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car available in India, its' only competitors- the Hindustan Ambassador and Premier Padmini were both around 25 years out of date at that point.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. 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. 1 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT DATA COLLECTION FOR W.I.C.S. & WELD SPOT CHECKING PROCESS STANDARDIZATION 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 MSIL„s 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 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT DATA COLLECTION FOR W.I.C.S. & WELD SPOT CHECKING PROCESS STANDARDIZATION 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 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT DATA COLLECTION FOR W.I.C.S. & WELD SPOT CHECKING PROCESS STANDARDIZATION 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 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT 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 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .I. & WELD SPOT CHECKING PROCESS STANDARDIZATION 1.S.DATA COLLECTION FOR W.C. & WELD SPOT CHECKING PROCESS STANDARDIZATION 1.I.12 The hierarchy diagram of MSIL 6 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .S.DATA COLLECTION FOR W.C. 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.I.C.S.DATA COLLECTION FOR W. & WELD SPOT CHECKING PROCESS STANDARDIZATION 1.1-5 MSS(D) Parts Inspection Division Engineering Division 7 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . & WELD SPOT CHECKING PROCESS STANDARDIZATION Supply Chain division Supply Chain.S.3 Division Shipping & transport Department Imports Department Consumables Department Information Technology Division Application Group1 (AG1) Application Group2 (AG2) Application Group3 (AG3) Information Technology Strategies(ITS) IT Operation and Services(ITOS) Marketing & Sales Secretariat Marketing Strategy & Development Marketing Sales Exports Web-IT.C.2. E-Commerce Spare Parts Division Spare Parts Procurement Warehousing & Dispatch Spare Parts Sales Accessories 8 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .DATA COLLECTION FOR W.1.I. & 3) Engine Assembly (1.2. 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.& 3) Machine Shop (1.& 3) Assembly Shop (1.& 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 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . & WELD SPOT CHECKING PROCESS STANDARDIZATION Vigilance Division Security Wing Vigilance Wing Finance Division Budget. Vehicle Inspection & Supplier Quality Assurance divisions in it.DATA COLLECTION FOR W. Major components of PBV Press Shop and Blanking Line Weld Shop (1.& 3) Materials – X (1.2.S.2.2.2.C.2 & 3) Paint Shop (1.I. C. & WELD SPOT CHECKING PROCESS STANDARDIZATION 1.2.I. 1.Process flow of Maruti Suzuki India Limited 10 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .DATA COLLECTION FOR W.14 LAYOUT OF PROCESS FLOW Fig.S. MUV FEBRUARY 1998 MODEL) MARUTI 800 (NEW MODEL) ZEN VX & ZEN VX AUTOMATIC JULY 1998 996CC. HATCHBACK SEPTEMBER 997 ESTEEM 98 1296CC. HATCHBACK DECEMBER 1983 OMNI 796CC.3L AX 1296CC. SEDAN OCTOBER 1997 NEWOMNI&OMNI-E 796CC. SEDAN NOVEMBER1995 ESTEEM 1. HATCHBACK OCTOBER 1996 GYPSY KING 1296CC. MUV NOVEMBER 1984 GYPSY 992CC.C. SEDAN OCTOBER 1990 ZEN 996CC. SEDAN JUNE 1996 ZEN AX (AUTOMATIC) 996CC.3L LX 1296CC. HATCHBACK APRIL 1986 MARUTI 1000 996CC.DATA COLLECTION FOR W.I. HATCHBACK 11 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . SEDAN NOVEMBER 994 ESTEEM 1. HATCHBACK OCTOBER 1993 ESTEEM 1. 4WD DECEMBER 1996 796CC.15 INTRODUCTION TO VARIOUS MODELS PRODUCT RANGE MODELS MARUTI 800 (FIRST SPECIFICATIONS YEAR OF LAUNCH 796CC.3L VX 1296CC. & WELD SPOT CHECKING PROCESS STANDARDIZATION 1.S. 4WD NOVEMBER1996 OMNI (E) 796CC. 4WD DECEMBER 1985 MARUTI 800 (MODIFIED) 796CC. MUV DECEMBER 1996 GYPSY (E) 1296CC. HATCHBACK OCTOBER 1999 OMNI XL 796CC.DATA COLLECTION FOR W. HATCHBACK FEBRUARY 2007 SWIFT DIESEL FEBRUARY 2007 GRAND VITARA MARCH 2007 SX4 1. HATCHBACK AUGUST 1999 ZEN VXI 996CC.STAR NOVEMBER 2008 RITZ MAY 2009 STINGRAY OCTOBER 2013 CELLARIO MARCH 2014 12 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . LXI 796CC. HATCHBACK JANUARY 2000 ALTURA 1586CC. HATCHBACK JANUARY 1999 ZEN CLASSIC 996CC. HATCHBACK DECEMBER 2006 SWIFT DIESEL 1296CC. HATCHBACK MAY 2005 ZEN ESTILO 1096CC. HATCHBACK JANUARY 1999 ZEN LX 996CC.600CC MAY 2007 SWIFT DZIRE MARCH 2008 A. HATCHBACK SEPTEMBER 000 VERSA 1296CC. & WELD SPOT CHECKING PROCESS STANDARDIZATION ZEN D 1200CC.C. HATCHBACK (BALENO) MARCH 2000 ALTO LX.S. SEDAN DECEMBER 1999 WAGON R 1096CC.I. HATCHBACK AUGUST 1998 MARUTI 800 EX 796CC. MUV DECEMBER 2001 SWIFT 1296CC. MUV OCTOBER 1999 BALENO 1586CC. Second plant launched. Installed capacity reached 40.000 units. Omni. 4WD off-road vehicle). 