A

REPORT ON PROJECT
TITLED
VEHICLE INSPECTION PROCESS STANDARDIZATION
Submitted in partial fulfilment of the requirements
For the award of the Certificate
of
MARUTI SUZUKI INDIA LTD. (MANESAR)

Internship from 20th Jan. to 30th April

Submitted By: Submitted To:

PRAVEEN SINGH Mr DEEPAK PATHRIA
(2012PUSETBMEX01395) (MGR. VI-MB)

DEPARTMENT OF VEHICLE INSPECTION PLANT B (MANESAR)

1. MARUTI SUZUKI INDIA LIMITED (MSIL)

1.1 COMPANY PROFILE

Maruti Suzuki India Limited was incorporated on February 24, 1981 with the name Maruti
Udyog Limited. The company was formed as a government company with Suzuki as a minor
partner to make a peoples car for middle class India. Over the years, the companys product
range has widened ownership has changed hands and the customer has evolved. In October 2,
1982, the company signed the license and joint venture agreement with Suzuki Motor
Corporation, Japan. Maruti Suzuki India Limited (MSIL, formerly known as Maruti Udyog
Limited) is a subsidiary of Suzuki Motor Corporation, Japan.

In the year 1983, the company started their production and manufacturing the
passenger vehicles in Gurgaon plant and launched Maruti 800. In the year 1992, Suzuki
Motor Corporation, Japan increased their stake in the company to 50%. In the year 1995, the
company commenced their second plant. In the year 1999, the third plant with new press,
paint and assembly shops became operational. In the year 2002, Suzuki Motor Corporation
increased their stake in the company to 54.2%. The company changed their name from
Maruti Udyog Limited to Maruti Suzuki India Limited with effect from September 17, 2007.
Over three decades from 1982 Maruti Suzuki is working in Gurgaon (Haryana) and the
company is Indias largest passenger car company, covered majority of the domestic car
market. Maruti Suzuki has been the leader of the Indian car market for over two and a half
decades. In 1982, India turned out just 40,000 cars every year. The Maruti 800 rolled out and
a new chapter began. It was become the seat of Indias automobile revolution. Maruti Suzuki
is not just one of the largest car makers, but also the largest car-products manufacturer in the
country. This has transformed the company, from just a car company to Indias way of life.

Head office of Maruti Suzuki India Limited is at New Delhi. The company has two
plants namely Gurgaon plant and Manesar plant. Regional offices of the company are situated
at Kolkata, Ranchi, Guwahati, Indore, New Delhi, Chandigarh, Lucknow, Jaipur, Chennai,
Bangalore, Cochin, Hyderabad, Mumbai and Pune. The company is listed on Bombay Stock
Exchange and National Stock Exchange.

1.2 PLANTS

The company has two manufacturing facilities located at Gurgaon and Manesar, south of
New Delhi, India. Both the facilities have a combined capability to produce over a 1.5 million
(1,500,000) vehicles annually. The company plans to expand its manufacturing capacity to
1.75 million by 2013. Gurgaon plant is where it all began, where the first Maruti 800 rolled
out. One that Mr Harpal Singh drives to that date.

This plant spread over 300-acres, the Gurgaon plant has 25% area dedicated as green
area. This plant turns out 9 lakhs cars every year. The Gurgaon premises also houses the K
Engine plant commissioned in 2008, the K-series engine plant has an installed capacity of
over 7.7 lakh units per annum. The highly fuel efficient, technologically advanced K-series
engines have been very well appreciated. The 600 acre Manesar facility located around 25 km
south of Gurgaon facility and it was inaugurated in February 2007. One of Asias most
advanced auto hubs; the Manesar plant spreads over 600 acres and houses 3 fully integrated
plants, with an annual capacity of 5.5 lakh cars. There is a high degree of automation and
robotic control in the press shop, weld shop and paint shop to help manufacture with acute
precision, high quality and speed. Both manufacturing facilities
are highly automated with advanced robotics, contemporary paint, and machining
infrastructure.

1.3 VISION AND CORE VALUES

The mission of company is to provide a car for every individual, family, need, budget and
way of life. The company believe that their core values drive them in all endeavours which
are as:

Customer Obsession
Fast, Flexible and First Mover
Innovation and Creativity
Networking and Partnership
Openness and Learning

1.4 CUSTOMER PERSPECTIVE

Maruti Suzuki is a leading manufacturer of passenger vehicles in India. The company
lovingly referred as the peoples car maker. The company was a story of an obsession with
customer delight, unheard of until then. It was about a commitment to create value of
innovation, quality, creativity, partnerships, openness and learning. It was a new story of
leadership. It was also the story of motoring revolution-cars that delivered great performance,
efficiency and environment friendliness with low cost of ownership. A story built on Suzukis
belief in small cars for a big future. Their relationships with the millions of Indians drive
them and a commitment to road safety that is making Indias roads safer.

