increases its stake to 50 per cent.
Produced the 1 millionth vehicle since the commencement of

1994 production.
Second plant launched, the installed capacity reached 200,000

1995 units.
1996 Launch of 24-hour emergency on-road vehicle service.
Produced the 2 millionth vehicle since the commencement of

1997 production.
1998 Launch of website as part of CRM initiatives.
Launch of Maruti - Suzuki innovative traffic beat in Delhi and

Chennai as social initiatives.
1999
13
IDTR (Institute of Driving Training and Research) launched

2000 jointly with Delhi government to promote safe driving habits.
Launch of customer information centres in Hyderabad,

2001 Bangalore, and Chennai.
SMC increases its stake to 54.2 per cent.

2002 Launch of Maruti Finance with 10 finance companies in Mumbai.
Start of Maruti True value in Mumbai.
Production of 4 millionth vehicle.

2003
Listed on BSE and NSE after a public issue oversubscribed 10 times.
Maruti closed the financial year 2003-04 with an annual sale of

2004 472122 units, the highest ever since the company began
operations 20 years ago.
The fiftieth lakh car rolls out in April, 2005.

2005.
Maruti tops jd power csi survey for record seventh time in a row
2006.
Govt of India awarded O SUZUKI with coveted padma bhusan

Board of directors give approval to new name MUL to become
2007
maruti Suzuki India limited.
M-800 crosses 25 lakh mark

MSIL celebrates SILVER JUBILEE
2008.
MSIL launches national road safety program.
Capacity to manufacture expanded from 800,000 to a million

units(Gurgaon plus Manesar) annually
2009 All India engineering export promotion council (EEPC) award.
MSIL achieved highest sales ever in Dec2009
14
CHAPTER 2
MANUFACTURING PROCESS AT M.S.I.L.
2.1 Blank
Coils are fed to blanking line & continuous supply of sheet to cutting dies result in
shaping of coils to plan blanks.
Blanks are cut by stamping or shearing process & are stacked one by one to form
large mass of blanks
These stacks of blanks are further sent to press machines for forming into shape of
body panels
Fig. 2.1 Stack of blanks
15
Panel
Blanks are supplied to press lines for pressing. Blanks are converted to body panels by
this process. Panels are stored in pallets which are supplied to Weld Shops for making
White Bodies.
Panels re
stacked in
pallet
trolleys
FIG. 2.2- Panel
16
2.2 PRESS SHOP

The press shop can be regarded as the starting point of the car manufacturing process.
Centrally located between weld 1, weld 2 and weld 3 supplies components to all the three
plants. The press shop has a batch production system whereas the plants have a line
production system. The press shop maintains an inventory of at least two days. The weld
shop as per the requirements picks the finished body parts from the press shop. These may be
divided as A, B and C. A components are large outer components as for example roof, door
panels etc. These components are manufactured in the press shop at Maruti due to design
secrecy and huge investment requirements. B and C components are manufactured by
joint ventures or bought from vendors.
2.2.1 Press Shop activity
1. Currently Press Shop is producing sheet metal components for 8 running models of Maruti
Suzuki and one model of GM India - Tavera
Steel coil Blank Panel
Fig. 2.3. Press shop activities
2. The Blanking and stamping shop processes 10000 metric ton of steel / month i.e. 400 tons
a day
17
2.2.2 Machine Used
Five Transfer Press (4000 ton , 3500 ton , 2400 ton -1 2000 ton -2, in terms of total
capacity i.e. (draw+trim+pierce+bend+restrike) &1 Tandem line(1500 ton draw capacity)
Two Coil processing lines (ROSL Shear line & Blanking line) SPM of 60
Capacity of 55,000 strokes / day from 400 tons of steel coils
4000 Ton
transfer
press
Pressed panels
come out from
this side
Fig. 2.4. Press machine
2.2.3 SMED: Single Minute Exchange of Dies new concept being adopted . This concept
helps in changing of die set up within single digit minute (below 9 minutes). This helps us in
improving machine utilization & operating efficiency. Since press machines are very high
cost investment & any idle time lost due to die exchange will be a cost to company.
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Upper die Lower die
Fig. 2.5. SMED
2.2.4 Yieldimprovement:-(Ratio of output panel to input coil in weight) is Best amongst the
SMC group Companies. ( Presently at 63.2% )
Modifications to improve yield are continuously done & till Oct-09 Press Shop has saved Rs.
7.786 millions of material in current year
120
105
Yield Improvement
100
77.86
80
56.94
50.12
LACS
46.2
60
29.6
40
21.0
13.0
20
19
WORLD
0 COLLEGE OF TECHNOLOGY & MANAGEMENT
Apr 09 May 09 Jun 09 Jul 09 Aug 09 Sep 09 Oct 09 Nov 09 Dec 09 Jan 10 Feb 10 Mar 10 Target
(09-10)
Yield is improved by
1. Reducing the blank size