1985 Launch of Maruti Gypsy (970cc. 1988 Installed capacity increased to 100. the installed capacity reached 200. 1987 Exported first lot of 500 cars to Hungary. 1992 SMC increases its stake to 50 per cent. a 796 cc hatchback. Launch of 24-hour emergency on-road vehicle service.S. 1983 1984 1994 1995 1996 1997 1998 1999 13 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .000 vehicles (cumulative production).C. a 796 cc MUV was in production.Suzuki innovative traffic beat in Delhi and Chennai as social initiatives. Launch of Maruti . 1982 Stepped into a JV with SMC of Japan.000 units. Launch of website as part of CRM initiatives.000 units.16 MILESTONES 1981 Maruti Udyog Ltd. Produced the 1 millionth vehicle since the commencement of production.I. Maruti 800.DATA COLLECTION FOR W. Produced the 2 millionth vehicle since the commencement of production. India's first affordable car was produced. 1986 Produced 100. was incorporated. & WELD SPOT CHECKING PROCESS STANDARDIZATION 1. 000 to a million units(Gurgaon plus Manesar) annually All India engineering export promotion council (EEPC) award.C. 2006.2 per cent. the highest ever since the company began operations 20 years ago. 2009 M-800 crosses 25 lakh mark MSIL celebrates SILVER JUBILEE MSIL launches national road safety program. 2005. Launch of customer information centres in Hyderabad. Maruti tops jd power csi survey for record seventh time in a row Govt of India awarded O SUZUKI with coveted padma bhusan Board of directors give approval to new name MUL to become maruti Suzuki India limited. and Chennai. Start of Maruti True value in Mumbai. Listed on BSE and NSE after a public issue oversubscribed 10 times.I. Maruti closed the financial year 2003-04 with an annual sale of 472122 units. 2004 2005. & WELD SPOT CHECKING PROCESS STANDARDIZATION 2000 2001 2002 2003 IDTR (Institute of Driving Training and Research) launched jointly with Delhi government to promote safe driving habits. 2007 2008. The fiftieth lakh car rolls out in April. Production of 4 millionth vehicle. Capacity to manufacture expanded from 800.DATA COLLECTION FOR W. Bangalore.S. Launch of Maruti Finance with 10 finance companies in Mumbai. SMC increases its stake to 54. MSIL achieved highest sales ever in Dec‟2009 14 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . & WELD SPOT CHECKING PROCESS STANDARDIZATION CHAPTER 2 MANUFACTURING PROCESS AT M.I.I.L. 2.S. 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.1 Stack of blanks 15 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .DATA COLLECTION FOR W.C.S.1 Blank Coils are fed to blanking line & continuous supply of sheet to cutting dies result in shaping of coils to plan blanks. 2. Panels are stored in pallets which are supplied to Weld Shops for making White Bodies. Blanks are converted to body panels by this process. & WELD SPOT CHECKING PROCESS STANDARDIZATION Panel Blanks are supplied to press lines for pressing.2.Panel 16 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .DATA COLLECTION FOR W.C. 2.I.S. Panels re stacked in pallet trolleys FIG. Tavera Steel coil Blank Panel Fig. „B‟ and „C‟ components are manufactured by joint ventures or bought from vendors. Press shop activities 2. weld 2 and weld 3 supplies components to all the three plants.DATA COLLECTION FOR W. The weld shop as per the requirements picks the finished body parts from the press shop.3.S. B and C. These may be divided as A.e. Currently Press Shop is producing sheet metal components for 8 running models of Maruti Suzuki and one model of GM India . These components are manufactured in the press shop at Maruti due to design secrecy and huge investment requirements. „A‟ components are large outer components as for example roof. Centrally located between weld 1.2.C. 400 tons a day 17 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . 2.2 PRESS SHOP The press shop can be regarded as the starting point of the car manufacturing process.I. & WELD SPOT CHECKING PROCESS STANDARDIZATION 2. The press shop has a batch production system whereas the plants have a line production system. The Blanking and stamping shop processes 10000 metric ton of steel / month i. door panels etc. 2. The press shop maintains an inventory of at least two days.1 Press Shop activity 1. S. This concept helps in changing of die set up within single digit minute (below 9 minutes). Press machine 2.3 SMED: “Single Minute Exchange of Dies” new concept being adopted .C. Since press machines are very high cost investment & any idle time lost due to die exchange will be a cost to company. 2.2 Machine Used Five Transfer Press (4000 ton .2.000 strokes / day from 400 tons of steel coils 4000 Ton transfer press Pressed panels come out from this side Fig.2. This helps us in improving machine utilization & operating efficiency. 3500 ton . & WELD SPOT CHECKING PROCESS STANDARDIZATION 2.e. in terms of total capacity i. (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.I.4.DATA COLLECTION FOR W. 2400 ton -1 2000 ton -2. 18 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . 86 29.5. 7.2% ) Modifications to improve yield are continuously done & till Oct-09 Press Shop has saved Rs. 2. & WELD SPOT CHECKING PROCESS STANDARDIZATION Upper die Lower die Fig. SMED 2.12 46.S.DATA COLLECTION FOR W.4 Yieldimprovement:-(Ratio of output panel to input coil in weight) is Best amongst the SMC group Companies.0 LACS 80 56.94 100 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) .6 60 21.786 millions of material in current year 105 120 Yield Improvement 20 50.2.I. ( Presently at 63.2 13.C.0 40 77. S.I. which is further divided into three parts: UNDER BODY: Here different underbody panels are welded together.DATA COLLECTION FOR W. WHITE BODY: The doors. 2. the conveyor roof and side body panels (prepared on the sub lines) are welded to it to give the main body. and front engine room panel. These comprise of rear underbody. burr and spatter and these defects are repaired. hood and back door are attached on the main body with the help of bolts and screws to make it a “white body”. each of. central underbody. After inspection and repairs the body is called WBOK. Reducing the blank size 2. It is sent to the paint shop thereafter. The weld shops have the following facilities. & WELD SPOT CHECKING PROCESS STANDARDIZATION Yield is improved by 1. These underbodies are put on the conveyor and welded together to give the underbody. The body is checked for dent. In a typical car body 1400 different components are welded together. 20 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .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”. The chassis number is punched on the cowl top and it is welded to the front engine room panel. MAIN BODY: As the body moves on. Utilization of scrap for making smaller sheet metal parts. Welding jigs Spot welding guns Kawasaki welding robots Hemming machines Punching machines PROCESS OUTLINE: The shop has different lines for different models.C. C. After applying the ED coat the body is baked in oven. After inspection and touch up. There are 4 coatings of paint. Sol-sealer and under coat: Here the left in the body (due to welding) are filled with sol-sealer to provide water proofing. For metallic coating. the paint body ok is sent to the assembly shop.DATA COLLECTION FOR W. 21 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .e. In paint shop all the models are painted on the same line. ED coat: This is done by electric deposition method. double coats are applied and aluminum flakes are provided to shine the metallic paints. i. & WELD SPOT CHECKING PROCESS STANDARDIZATION 2. only ZEN and ALTO are painted. the PBOK.I. Intermediate coat: This is done by spray-painting method using 10 Kawasaki Robots. 1] Phosphate coating 2] ED coating 3] IC coating 4] TOP coating Inside portion of vehicle is painted manually and outside is by Robots. In paint shop II. Top coat: This is done by spray-painting method using 20 Kawasaki Robots. Paint used is Nerolac. 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. Under coat is done on the surface above wheels to prevent damage of body in that portion.S. Painting done is basically an intermediate coating to provide base for the final coat.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. the body is dried in the oven. at 240V-DC supply. After applying the coat. & WELD SPOT CHECKING PROCESS STANDARDIZATION 2.S. Vehicle before coming to ED dip.2 ED PAINTING ED is electro deposition.1 PRE TREATMENT Before sending vehicle to painting process pretreatment is done to check the quality of paint. In that phosphating is done.6. M). In this around 300V is passed to make paint to be attached. Pre. in this.I.4. WBS Spray degreasing Hot water rinse SURFACE CONTROL PHOSPHATING WR II WR III WR IV Dip de WR V ED PROCESS WR I WR VI WR VII DI WATER MIST Fig. it undergoes pre treatment.C. This is about whole process. ED is very accurate to apply. When current is passed paint will be attracted by vehicle till its thickness will be covered. 