Maruti Suzuki has taken care of all car needs of the consumers and has offered efficient
service ever since its inception. The list of services offered by Maruti Suzuki includes
finance, insurance, genuine accessories, genuine parts, driving school and auto card. Creating
customer delight is not a recent discovery for the company rather the expression finds roots in
the company vision. Taking forward the same spirit the company is committed to serve many
more customers through a numerous way.

Maruti Suzuki has impacted the lifestyle and awareness of an entire generation of Indian
middle class through the quality of its products and services that are in direct according with
the needs of the Indian common people. Customer get more power, more driving, for lesser
fuel consumption. Customer delight has been driving the core business. The company says
that, we aim to grow larger with higher objectives; we realize the key factor is customer
delight, we have been developing products in line with customer expectations and changes in
lifestyle, we have been listening to the customer and changing with the needs, which is the
key driver for growth.

1.5 MANUFACTURING FACILITIES

Maruti Suzuki has two manufacturing facilities in India. Both manufacturing facilities have a
combined production capacity of 14,50,000 vehicles annually. The Gurgaon manufacturing
facility has three fully integrated manufacturing plants and is spread over 300 acres (1.2 km2).
The Gurgaon facilities also manufacture 240,000 K- Series engines annually. The Gurgaon
Facilities manufactures the 800, Alto, WagonR, Estilo, Omni, Gypsy, Ertiga, Ritz and Eeco.
 The Manesar manufacturing plant was inaugurated in February 2007 and is spread
over 600 acres (2.4 km2). Initially it had a production capacity of 100,000 vehicles annually
but this was increased to 300,000 vehicles annually in October 2008. The production capacity
was further increased by 250,000 vehicles taking total production capacity to 800,000
vehicles annually. The Manesar Plant produces the A-star, Swift, Swift DZire, SX4, Vitara
Brezza, Ritz and Celerio. On 25 June 2012, Haryana State Industries and Infrastructure
Development Corporation demanded Maruti Suzuki to pay an additional Rs 235 crore for
enhanced land acquisition for its Haryana plant expansion. The agency reminded Maruti that
failure to pay the amount would lead to further proceedings and vacating the enhanced land
acquisition. It plans to set up a plant in Gujarat and has acquired 600 acres of land

2 PROJECT
TITLE: VEHICLE INSPECTION PROCESS STANDARDIZATION

Date: 21th march to 21 April

The project is about the standardized form of instructions for the workers to give them
knowledge about the various steps involved to perform their job at various vehicle inspection
stations.

The standardized form contains the various terms are as follows;

Operation procedure
Key points
Possible defects

Operation procedure contains the information about what part should be check in the vehicle.
Key points contains the information about the steps how any part should be checked.
Possible defects are the defects may be occur if any part should not checked.
The previous WIS (WORK INSTRUCTION SHEET) does not contain any data about the defects
which may occur on various stations but in the new WIS the possible defects can be added. This can
help the new workers in training for better understanding about the defect followed by any part which
is not checked.

There are some checkpoints which are generally checked in every vehicle. They are as follow:

Headlights (high / low operation and headlight aim, cracks, chips, scratches, pitting)
Brake lights
Turn signal lights (operation, cracks, chips, scratches)
Parking lamps
Fog lamps (if applicable)
Running lights (if applicable)
License plate light
Tail lights (operation, cracks, chips, scratches, damage)
Back-up lamps
Emergency flasher
Water leaks (look for evidence of water intrusion)
Fuel gauge operation
Temperature gauge operation
All warning lights illuminated with ignition ON Dash light operation
Windshield wiper / washer operation
Audio System - Radio / CD / audio inputs, speaker operation (Audio steering wheel
controls if equipped)
Navigation operation (if equipped)
 Rear camera
Clock functions
Steering wheel tilt/lock
Sunroof operation (if applicable)
Headliner condition
Cigarette lighter / power outlets (if equipped)
Alarm / theft system operation (check remote)
SRS air bags (exterior condition / check warning lamp self check)
Outside mirror operation (left and right)
Rear view mirror operation (day / night operation)
Window operation (noise, speed and full travel)
Door locks (check manual and or power operation and child safety function)
Seat belts (condition, proper latching and retraction operation)
Seat upholstery / leather condition (front & rear)
Seat heaters (if equipped and check for proper operation)
Headrest movement
Rear defrost operation
Inside mirror / vanity light operation
Interior lights (switch / door operation, warning chimes)
Glove box / glove box light operation
Luggage compartment (jack and tool present)
Trunk lid release / trunk lid light operation
Fuel door release
Hood release operation
Underhood (clean engine compartment)
Front bumper (facia, guards, finish)
Grille (headlights, other lights, trim, emblems)
Hood (emblems & finish)
LF fender (finish, trim)
LF door (finish, trim)
LR door (finish, trim)
LR fender (finish, trim)
Trunk lid (finish, trim)
Rear bumper (facia, guards, trim)
RR fender (finish, trim)
RR door (finish, trim)
RF door (finish, trim)
RF fender (finish trim)
Roof (finish, trim)
Windshield / glass (cracks, chips, scratches, pitting)
Check for dent, dings & scratches on all body panels and bumpers
Dash and instrument panels
Console / centre arm rest / cup holders
Front doors (controls, trim condition)
 Rear doors / quarter Trim (controls, trim condition)
Luggage compartment (mat / trim / carpet condition)