2. Utilization of scrap for making smaller sheet metal parts.
2.3 WELD SHOP
The body panels produced in the press shop and the other small components are joined here
to give the white body or shell. In a typical car body 1400 different components are
welded together. The weld shops have the following facilities.
Welding jigs
Spot welding guns
Kawasaki welding robots
Hemming machines
Punching machines
PROCESS OUTLINE: The shop has different lines for different models, each of, which is
further divided into three parts:
UNDER BODY: Here different underbody panels are welded together. These comprise of
rear underbody, central underbody, and front engine room panel. These underbodies are put
on the conveyor and welded together to give the underbody.
MAIN BODY: As 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.
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. After inspection and repairs the body is called WBOK. It is
sent to the paint shop thereafter.
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2.4 PAINT SHOP
In the paint shop following processes are carried out: -

There are five plants/units 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 are: -
Pre-treatment (PT): The body is thoroughly washed to remove the dirt and oil
scales. Then the body is treated with ZnPO4 (phosphating) to prevent corroding of the
body.
ED coat: This is done by electric deposition method, at 240V-DC supply. After
applying the ED coat the body is baked in oven.
Sol-sealer and under coat: Here the left in the body (due to welding) are filled with
sol-sealer to provide water proofing. Under coat is done on the surface above wheels
to prevent damage of body in that portion.
Intermediate coat: This is done by spray-painting method using 10 Kawasaki
Robots. After applying the coat, the body is dried in the oven. Painting done is
basically an intermediate coating to provide base for the final coat.
Top coat: This is done by spray-painting method using 20 Kawasaki Robots. For
metallic coating, double coats are applied and aluminum flakes are provided to shine
the metallic paints.
After inspection and touch up, the PBOK, i.e. the paint body ok is sent to the assembly shop.
In paint shop II, only ZEN and ALTO are painted. Paint used is Nerolac. There are 4 coatings
of paint.
1] Phosphate coating
2] ED coating
3] IC coating
4] TOP coating
Inside portion of vehicle is painted manually and outside is by Robots.
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2.4.1 PRE TREATMENT
Before sending vehicle to painting process pretreatment is done to check the quality of
paint.
WBS
Hot water rinse Spray degreasing Dip de
SURFACE CONTROL WR III WR II WR I
PHOSPHATING WR IV WR V WR VI WR VII
ED PROCESS DI WATER MIST
Fig. 2.6. Pre- treatment procedure
2.4.2 ED PAINTING
ED is electro deposition. Vehicle is dipped in the ED solution. In this around 300V is passed
to make paint to be attached. ED is 17% of paint rest is water and some additives (EDD, M).
PROCESS
The whole solution of ED acts as electrolytic solution. Vehicle before coming to ED dip, it
undergoes pre treatment. In that phosphating is done, in which Zn phosphate is made to
attach vehicle body which help in electro deposition, in this, vehicle acts as cathode and paint
as positive ions. When current is passed paint will be attracted by vehicle till its thickness
will be covered. ED is very accurate to apply. This is about whole process. Rinsing is done
22
after to remove excessive color. In rinsing industrial water is used which will not be left go
waste. That will be filtered and used again.
WR I WR II
ED DIP
WR IV WR III RINSING BY DIPPING
WR V DI WATER OVEN
Fig. 2.7. ED Coating procedure
2.4.3 ULTRA FILTRATION
Ultra filtration is the process in which all the rinse pipes and dip tanks will be filtered and
cleaned, by this way water is recycled. Here Osmosis process is used to filter water.
2.4.4 IC painting
IC is intermediate coating in which 3 colors are used. They are white, blue and red. Outside
portion of vehicle is painted by robots and inside is done manually. Paint thickness is taken
care, after that vehicle is sent to IC oven. Oven temperature is 198+/-5C.
2.4.5 TOP COAT Painting
Top coating is done after checking in Dry sanding II. There are 2 sub coatings Base coat and
Clear coat. Here 11 colors are used; 8 metallic and 3 solid. Only metallic colors are coated
with clear coating. Here also outside portion of vehicle is painted by robots and inside is done
manually.
Next vehicle will move to final inspection and will be sent to assembly.
23
DRY SANDING
Following repairs are done:

