PROJECT REPORT

PRODUCTION OF CAR
SEATS

CAR SEAT

CONTENTS

INTRODUCTION
HISTORY
CERTIFICATION
VENDORS
UNSAFE ACTS
6 F PRINCIPLE
WELDING PROCESSES
PU SHOP
ASSEMBELY SHOP

INTRODUCTION

KML started its operations with

only 1 model and a production
capability of 40 sets/day. Today
we manufacture 16 different
models. Krishna Maruti Limited
has a production capacity
of400,000SeatingSystems/ann
um.Presently Krishna Maruti
Limited produces 16 different
Variants of seating systems of
following Models: WAGON R,
ZEN, OMNI, MARUTI 800cc &
ALTO.

INTRODUCTION CONTD.

Krishna Maruti Limited is

also India's first
Company to use Robotic
PU Plants. Both the PU
Plants are Fully
Automatic & Robotic and
are capable of producing
Dual hardness Pads for
better orthopedic
comfort.

INTRODUCTION CONTD.

Krishna Maruti Limited has in-house Welding Shop for

manufacturing Frames for Seating System This weld shop
is equipped with CNC machines and conventional welding
machines like Mig Welding, Resistance Welding.
For painting of seat frames KML has fully automatic &
conveyorised Pretreatment & Paint Plant. Water based
paints are used in Shower Painting process.
Assembly is performed on Conveyorised lines using SNIC
's technology.
KML is capable of conducting test as per European
Homologation and Japanese's Standards.

HISTORY

Krishna Maruti Limited is a

Joint Venture Company of
Suzuki Motor Corporation of
Japan, Maruti Udyog Limited
and Ashok Kapur &
Associates. The company has
a technical collaboration with
SNIC of Japan. Krishna Maruti
Limited is South Asia's
Largest Manufacturer of
Seating Systems for
Automobiles.KML started its
building operation in Dec
1993. The Rs. 265 Million
project was completed in a
record time of 120 days!

HISTORY CONTD.

KML entered the auto interior

manufacturing business with a
single product (seating system
for Maruti 800 CC Car) in year
1994.
Today we manufacture 8
different products with over 100
different models.
We are India's First Total Auto
Interior Group of Companies
manufacturing all the
requirements of auto interiors
including Seating Systems, Rear
View Mirrors, Head Rest
Assemblies, Arm Rest
Assemblies, Seat Trims (Covers),
Injection Moulded Door Trims,
Roofliners & Moulded Carpets.

CERTIFICATION

Company has been certified as

ISO 9002 in year 1996 by TUV
Bayran and QS 9000 in Year
1997 by AV Vincotte, Belgium.
Towards our quest to become a
World Class Company, we at
KML commenced the TQM
Mission jointly organized by CII
and MUL since 1998.
At Krishna Maruti Limited we
are totally committed to Quality
Standards set by our
customers. Our line rejection is
less than 500 PPM and we have
achieved Zero MARU 'A' Defect.

VENDORS

SKH METAL-1
SKH METAL-2
GANDHI SPRINGS
SI INTERPACK (TRIM)
SI INTERPACK(PE COVER)
KARAN AUTO
SANDHAR
SOL AUTO
SWARAJ
ESSMA
AUTOMAX
MODERN IND
SAI SUPREME

RAW MATERIALS USED

At Krishna the basic raw materials used are :

Polyurethane raw materials to produce moulded cushion pads
-Polyols & Isocynates.
CRCA sheet metal components.
Tubular lengths of various sizes.
Water soluble black paints & pre treatment chemical.
PVC fabrics.Laminated polyester & cotton fabrics.
Wire Spring
Polypropylene for injection moulded components
Hardware items.
Various industrial consumables like mig wire, adhesives, safety
items, spot welding electrodes etc.

CONTD.

Seat adjuster mechanism assemblies.

Seat recliner mechanism assemblies.
Rear seat lock assemblies.
Automotive fabric.
Treads.Substrate for roof headliner(rigid foam).
Mirror sheets.
Felt for moulded carpet.
Needle punch fabric for moulded carpet.
CRCE sheet.Non - woven fabric.Fasteners for
various sizes.

6-F PRINCIPLE

Focused: Focus towards customer delight, engineering

infrastructure, cost consciousness and continuous
improvements through '5 - S', 'Kaizens', Quality Circle
Meetings and Suggestion Meetings.
Fast: Fast system & technological up - gradation and
implementation.
Flexible: Flexible towards customer requirements.
Friendly: Creating friendly environment among customer,
employees & vendors.
Firm: Firmly adhering to laid down policies & procedures
Fun: Achieving the targets in stipulated time.

SPOT WELDING

Spot welding is one of the

oldest welding processes. It
is used in a wide range of
industries but notably for the
assembly of sheet steel
vehicle bodies. This is a type
of resistance welding where
the spot welds are made at
regular intervals on
overlapping sheets of metal.
Spot welding is primarily
used for joining parts that
are normally up to 3 mm in
thickness.

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.

PROJECTION WELDING

Projection welding is a variation of spot welding. Projections are

designed in one part. These act as current concentrators for the
welding process. When the two parts are mated together, these
projections are the high points that first make contact. As the
power is cycled, the projections simultaneously carry the
current and are welded.
Due to the efficiency of power transfer, thicker materials can be
successfully welded. Materials as thick as 3 mm (0.125 in) can
be successfully welded.
Low carbon steels, low alloy steels, stainless steels, as well as
aluminum can be welded using this process.
Projections are usually semi-spherical or blunt conical type.
Projection welding requires that the height of projections be
controlled to within a range of 0.075 mm (0.003 in).

PU SHOP PROCESSES
STATION 1
MOULDING
STATION 2
RELEASE AGENT SPRAY
STATION 3
MOULD CLEANING
STATION 4
DEMOULDING
STATION 5
CRUSHING

COMPONENTS USED IN
ASSEMBELY OF SEATS

M8
M10
KNOB
BUCKLE
HANDLE
PROTECTOR
ROD
RUBBER WASHER

UNSAFE ACTS
MAKING

SAFETY DEVICE INOPERATIVE

REMOVING GUARDS
UNSAFE LOADING
LIFTING TOO HEAVY LOADS
OVERLOADING
UNSAFE SPEED
USING HANDS TO FEED
USING DEFECTIVE TOOLS