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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. Until
recently, 18.28% of the company was owned by the Indian government, and 54.2% by
Suzuki of Japan. 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Hindustan Ambassador and Premier Padmini were both around 25 years out of date at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. Through 2004, Maruti has produced over 5 Million vehicles. 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 so far. 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.
Maruti Suzuki India Limited, a subsidiary of Suzuki Motor Corporation of Japan, has
been the leader of the Indian car market for over two decades.
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It’s manufacturing facilities are located at two facilities Gurgaon and Manesar south of
New Delhi. Maruti’s 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.
More than half the cars sold in India are Maruti cars. The company is a subsidiary of
Suzuki Motor Corporation, Japan, which owns 54.2 per cent of Maruti. The rest is
owned by the public and financial institutions. It is listed on the Bombay Stock Exchange
and National Stock Exchange in India.
During 2007-08, Maruti Suzuki sold 764,842 cars, of which 53,024 were exported. In all,
over six million Maruti cars are on Indian roads since the first car was rolled out on
December 14, 1983.
Maruti Suzuki offers 12 models, Maruti 800, Omni, Alto, Versa, Gypsy, A Star, Wagon
R, Zen Estilo, Swift, Swift Dzire, SX4, Grand Vitara. Swift, Swift dzire, A star and SX4
are maufactured in Manesar, Grand Vitara is imported from Japan as a completely built
unit (CBU), remaining all models are manufactured in Maruti Suzuki's Gurgaon Plant.
Suzuki Motor Corporation, the parent company, is a global leader in mini and compact
cars for three decades. Suzuki’s technical superiority lies in its ability to pack power and
performance into a compact, lightweight engine that is clean and fuel efficient.
Maruti is clearly an “employer of choice” for automotive engineers and young managers
from across the country. Nearly 75,000 people are employed directly by Maruti and its
partners.
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The company vouches for customer satisfaction. For its sincere efforts it has been rated
(by customers)first in customer satisfaction among all car makers in India for nine years
in a row in annual survey by J D Power Asia Pacific.
Maruti Suzuki was born as a government company, with Suzuki as a minor partner to
make a people's car for middle class India. Over the years, the product range has
widened, ownership has changed hands and the customer has evolved. What remains
unchanged, then and now, is Maruti’s mission to motorize India.
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:
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 MSIL ‘s
requirements in terms of product mix, technology transfer, and equality
participation and had the
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.
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A diesel engine and transmission plant, set up under a joint venture of SMC and
MSILcalled Suzuki Power train India Limited (SPIL)
COMPANY MISSION
A pride of India!
LEADERSHIP
By operational practices
By people strategy
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CUSTOMER DELIGHT
Quality
Service
A PRIDE OF INDIA
As a corporate citizen
Products
People
Practices
Customers
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VALUES
Customer Obsession
QUALITY POLICY
DO
PLAN
QUALITY
POLICY
ACT CHECK
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QUALITY TOOLS
5S
4M
3M
3G
3K
What is 5S?
SEITION – ARRANGEMENT
SEISO – CLEANING
SEIKETSO – CLEANLINESS
SHITSUKE – DISCIPLINE
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What is 4M?
The factory is essentially a mix of man, materials, machines and methods. These
should move continuously and effectively to produce a quality product at low cost. The
most essential work in quality control is to thoroughly investigate regarding the problems
concerning quality, decide suitable counter measures and carry out improvements
accordingly.
MAN
MACHINE
MATERIAL
METHODS
What is 3M?
MURI – INCONVENIENCE
MUDA – WASTAGE
MURA – INCONSISTENCY
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What is 3G?
PRODUCT RANGE
ORGANISATIONAL STRUCTURE
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Maruti has believed, since the very beginning that it is its employees who could make it
have built up a flat organization with a family type of atmosphere at our place of work.
The company is divided into different divisions according to the various functional areas.