1. Roof sanding
2. Side repair if any.
Following checking is done:

1. Dosing mark
2. Sanding mark
SOL SEALING LINE
Sealer appearance is given the preference.

3 types of guns are used.
1. Pencil gun
2. Flat gun
3. Blind gun
4. Moti gun
In this line followings are checked;
1. Powder dust
2. Extra sealer
3. Extra sealer
4. Pin hole in lamp area
5. Sealer appearance
2.5 ASSEMBLY SHOP

In the assembly shop the body is loaded on an overhead conveyor. As the conveyor moves
the body, fitments are made at various stations. There are three Assembly Shops named
ASSY-1, ASSY-2 and ASSY-3. Plant 2 and Plant 3 have similar setup but in Plant-1 there are
separate assembly lines for separate models. The assembly shop has a continuous production
system. The assembly line can be subdivided into the followings: -
24
(a) 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.
(b) 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.
(c) 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.
Features
Different assembly shop layouts are followed to reduce material handling operations & to
facilitate material flow between workstations.
a) Straight-line layout Car & omni line (Assy shop-1): Simplest layout in which
material enters at 1 end & leaves at the other end.
b) U shape layout Assy shop 2 & 3: Receiving & shipping ends of line are at same
end of plant, due to material handling considerations (same forklift for both needs) or
external needs.
c) S shape layout Esteem line (AS-1): Serpentine layout to fit longer assy line in
square shop.
Separate door Assy line: - Doors are taken out from the vehicle at the first station of the trim
line. Doors fitted in the final line make working easier.
25
2.6 OTHER SHOPS/DEPARTMENTS
MACHINE SHOP
The machine shop is the source of all major components for the engine assembly shop. The
un-machined crankshaft and camshaft forgings, transmission case cylinder head and cylinder
block castings are brought in the form of raw materials from the vendors. The cylinder heads
and transmission case are aluminum castings while crankshaft and camshaft are steel
forgings.
It has the following lines:
(a) Transmission case line

(b) Cylinder head line
(c) Cylinder block line
(d) Crankshaft line
(e) Camshaft line.
ENGINE ASSEMBLY
There are four types of engines which are assembled in the Engine Plant
1. FC Engine Engine with cast iron block

a. M-800
b. Omni
c. Alto
d. Wagon-R
e. Zen Estillo
2. Aluminium Engine Engine with aluminium block
a. Gypsy
b. SX4
c. Swift (Petrol)
d. Dezire (Petrol)
26
3. KB Engine (New series of engines with aluminium block)

