ACKNOWLEDGEMENT I take this opportunity to express my sincere thanks and deep gratitude to all those peop people le who who exte extend nded ed thei theirr whol whole e hear hearte ted d co-o co-ope pera rati tion on and and have have help helped ed me in completing this project successfully. successfully. First of all, I would like to thank Mr. S. K Bhatia, Dy. Manager (HRD), for giving me an opportunity to do my training in this prestigious organization. I’d also like to express my sinc sincer ere e
grat gratitu itude de towa toward rds s Mr. Mr.
V.K V.K.
Arora rora (Ass (Asstt tt..
Gener enera al
Man Manager ager,,
Plan lant
Maintenan Maintenance) ce) ,Mr. S. Prabhakar Prabhakar (Sr. Manager Manager,, Plant Maintenance) Maintenance) & Mr. Manoj Attri (Engineer, Plant Maintenance)for Maintenance)for their guidance & help which enabled me to get the require required d data data & inform informati ation on require required d to finish finish my assign assignmen ments ts Their Their inspir inspiring ing suggestions and timely guidance enabled me to perceive the various aspects of the projects in a new light. I would also like to thank all senior members and workers of Plant Maintenance for having guided and encouraged me throughout the duration of the project. In all I found a congenial work environment in MSIL and the completion of the projects will mark a new beginning for me in the coming days.
Company Profile:
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, government, and 54.2% by Suzuki of Japan. Japan. The Indian Indian govern governmen mentt held held an initial public offering of 25% of the company in June 2003. As of May 10, 10, 2007 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 Maruti Udyog Udyog Limite Limited d (MUL) (MUL) was was establ establish ished ed in Februa February ry 1981, 1981, though though the actual actual production commenced in 1983 with the Maruti 800, based on the Suzuki Alto car car which which at the the time time was was the the only only mode modern rn car car avai availa labl ble e in Indi India, a, its' its' only only comp compet etit itor orss- the the Hindustan Ambassador and 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 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, 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.
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.
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.
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.
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 NonGovernment Company with a total Equity base of Rs. 1322.92 million.
BACKGROUND OF SMC SUZUKI was founded in 1909 as Suzuki Loom Manufacturing Company. It started manufacturing motorcycles in 1952 and has become a world leader in the manufacture of two-wheelers .SUZUKI started producing cars from 1955.Today it is Japan’s largest manufacturers of small , fuel-efficient cars. At present the company’s name is SUZUKI MOTOR CORPORATION.
SUZUKI AND MARUTI’S WORLD-CLASS MANUFACTURING FACILITIES AT MANESAR On February 06,2007 Mr. Bhupendera Singh Hooda , Chief Minister of Haryana inaugurated three world-class manufacturing facilities set up by SMC and Maruti Suzuki India Limited.
The facilities inaugurated were as follows:
•
•
MSIL’s fourth car Assembly plant.
A diesel engine and transmission plant, set up under a joint venture of SMC and MSILcalled Suzuki Power train India Limited (SPIL)
•
SMC’s two-wheeler plant in Gurgaon, Suzuki Motorcycle India Private Limited (SMIPL).
INTRODUCTION TO MARUTI SUZUKI INDIA LIMITED
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A License and a Joint Venture Agreement was signed with Suzuki Motor Company of Japan, in OCT. 1982
•
Market leader with over 54% Share in Domestic Car Market Exporting cars to over 70 countries around the world including most advance Western European Markets.
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Maruti has revolutionized the Indian Automobile and Component Industry and has set standards in quality of products and service.
MARUTI INSTALLED CAPACITY
•
PLANT 1 200,000 units
•
PLANT 2 150,000 units
•
PALNT 3 150,000 units
•
PLANT 4 100,000 units
COMPANY MISSION
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A leader in the Indian Automobile Industry.
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Creating Customer Delight and Shareholders wealth.
•
A pride of India!