2.4. Rinsing is done 22 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . ED is 17% of paint rest is water and some additives (EDD. in which Zn phosphate is made to attach vehicle body which help in electro deposition. Vehicle is dipped in the ED solution. PROCESS The whole solution of ED acts as electrolytic solution.DATA COLLECTION FOR W.treatment procedure 2. vehicle acts as cathode and paint as positive ions. They are white.C.4. & WELD SPOT CHECKING PROCESS STANDARDIZATION after to remove excessive color. ED Coating procedure 2. 2.3 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. 2. 2.5 TOP COAT Painting Top coating is done after checking in Dry sanding II.S.I. Next vehicle will move to final inspection and will be sent to assembly. Here Osmosis process is used to filter water.DATA COLLECTION FOR W. In rinsing industrial water is used which will not be left go waste. Outside portion of vehicle is painted by robots and inside is done manually. after that vehicle is sent to IC oven. Paint thickness is taken care. 23 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . Only metallic colors are coated with clear coating. Oven temperature is 198+/-5‟C. blue and red.4 IC painting IC is intermediate coating in which 3 colors are used.7. That will be filtered and used again. Here 11 colors are used. Here also outside portion of vehicle is painted by robots and inside is done manually. 8 metallic and 3 solid.4. WR I ED DIP WR IV WR III WR V DI WATER WR II RINSING BY DIPPING OVEN Fig. There are 2 sub coatings Base coat and Clear coat.4. Dosing mark 2. As the conveyor moves the body.C.DATA COLLECTION FOR W. 1. Blind gun 4. 1. fitments are made at various stations. ASSY-2 and ASSY-3. The assembly shop has a continuous production system. Following checking is done: 1. 3 types of guns are used.I. Sanding mark SOL SEALING LINE Sealer appearance is given the preference. Roof sanding 2. Pin hole in lamp area 5. & WELD SPOT CHECKING PROCESS STANDARDIZATION DRY SANDING Following repairs are done: 1. Plant 2 and Plant 3 have similar setup but in Plant-1 there are separate assembly lines for separate models. Extra sealer 3. Side repair if any.S. Sealer appearance 2. Flat gun 3.5 ASSEMBLY SHOP In the assembly shop the body is loaded on an overhead conveyor. Powder dust 2. Moti gun In this line followings are checked. Pencil gun 2. The assembly line can be subdivided into the followings: 24 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . There are three Assembly Shops named ASSY-1. Extra sealer 4. Features Different assembly shop layouts are followed to reduce material handling operations & to facilitate material flow between workstations. seats. Separate door Assy line: .I. along with the starter and alternator. as well as finishing touches like covers and vents. vents and lights. Power steering oil are filled and also the A/C gas are charged. torque. gas tanks and power steering are double-checked. 25 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . tires and the battery are added. Brake oil. due to material handling considerations (same forklift for both needs) or external needs.DATA COLLECTION FOR W. The engine is installed. it starts to look less like a shell and more like a car.S. Then come suspension and exhaust systems. Coolant. glove box and steering wheel. This is also where bumpers.Doors are taken out from the vehicle at the first station of the trim line. Then wheel is mounted with the help of wheel nut fastening machine. carpet. a) Straight-line layout – Car & omni line (Assy shop-1): Simplest layout in which material enters at 1 end & leaves at the other end. Then. Then they put in wiring. After an instrument panel. (b) Chassis Line This is where many safety-related items are installed. Things like brake lines. which covers many interior items such as the console. steering column and bumper supports are added. windows. c) S shape layout – Esteem line (AS-1): Serpentine layout to fit longer assy line in square shop. moldings and pads. (c) Final Line From there the vehicle enters Final 1.C. b) U shape layout – Assy shop 2 & 3: Receiving & shipping ends of line are at same end of plant. Doors fitted