A Divisional Manager heads each Division. Divisions are further divided into
Departments that are headed by Department Managers who report to the respective
responsibility and not levels as in terms of the company’s philosophy designations and
The total operations of the Company are divided into Divisions like Marketing & Sales,
Production Division
Plant- 1
Plant- 2
Plant- 3
Plant- 6 at Manesar
Production Engineering
Engineering Directorate
QAIN Division
Service Division
Service- 1-5
MSS(D)
Parts Inspection Division
Engineering Division
Exports
Web-IT, E-Commerce
Vigilance Division
Security Wing
Vigilance Wing
Finance Division
The total project costs, priority, completion time and personnel’s required were
estimated. Initial plans were drawn up as to how the project would proceed to its final
implementation, while running the existing system so that company’s information
needs were not affected.
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Without the ability to locate and track units as they make their way through
manufacturing, testing and repair processes, managers lack the ability to achieve
optimum performance for their business and are forced to rely on outdated,
The most powerful tool for any manager is accurate, real-time information about the
information to track, measure and manage vehicles anywhere within a facility, both
vehicle tracking and management in today's vehicle assembly, delivery chain and
fleet operations and is the first solution to provide real-time information to today’s
chain or fleet operation to know in real-time or historically exactly where the vehicle
Vehicle Tracking and Management System is one of the world’s first systems to
vehicle typically before the vehicle enters the off-line processing areas., the solution
In addition, beyond the ability to locate a vehicle on demand, the tracking data can
be used to monitor such things as adherence to process, process cycle time, and
execution and monitoring of performance — making it the ultimate support tool for
BENEFITS:
Increase vehicle throughput
Improve order to delivery
Reduce dwell time
By utilizing this data, and closely monitoring the precise run-time and utilization of
the equipment, Equipment Tracking and Management System can significantly
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reduce the total operating costs through proper "right-sizing" of the equipment fleet,
by total quantity and by equipment type.
Access Control
Reduces injuries by ensuring that only approved users can operate the
equipment by using a contact button or proximity card.
Eliminates government fines associated with access controls.
Decreases abuse or misuse by linking incidents to specific operators.
Preventive Maintenance
Maximizes equipment life through routine maintenance based on actual engine
runtime hours.
Increases operator productivity with improved up-time of equipment.
Reduces costs and increases useful life by performing usage based preventive
maintenance.
Equipment Utilization
"Right-size" fleet by tracking actual utilization.
Increases useful life of equipment with better accountability and management.
Reduces headcount through increased productivity.
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BENEFITS
Increase productivity
Reduce injuries
Reduce labour
Better efficiency
VTS OBJECTIVES
High System availability and real time response.
Enable mixed production in various shops as per VBS.
Interfacing with Shop Equipment.
Automatic component selection system(Pika-Pika).
Material Flow Sequence Supply.
Engine-Assembly Planning.
Eliminate human error creeping in system at manual data entry.
Modular and Scalable.
MAIN FEATURES
The Vehicle Tracking System or VTS was developed in house by the cross functional
team of IT, PE and Production of Maruti Suzuki India Limited to reduce the company’s
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response time to market demand, and to handle the complexities of producing vehicles
across multiple variants
VTS IMPLEMENTATION
VTS acts as a intermediary between the database server and the various shop floor
terminals and devices.
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It facilitates real time communication for transferring data between the computer
system and the PLC system which in turn provides data to the robots and to the
equipments that enables them to pick up the right component and also to broadcast
the requisite information to the printer.
Thus providing data to the technicians. The technicians use this data for the
assembly of the vehicles and finally VTS aids the implementation of the production
plan sequence on the shop floor.
The production plan contains all the requisite information in terms of the path to be
followed by each vehicle through the manufacturing plant the vehicle code, its color,
the country code, and chassis number. It also specifies the start and end point for
each process.
The VTS facilitates this complex planning using which a vehicle under production
can be routed in a flexible manner across various shops and lines in the most
effective manner.
The VTS enables the engine from multiple locations to be tracked as manufacturing
process progresses.