LEADERSHIP
•
By Market share and brand equity
•
By operational practices
•
By people strategy
CUSTOMER DELIGHT
•
Values for money
•
Quality
•
Service
SHARE HOLDERS WEALTH
•
High Profitability & Image
A PRIDE OF INDIA
•
As a corporate citizen
•
Products
•
People
•
Practices
•
Customers
VALUES
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Customer Obsession
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Fast, Flexible, First Mover
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Innovation and creativity
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Networking and partnership
•
Openness and learning
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
QUALITY TOOLS
•
5S
•
4M
•
3M
•
3G
•
3K
CHECK
What is 5S? SEIRI
– PROPER SELECTION
SEITION
– ARRANGEMENT
SEISO
– CLEANING
SEIKETSO – CLEANLINESS
SHITSUKE – DISCIPLINE
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? In Japanese Language 3M is:
MURI
– INCONVENIENCE
MUDA
– WASTAGE
MURA
– INCONSISTENCY
What is 3G? In Japanese Language 3G is:
GENCHI
–
GO TO ACTUAL PLACE
GENBUTSU –
SEE THE ACTUAL THING
GENJITSU –
TAKE APPROPRIATE ACTION
INTRODUCTION TO VARIOUS MODELS PRODUCT RANGE
MODELS MARUTI 800 (FIRST MODEL) OMNI GYPSY MARUTI 800 (MODIFIED) MARUTI 1000 ZEN ESTEEM 1.3L LX ESTEEM 1.3L VX ESTEEM 1.3L AX ZEN AX (AUTOMATIC) GYPSY KING OMNI (E) GYPSY (E) MARUTI 800 (NEW MODEL) ESTEEM 98 NEW OMNI & OMNI-E ZEN VX & ZEN VX AUTOMATIC ZEN D
SPECIFICATIONS
YEAR OF LAUNCH
796CC, HATCHBACK
DECEMBER 1983
796CC, MUV 992CC, 4WD 796CC, HATCHBACK 996CC, SEDAN 996CC, HATCHBACK 1296CC, SEDAN 1296CC, SEDAN 1296CC, SEDAN 996CC, HATCHBACK 1296CC, 4WD 796CC, MUV 1296CC, 4WD
NOVEMBER 1984 DECEMBER 1985 APRIL 1986 OCTOBER 1990 OCTOBER 1993 NOVEMBER 994 NOVEMBER1995 JUNE 1996 OCTOBER 1996 NOVEMBER1996 DECEMBER 1996 DECEMBER 1996
796CC, HATCHBACK
SEPTEMBER 997
1296CC, SEDAN 796CC, MUV
OCTOBER 1997 FEBRUARY 1998 JULY 1998
996CC, HATCHBACK 1200CC,
AUGUST 1998
MARUTI 800 EX ZEN LX
HATCHBACK 796CC, HATCHBACK 996CC, HATCHBACK
ZEN CLASSIC
996CC, HATCHBACK
AUGUST 1999
ZEN VXI OMNI XL BALENO
996CC, HATCHBACK 796CC, MUV 1586CC, SEDAN 1096CC,
OCTOBER 1999 OCTOBER 1999 DECEMBER 1999
WAGON R
HATCHBACK
JANUARY 1999 JANUARY 1999
JANUARY 2000
1586CC, ALTURA
HATCHBACK
MARCH 2000
ALTO LX, LXI VERSA
(BALENO) 796CC, HATCHBACK 1296CC, MUV 1296CC,
SEPTEMBER 000 DECEMBER 2001
SWIFT ZEN ESTILO SWIFT DIESEL SWIFT DIESEL GRAND VITARA SX4 SWIFT DZIRE A- STAR RITZ
HATCHBACK 1096CC, HATCHBACK 1296CC, HATCHBACK
1.600CC
MAY 2005 DECEMBER 2006 FEBRUARY 2007 FEBRUARY 2007 MARCH 2007 MAY 2007 MARCH 2008 NOVEMBER 2008 MAY 2009
ORGANISATIONAL STRUCTURE Maruti has believed, since the very beginning that it is its employees who could make it into an organization with a difference .Accordingly, as against the traditional hierarchical System of management, which causes unnecessary delays in decision-making, we 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 Divisional Managers. Designations in the company are based on the functional responsibility and not levels as in terms of the company’s philosophy designations and functional responsibility are de-linked from the salary levels.