in the final line make working easier. & WELD SPOT CHECKING PROCESS STANDARDIZATION (a) Trim line The vehicle proceeds through a series of Trim workstations where team members begin by installing weather stripping. transmission case cylinder head and cylinder block castings are brought in the form of raw materials from the vendors.C. Zen Estillo 2. Dezire (Petrol) 26 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . & WELD SPOT CHECKING PROCESS STANDARDIZATION 2. It has the following lines: (a) Transmission case line (b) Cylinder head line (c) Cylinder block line (d) Crankshaft line (e) Camshaft line. Gypsy b.DATA COLLECTION FOR W.S. Omni c. Wagon-R e.I. SX4 c. FC Engine – Engine with cast iron block a. ENGINE ASSEMBLY There are four types of engines which are assembled in the Engine Plant 1. The un-machined crankshaft and camshaft forgings. The cylinder heads and transmission case are aluminum castings while crankshaft and camshaft are steel forgings. Alto d. M-800 b. Aluminium Engine – Engine with aluminium block a.6 OTHER SHOPS/DEPARTMENTS MACHINE SHOP The machine shop is the source of all major components for the engine assembly shop. Swift (Petrol) d. & WELD SPOT CHECKING PROCESS STANDARDIZATION 3. Swift (Diesel) b.C. Ritz 4.I.DATA COLLECTION FOR W. A-Star b. KB Engine (New series of engines with aluminium block) a. Diesel Engine a. Ritz (Diesel) 27 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .S. Dezire (Diesel) c. These data have been fed to the PLC (programmable logic controller). Also.1 INTRODUCTION As we know. In this technique. Maruti Suzuki India Limited was checking the spots of every export car and every 10th import car.e. & WELD SPOT CHECKING PROCESS STANDARDIZATION CHAPTER 3 WELD INFORMATION CONTROL SYSTEM 3.C. the robot would stop working itself and show faults on computer screen. 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. 28 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . The data‟s of welding parameters are noted. So. weld information control system came to being in use.I.2 WELD INFORMATION CONTROL SYSTEM Weld information control system is a non-destructive testing technique to check the spots. IT department has implemented a server which would be directly linked with the PLC. But. the spots of a car are the most précised work done on a car as their failure can cause accident. there was a need to implement a method which would help the company in providing the best quality car. 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. Also. 3. Due to this reason. we can correct the spot by taking counter measure. if the spots does not have the same characteristics as provided to 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.DATA COLLECTION FOR W. this technique will help us in having a control on NG welding flow. Till now. the company prefers to check the spots of car as it directly refer us to the company quality. a spot id is given to every spot of the car. So that.S. the robot line would stop in which problem has occurred i. 3 NG Welding Flow NG welding flow occurs at a point where the robot is not able to weld the spot correctly i.I.C.4 W.DATA COLLECTION FOR W.C.I.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 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .e.S. 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. & WELD SPOT CHECKING PROCESS STANDARDIZATION 3. C. 30 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .1.S. 3.DATA COLLECTION FOR W.I.5 SYSTEM CONFIGURATION Fig.I. System configuration of W.CS. & WELD SPOT CHECKING PROCESS STANDARDIZATION 3. 31 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . the resistance value first decreases but as the temp. & WELD SPOT CHECKING PROCESS STANDARDIZATION 3.S.2.2.C. RESISTANCE WAVES Resistance waves are the graphical representation between resistance values and the weld time to show that the nugget formed is absolutely correct.I.I.DATA COLLECTION FOR W.C. 3.I. 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.6 W. METHODOLOGY The methodology on which W. depends is to study about the resistance waves as the reason for the spot failure could be known by this methodology. Fig. the resistance value again decline.C.S.S. Principle of Resistance Waves As we can see from the above figure 3. DATA COLLECTION FOR W.3.C. 3. white body check. Fault due to get out of parts position. 1. 