a. A-Star
b. Ritz
4. Diesel Engine
a. Swift (Diesel)
b. Dezire (Diesel)
c. Ritz (Diesel)
27
CHAPTER 3
WELD INFORMATION CONTROL SYSTEM
3.1 INTRODUCTION
As we know, the spots of a car are the most prcised work done on a car as their failure can
cause accident. So, the company prefers to check the spots of car as it directly refer us to the
company quality. But, it was not possible for the company to check the spots of every car as
it was a very time consumable process as the processes done to check the spots were
hammering test and peeling test. Till now, Maruti Suzuki India Limited was checking the
spots of every export car and every 10th import car. But this does not give assurance to the
customer for the best quality car as there was no tool for analysis of weld spot quality. So,
there was a need to implement a method which would help the company in providing the best
quality car. Due to this reason, weld information control system came to being in use.
3.2 WELD INFORMATION CONTROL SYSTEM
Weld information control system is a non-destructive testing technique to check the spots. In
this technique, a spot id is given to every spot of the car. The datas of welding parameters
are noted. These data have been fed to the PLC (programmable logic controller). IT
department has implemented a server which would be directly linked with the PLC. PLC
provides a graphical characteristic of every spot in computer screen with the help of server
from which we could ensure defective spots on line. Also, the robot line would stop in which
problem has occurred i.e. if the spots does not have the same characteristics as provided to
the PLC, the robot would stop working itself and show faults on computer screen. So that, we
can correct the spot by taking counter measure. Also, this technique will help us in having a
control on NG welding flow.
28
3.3 NG Welding Flow
NG welding flow occurs at a point where the robot is not able to weld the spot correctly i.e.
the weld does not took properly due to following reasons:-
a) Spatter control
b) Spot Miss
c) Gun alignment NG
d) Tip / Tip Dressing NG
e) Half spot
f) Spot out of position
g) Gun shunting
h) Part deformation (part mismatch)
3.4 W.I.C.S. FUNCTIONALITY
Prevents NG Welding Flow
Accurate Detection of Faults
a) Spatter control
b) Spot Miss
c) Gun alignment NG
d) Tip / Tip Dressing NG
e) Half spot
f) Spot out of position
g) Gun shunting
h) Part deformation (part mismatch)
Analysis of every weld spot
Storage of weld spot parameters (upto 10 years)
29
3.5 SYSTEM CONFIGURATION
Fig. 3.1. System configuration of W.I.CS.
30
3.6 W.I.C.S. METHODOLOGY
The methodology on which W.I.C.S. depends is to study about the resistance waves as the
reason for the spot failure could be known by this methodology.
RESISTANCE WAVES
Resistance waves are the graphical representation between resistance values and the weld
time to show that the nugget formed is absolutely correct.
Fig. 3.2. Principle of Resistance Waves
As we can see from the above figure 3.2, the resistance value first decreases but as the temp.
of base metal is raised the resistance value climb up and form a nugget and as the nugget
expansion takes place with the increase in electrical path, the resistance value again decline.
31
3.6.1 BENEFITS FOR OBSERVING RESISTANCE WAVES
Resistance wave profile is full spot welding, white body check.

Detect the abnormal conditions early.
Prevent NG Welding Flow.
3.6.2 RESULTS OBTAINED BY OBSERVING RESISTANCE WAVES
By observing the resistance waves, we could get to know the various methods because of
which the NG Welding Flow occurs.
1. Fault due to get out of parts position.
Fig. 3.3. Fault seen due to get out of parts position
32
From the above fig. 3.3, we can clearly see that the nugget formation takes place at any other
position than required.
2. Fault due to bend parts.
Fig. 3.4. Fault seen due to bend parts
From the above fig. 3.4, we can clearly see that the nugget formation does not took place
correctly as the parts in which the spot was to be applied was bent.
33
3. Fault due to get out of position.
Fig. 3.5. Fault due to get out of position seen
From the above fig. 3.5, we can clearly see that the nugget formation was formed slightly
side from its position due to which spot was not formed as required.
34
3.6.3 FAULTS RELATED TO RESISTANCE WAVES
E79 Resist wave fault
Fault occurs due to low quantity of heat, Tip diameter expansion, Lack or 2sets of work, Shift
of weld position, Gun touch, terrible expulsion etc.
Fig. 3.6. Fault of E79 resistance waves
-Reset possible at reset box
-Be cautious that when same control no. and same condition has been used continuously,
judgment will not be done.
NG body dont stop, even if no check and reset.
When you returns weld points before more than 1 weld point by manual operation and you
re-welded the weld points, it is possibility existence to stop by fault again.
E85 Wave Resist Frequent
Fault occurs due to tip dress, etc.
35
-Timers output E85, when weld points more than thresholds of a warning level occurred
frequently in res. decrease width or aver. res.
-Reset possible in reset box
E80 High Resistance
Faults occur due to dust between the tip, power cable break etc.
Fig. 3.7. Fault of E80 high resistance waves
-Timers output E80 when it detect resistance value ahead of a threshold of high resistance
and it doesnt send weld current according to the setting value.
-Discontinue the power supply at the detection of the fault
- Measures are the basically same as low current fault.
- We can reset the fault at a reset box, but it occurs again till the fault state is removed
36
GRAPHICAL REPRESENTATION OF RESISTANCE WAVES
Fig. 3.8, shows the graphical representation of resistance values at the time of welding.
Fig. 3.8. Graphical representation of resistance values
This representation shows us the difference in the resistance decreasing width. This is shown
by the line arrays of red, yellow and blue colour in above fig.
37
3.6.4 METHOD FOR OBSERVING RESISTANCE WAVEFORM
To measure the transition of resistance value in every 0.5 cycle in welding, we have to
calculate the parameter 1 to 4 and supervise them. The parameter to be calculated are as
follows:-
1. Resistance width decrease: - Max. resistance value final resistance value