The total operations of the Company are divided into Divisions like Marketing & Sales, Spares, Engineering, Q.A. & Services, Production, Production Engineering, Materials, Information Services, Finance, Personnel & Administration, etc. Each division is furthering divided into Departments and headed by Departmental Managers who is assisted by Supervisory Executives.
The hierarchy diagram of MSIL
DIVISIONS AND DEPARTMENTS Corporate Services Division
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Legal & Secretarial Department
•
Corporate Communication Cell
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Protocol
•
Strategic Initiative Group
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Recruitment & Management Compensation
Human Resource Division
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Employee Relations Department
•
Establishment & Time Office
•
Factory Administration Department
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Organizational Development Department
Production Division
•
Plant- 1
•
Plant- 2
•
Plant- 3
•
Plant- 6 at Manesar
Production Engineering
•
Production Engineering Division
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Production Service Division
Engineering Directorate
•
QAIN Division
•
Service Division
•
Service- 1-5
•
MSS(D)
•
Parts Inspection Division
•
Engineering Division
Supply Chain division
•
Supply Chain- 1,2,3 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
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Web-IT, E-Commerce
Spare Parts Division
•
Spare Parts Procurement
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Warehousing & Dispatch
•
Spare Parts Sales
•
Accessories
Vigilance Division
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Security Wing
•
Vigilance Wing
Finance Division
•
Budget, Cost & Accounts Department Income Accounting
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
Milestones 1981
•
Maruti Udyog Ltd. was incorporated.
1982
•
Stepped into a JV with SMC of Japan.
1983 1984
•
•
Maruti 800, a 796 cc hatchback, India's first affordable car was produced. Installed capacity reached 40,000 units. Omni, a 796 cc MUV was in production.
1985
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Launch of Maruti Gypsy (970cc, 4WD off-road vehicle).
1986
•
Produced 100,000 vehicles (cumulative production).
1987
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Exported first lot of 500 cars to Hungary.
1988
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Installed capacity increased to 100,000 units.
1992
•
SMC increases its stake to 50 per cent.
1994 1995 1996 1997 1998
•
•
•
•
•
•
Produced the 1 millionth vehicle since the commencement of production. Second plant launched, the installed capacity reached 200,000 units. Launch of 24-hour emergency on-road vehicle service. Produced the 2 millionth vehicle since the commencement of production. Launch of website as part of CRM initiatives. Launch of Maruti - Suzuki innovative traffic beat in Delhi and Chennai as social initiatives.
1999
2000 2001
•
•
IDTR (Institute of Driving Training and Research) launched jointly with Delhi government to promote safe driving habits. Launch of customer information centers in Hyderabad, Bangalore, and Chennai.
•
SMC increases its stake to 54.2 per cent. Launch of Maruti Finance with 10 finance companies in Mumbai.
•
Start of Maruti True value in Mumbai.
•
2002
•
2003
Listed on BSE and NSE after a public issue oversubscribed 10 times.
•
2004 2005. 2006.
•
•
•
2007
•
The fiftieth lakh car rolls out in April, 2005. 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.
•
•
MSIL launches national road safety program.
•
2009
Maruti closed the financial year 2003-04 with an annual sale of 472122 units, the highest ever since the company began operations 20 years ago.
M-800 crosses 25 lakh mark MSIL celebrates SILVER JUBILEE
•
2008.
Production of 4 millionth vehicle.
•
•
Capacity to manufacture expanded from 800,000 to a million units(Gurgaon plus Manesar) annually All India engineering export promotion council(EEPC) award. MSIL achieved highest sales ever in Dec’2009