3.6.2 RESULTS OBTAINED BY OBSERVING RESISTANCE WAVES By observing the resistance waves. Detect the abnormal conditions early.1 BENEFITS FOR OBSERVING RESISTANCE WAVES Resistance wave profile is full spot welding. we could get to know the various methods because of which the NG Welding Flow occurs.6. Fault seen due to get out of parts position 32 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . & WELD SPOT CHECKING PROCESS STANDARDIZATION 3.I. Prevent NG Welding Flow. Fig.S. 3. & WELD SPOT CHECKING PROCESS STANDARDIZATION From the above fig. 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. Fig. 2.DATA COLLECTION FOR W.4.I.3. 33 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . 3.C. Fault seen due to bend parts From the above fig.S. 3. Fault due to bend parts. we can clearly see that the nugget formation takes place at any other position than required.4. 5. Fault due to get out of position. we can clearly see that the nugget formation was formed slightly side from its position due to which spot was not formed as required. Fault due to get out of position seen From the above fig.5.DATA COLLECTION FOR W. & WELD SPOT CHECKING PROCESS STANDARDIZATION 3.C. Fig. 3.S. 34 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . 3.I. Lack or 2sets of work. Fault of E79 resistance waves -Reset possible at reset box -Be cautious that when same control no. 3.DATA COLLECTION FOR W. When you returns weld points before more than 1 weld point by manual operation and you re-welded the weld points. 35 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . terrible expulsion etc. etc. judgment will not be done.6. & WELD SPOT CHECKING PROCESS STANDARDIZATION 3.3 FAULTS RELATED TO RESISTANCE WAVES E79 Resist wave fault Fault occurs due to low quantity of heat.6.S. E85 Wave Resist Frequent Fault occurs due to tip dress. and same condition has been used continuously. Fig. Gun touch. Tip diameter expansion. even if no check and reset. Shift of weld position.I.C. it is possibility existence to stop by fault again. NG body don‟t stop. 3.We can reset the fault at a reset box. .I. decrease width or aver. Fault of E80 high resistance waves -Timers output “E80” when it detect resistance value ahead of a threshold of high resistance and it doesn‟t send weld current according to the setting value. when weld points more than thresholds of a warning level occurred frequently in res.DATA COLLECTION FOR W.S.C. but it occurs again till the fault state is removed 36 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . Fig. power cable break etc. & WELD SPOT CHECKING PROCESS STANDARDIZATION -Timers output “E85”. -Reset possible in reset box E80 High Resistance Faults occur due to dust between the tip. res.Measures are the basically same as low current fault.7. -Discontinue the power supply at the detection of the fault . 3. This is shown by the line arrays of red. Fig. Graphical representation of resistance values This representation shows us the difference in the resistance decreasing width. & WELD SPOT CHECKING PROCESS STANDARDIZATION GRAPHICAL REPRESENTATION OF RESISTANCE WAVES Fig.C.S.8.DATA COLLECTION FOR W. 37 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .I.8. 3. shows the graphical representation of resistance values at the time of welding. yellow and blue colour in above fig. Max. 3. Average resistance value:.Max value between setting time and weld time (setting time) -1.5cyc 3. The parameter to be calculated are as follows:1. Resistance width decrease: . resistance value – final resistance value 2. 3.5cyc Fig.5cyc and weld time (setting time) -0.4 METHOD FOR OBSERVING RESISTANCE WAVEFORM To measure the transition of resistance value in every 0.9 Resistance waveform 38 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .5cyc 4.S.I.Resistance Value of weld time (setting time) -0. Final resistance value:. & WELD SPOT CHECKING PROCESS STANDARDIZATION 3.Average of resistance value between 2.5 cycle in welding.DATA COLLECTION FOR W. we have to calculate the parameter 1 to 4 and supervise them.C.6.Max resistance value:. Misjudgment occur a lot of times.6. Fault level: . there is the case that NG points cannot stop. only the thin sheet side is weld NG on sheet combination such as thin.When the nugget formation does not take properly. then the line would automatically spot.C. In this case. 3.DATA COLLECTION FOR W. Now.S.6 PROBLEMS OCCURING IN OBSERVATION There is a case when there is not a change of resistance. But it cannot detect weld NG. Whether fault stops or not depend on a limit setting.5 SETTING OF RESISTANCE LIMIT Resistance limits refers us to a position after which alarm would rang. & WELD SPOT CHECKING PROCESS STANDARDIZATION 3. Therefore. 