2. Average resistance value:- Average of resistance value between 2.5cyc and weld time
(setting time) -0.5cyc
3. 3.Max resistance value:- Max value between setting time and weld time (setting time)
-1.5cyc
4. Final resistance value:- Resistance Value of weld time (setting time) -0.5cyc
Fig. 3.9 Resistance waveform
38
3.6.5 SETTING OF RESISTANCE LIMIT
Resistance limits refers us to a position after which alarm would rang. Resistance limits are
classified in two levels: -
1. Alarm Level: - When the nugget formation does not take properly, limit of alarm level
is reached and the alarm rang so that the worker or engineer could take the counter
measure.
2. Fault level: - When the engineer or worker does not take counter measure after the
alarm, then the line would automatically spot.
3.6.6 PROBLEMS OCCURING IN OBSERVATION
There is a case when there is not a change of resistance. In this case, only the thin
sheet side is weld NG on sheet combination such as thin- thick-thick sheets and in the
case of sheet combination of thin-thin sheets. Therefore, there is the case that NG
points cannot stop.
Whether fault stops or not depend on a limit setting. Misjudgment occur a lot of times,
when limit setting is too rigorous. But it cannot detect weld NG, when limit setting is too
indulgent.
Now, we set limits from average and unevenness of the present data which WICS system
collect.
39
3.7 SYSTEM SUMMARY
It gives the whole functioning of W.I.C.S.
Fig. 3.10. System Summmary
40
3.7 FORMAT
Fig. 3.11. Format of W.I.C.S.
41
3.9 DATA REFERENCE MENU
Collection serverData reference destination of the body which does not pass M/B as of
5:00 before three days.
Offer serverData reference destination of the body which passed a M/B as of 5:00 before
three days.
Wave form of one weld ID:
-It displays wave form of resistance and current value of optional weld point on same graph.
-When I search it by a robot and a body unit, I use it
Fig. 3.12. DATA REFERNCE MENU VERSION
Wave form of each weld ID and transition:
-It displays a wave pattern of resistance value or current value of a optional weld ID on the
same graph.
-It displays transition such as resistance decrease width, an average resistance value in a
designated period for a optional weld ID.
42
Judgment of all weld ID
It displays a judgment (OK, NG, dust) for weld ID of a optional body with a table.
Specified weld ID wave form monitor:
-It is always (It update it by a period for about 50 seconds) displayed the latest wave pattern
of a optional model and weld ID.
3.10 CONCLUSIONS OF W.I.C.S.
1. Customer Satisfaction: - The main motive of implementing W.I.C.S. in the YL8 line is to
provide satisfaction to the customer. As the satisfaction of customer would increase, he/
she would increase their faith on the company as a result more customers would come to
buy the car.
2. Best Quality:- the implementation of W.I.C.S. increases the quality of the car as a result
the people would be assure that this company cannot make bad products as they are
perfect in their quality.
43
CHAPTER 4
4.1 Maruti Operation Standard Inspection
MOS I is known as Maruti Operation Standard Inspection sheet in which a list of all the spots
are made and their robots are mentioned which apply these spots. Cycles are divided
according to the application of spots. This sheet has a full spot detail of a car and the copy of
every sheet is listed in the file on the line so that any engineer could go on the line and with
this sheet could know about the inspection of this spot. The sheet is divided according to
main body, main body pit, white body, cowl box, etc. and their cycles.
4.2 DESCRIPTION OF MOS I
The first thing that an engineer should know in welding department is the layout of
department.
He should know that which robot is working on which car.
He should know which spots can be checked and which cannot be checked.
He should know how many men are needed for checking the spots in a given
component.
For this, MOS I has been made so that the engineer have a list of all the spots being
implemented on the components of the car.
44
4.3 OBJECTIVES OF MOS I
1. To mark the spots with different colours of different robots working on the
component.
2. To mark the G.A. spots and Maru - A spots of the component.
3. To mark the cycle so that we could know how many men are needed for checking the
spots? No. of cycles is equal to no. of men needed to check the spots.
4. To know how many robots are doing welding in a given component and how many
spots are there in the given component.
4.4 METHODOLOGY ADOPTED
A MOS I sheet was made in which the picture of component with the spots was
printed.
The robots which are applying those spots in a given component were noted down
along with their spots.
Maru- A spots and G.A. spots were seen and marked on it.
The men working on a given component to check the spots were noted and cycles
were made according to their work.
45
4.5 CONCLUSIONS
Easy for engineer to find the robot.
Easy to find out the component details with the help of index.
To know how much labour required for checking the spots.
46