AREAS COVERED
In the above fig,each model is specified with different color and the path followed by each is
represented by the arrows joining different shops
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SERVER CONFIGRATION
VTS & as soon as triggering mechanism will get signal of presence of a particular
model it will pass on the signal to PLC of the equipment & the equipment will come
in that mode automatically. Vehicle Tracking from 1st control point to last control
(For example if we want to see No. of vehicles in WIP in Paint Shop then we have to
give command to system for PB ON to PB OK & No of vehicles will be under Paint Shop
WIP)
sequence of models is in line will be known in advance & that sequence can be
printed by line printers which can be displayed for operator to see what model of
At the AB-ON point, the data is transferred to the PLC and the vehicle sequence is
broadcast at various control points to different areas.
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Let us take a closer look on some of the areas points at which such broadcasts take
place:
The Main Fundoshi Printer — this contains the details of components, and this
information helps the operators to fix the right components in the correct vehicles.
The Door Mini Fundoshi Printers — these printouts are stuck to the doors. Based
The Process Check Sheet — this document is used to check the completion of the
Engine Storage Out — engines are put on the Engine Docking Line according to
the AB-ON sequence, which is broadcast to the printer at the time of AB-ON. At the
Engine-Body marriage point, the Engine Number is matched against the Chassis
Various other sequence printers are used for different sub-assembly lines:
Tyre sub-assembly;
Instrument panel sub-assembly;
Windshield sub-assembly;
Door sub-assembly;
Door latch sub-assembly; and
ID plate
At certain points, PC Monitor applications are also used to broadcast the sequence.
The marriage of the engine with the vehicle is done at the EG Storage-Out point — this
is integrated with the VTS to avoid the possibility of wrong engine marriage.
Key features
Tracking points: AB-ON , AB-OK.
etc)
SCHEMATIC LAYOUT
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Equipment interfacing
PLC-EQUIPMENT INTERFACING
As soon as the vehicle comes in position it hits the limit switch which is
connected to the line PLC
The line PLC then interacts with the server to collect the information about the
vehicle (which in this case is amount of engine & break oil)
The PLC then passes this information to the fuel filling machine for the particular
vehicle
The information is also displayed in the GOT
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PIKKA-PIKKA SYSTEM
The selection of components in the main areas is carried out through the VTS using
Pika-Pika.
This is a LED-based system.
A LED glows on the bin from which the operator is supposed to pick the component,
thereby guiding the operator to pick up the correct component.
As soon as he picks the component, the LED turns off.
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However, if the operator puts his hand into the wrong Bin, a warning signal is
generated.
Green light
glows on
correct part
The information pertaining to the vehicles in line is passed by the VTS to the line
Pikka-pikka system has series of rows & columns of the component for the particular
A LED glows above the particular column having components for the coming vehicle
model
The LED goes off as soon as the operator picks up the correct component
operator
Thus through the pika-pika ,the VTS fool proofs the component selection process.
RFID TRACKING
technology is used.
The system acts as an interface between the host computer and the production floor
and is used to transfer production plan information, dressing data to plant devices
and tags and obtaining production process data, traceability data and quality data from
the tag.
The system then stores the data to the host computer for storing analyzing and for
future useThe data related to testing is handled by the test management system or
At these stations the magnetic RFID Tag communicates with the tracking system
known as PMS system via the Tag Controller to exchange and verify the data.
Additionally, the RFID tags also exchange data with other equipment and machines
on the assembly line in the same way, using the Tag Controller. The Tag contains
The RFID Tag will start receiving data from set up station — for example, type of
engine, engine number, master data, etc. As the pallet goes along the line and
different operations are performed on the engine by various machines, the RFID Tag
continues collecting data from machines recording the operation done, its status,
etc. When the pallet reaches the release station, the entire data in the RFID Tag is
transferred to the PMS and after updating, it is flushed from the Tag. Now the tag is
FC-ON and
FC-OK.
tolerance. All defects details are tracked through the VTS to ensure that no vehicle gets
Hence, VTS is a system that offers real time data to facilitate quick decision. It carries
out real time monitoring to detect errors and quality issues well in time; it broadcasts
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