2. we set limits from average and unevenness of the present data which WICS system collect. Resistance limits are classified in two levels: - 1.I. when limit setting is too rigorous.6. when limit setting is too indulgent.thick-thick sheets and in the case of sheet combination of thin-thin sheets. limit of alarm level is reached and the alarm rang so that the worker or engineer could take the counter measure.When the engineer or worker does not take counter measure after the alarm. 39 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . Alarm Level: . 3. & WELD SPOT CHECKING PROCESS STANDARDIZATION 3.7 SYSTEM SUMMARY It gives the whole functioning of W.I.S.10. Fig.I.C. System Summmary 40 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .S.C.DATA COLLECTION FOR W. S.S.I. & WELD SPOT CHECKING PROCESS STANDARDIZATION 3.C.C.7 FORMAT Fig. 41 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . 3.11.I.DATA COLLECTION FOR W. Format of W. DATA COLLECTION FOR W. 3. -It displays transition such as resistance decrease width.9 DATA REFERENCE MENU Collection server：Data reference destination of the body which does not pass M/B as of 5:00 before three days.12.S. 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. & WELD SPOT CHECKING PROCESS STANDARDIZATION 3. 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. 42 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . Offer server：Data reference destination of the body which passed a M/B as of 5:00 before three days.C. an average resistance value in a designated period for a optional weld ID. I use it Fig. he/ she would increase their faith on the company as a result more customers would come to buy the car. & WELD SPOT CHECKING PROCESS STANDARDIZATION Judgment of all weld ID： It displays a judgment (OK. As the satisfaction of customer would increase.the implementation of W.I. NG.S. 3. 1. 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.The main motive of implementing W.S. in the YL8 line is to provide satisfaction to the customer.S. dust) for weld ID of a optional body with a table.I. Best Quality:. 43 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .C.I. Customer Satisfaction: .C. 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. 2.DATA COLLECTION FOR W.C.C.S.10 CONCLUSIONS OF W.I. white body. 4. main body pit. He should know which spots can be checked and which cannot be checked.DATA COLLECTION FOR W.I. He should know how many men are needed for checking the spots in a given component.2 DESCRIPTION OF MOS I The first thing that an engineer should know in welding department is the layout of department. 44 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .S. The sheet is divided according to main body. He should know that which robot is working on which car. MOS I has been made so that the engineer have a list of all the spots being implemented on the components of the car. and their cycles.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.C. etc. Cycles are divided according to the application of spots. For this. 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. & WELD SPOT CHECKING PROCESS STANDARDIZATION CHAPTER 4 WELD SPOT CHECKING PROCESS STANDARDIZATION 4. cowl box. 4. 2. The robots which are applying those spots in a given component were noted down along with their spots.3 OBJECTIVES OF MOS I 1. of men needed to check the spots. The men working on a given component to check the spots were noted and cycles were made according to their work. To mark the G.A. To know how many robots are doing welding in a given component and how many spots are there in the given component.C.A spots and G.A spots of the component. 4.4 METHODOLOGY ADOPTED A MOS I sheet was made in which the picture of component with the spots was printed. of cycles is equal to no.S.I. Maru. 45 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT . spots were seen and marked on it.A. spots and Maru . & WELD SPOT CHECKING PROCESS STANDARDIZATION 4.DATA COLLECTION FOR W. 3. To mark the spots with different colours of different robots working on the component. To mark the cycle so that we could know how many men are needed for checking the spots? No. DATA COLLECTION FOR W. Easy to find out the component details with the help of index.5 CONCLUSIONS Easy for engineer to find the robot.I.C. 46 WORLD COLLEGE OF TECHNOLOGY & MANAGEMENT .S. To know how much labour required for checking the spots. & WELD SPOT CHECKING PROCESS STANDARDIZATION 4.