Data Collection for Maruti Suzuki Process

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DATA COLLECTION FOR W.I.C.S.

1.2 BACKGROUND OF THE INDIAN AUTO INDUSTRY

Modernization of Indian Automobile Industry.

1.3 Choice of product and collaborator

1.4 COMPANY MISSION

A leader in the Indian Automobile Industry.

By Market share and brand equity

1.6 CUSTOMER DELIGHT

Values for money

1.7 SHARE HOLDERS WEALTH

High Profitability & Image

1.8 A PRIDE OF INDIA

1.10 QUALITY POLICY

To increase consumer satisfaction through continuous improvement of products and

Fig. 1.1- Maruti Suzuki India Limited Company Policy

1.11 QUALITY TOOLS

SEIRI PROPER SELECTION

GENCHI GO TO ACTUAL PLACE

1.12 The hierarchy diagram of MSIL

1.13 DIVISIONS AND DEPARTMENTS

Corporate Services Division

Legal & Secretarial Department

Human Resource Division

Employee Relations Department

Production Engineering Division

Supply Chain division

Supply Chain- 1,2,3 Division

Information Technology Division

Application Group1 (AG1)

Marketing & Sales Secretariat

Marketing Strategy & Development

Spare Parts Division

Spare Parts Procurement

Budget, Cost & Accounts Department Income Accounting

Production Division of Maruti Suzuki India Limited

Major components of PBV

Press Shop and Blanking Line

1.14 LAYOUT OF PROCESS FLOW

Fig. 1.2- Process flow of Maruti Suzuki India Limited

1.15 INTRODUCTION TO VARIOUS MODELS

MODELS SPECIFICATIONS YEAR OF LAUNCH

MARUTI 800 (FIRST

OMNI 796CC, MUV NOVEMBER 1984

GYPSY 992CC, 4WD DECEMBER 1985

MARUTI 800 (MODIFIED) 796CC, HATCHBACK APRIL 1986

MARUTI 1000 996CC, SEDAN OCTOBER 1990

ZEN 996CC, HATCHBACK OCTOBER 1993

ESTEEM 1.3L LX 1296CC, SEDAN NOVEMBER 994

ESTEEM 1.3L VX 1296CC, SEDAN NOVEMBER1995

ESTEEM 1.3L AX 1296CC, SEDAN JUNE 1996

ZEN AX (AUTOMATIC) 996CC, HATCHBACK OCTOBER 1996

GYPSY KING 1296CC, 4WD NOVEMBER1996

OMNI (E) 796CC, MUV DECEMBER 1996

GYPSY (E) 1296CC, 4WD DECEMBER 1996

MARUTI 800 (NEW

ESTEEM 98 1296CC, SEDAN OCTOBER 1997

NEWOMNI&OMNI-E 796CC, MUV FEBRUARY 1998

ZEN VX & ZEN VX JULY 1998

ZEN D 1200CC, HATCHBACK AUGUST 1998

MARUTI 800 EX 796CC, HATCHBACK JANUARY 1999

ZEN LX 996CC, HATCHBACK JANUARY 1999

ZEN CLASSIC 996CC, HATCHBACK AUGUST 1999

ZEN VXI 996CC, HATCHBACK OCTOBER 1999