2.1 VEHICLE INSPECTION STUDY

Date: 20th Jan. to 20th march

Vehicle inspection is a procedure mandated by national or subnational governments in many

countries, in which a vehicle is inspected to ensure that it conforms to regulations
governing safety, emissions, or both. Inspection can be required at various times, e.g.,
periodically or on transfer of title to a vehicle. If required periodically, it is often
termed periodic motor vehicle inspection; typical intervals are every two years and every
year. When a vehicle passes inspection, often a sticker is placed on the vehicle or registration
plate to simplify later controls. Inspection stations are places to drive inside to see if a
vehicle passes inspection once a vehicle is due for inspection. But on the other hand vehicle
manufacturing companies also inspect the vehicle to increase the quality of the vehicle.

Stations on which various inspection are done they are;

1. Toe- adjustment
2. Headlamp adjustment
3. Sideslip testing
4. Appearance inspection
5. Drum testing
6. Brake testing
7. Underbody inspection
8. Engine room inspection
9. Shower leakage inspection
 10. Off road test
11. Final check

2.2 TOE ADJUSTMENT

Toe will change depending on vehicle speed. As aerodynamic forces change the riding height,
the toe setting may change due to the geometry of the steering linkage in relation to the
geometry of the suspension. Because of this, specifications are determined for a vehicle that
is not moving based on the toe being at zero when the vehicle is at highway speed. In the
early days prior to radial tires, extra toe-in was added to compensate for tire drag at highway
speed. On some older alignment machines, toe-in was measured at each wheel by referencing
the opposite wheel. This method caused problems with getting the steering wheel straight the
first time and necessitated corrective adjustments before the wheel was straight. Newer
machines reference the vehicle's centreline by putting instruments on all four wheels. For
more information on this see Steering Centre and Thrust angle.

Toe-in

2.2.1 DEFECTS OCCUR DUE TO TOE IN

1. Lower control arm bent.

2. Frame bent.
3. Worn or stripped tie rod end sleeves.
4. Wheel bearings worn or loose.
Operation procedure Key points Possible defects

1. Put the vehicle in toe- Scan the check sheet

tester.

2. Fix the steering Fix with the help of jig so the if not straight reading must be
steering should be straight. wrong

3. check reading after roller See the reading in the

stop monitor

4. loose the tie rod nut and set the toe value near zero If not in green zone side slip
try to adjust the toe value is more and tire wear is more

5. tight the tie rod nut Tight the tie rod nut and If torque is not applied causes
apply torque steering failure

6 mark the tie rod after Marking should be pass marking is not done indicates
tightened the nut through nut and tie rod toe value not set

HEAD LAMP ADJUSTMENT

Do not obstruct the m/c path Ensure that there should be

no one in between the vehicle
lamp and m/c
Adjust the lamp focus in Try to adjust in the center of If not in the rectangle not
green rectangle for right hand the rectangle shown in the adjusted properly
side lamp monitor.
Adjust with the help of
 adjusting the screw in hyead
lamp

Adjust the lamp focus in Try to adjust in the center of If not in the rectangle not
green rectangle for left hand the rectangle shown in the adjusted properly
side lamp monitor.
Adjust with the help of
adjusting the screw in hyead
lamp
Check USB port Check USB by using mobile USB port not working
and USB cable

Sideslip testing

out the vehicle from toe tester Move vehicle without jurk

Move the vehicle over side Speed should be maintain at More speed causes wrong
slip tester 3-4 km/hr. reading

See the reading in the Reading should not more than More sideslip causes tire
monitor 3m/km wear

Appearance

Stop the vehicle in Keep some distance from

appearance section above vehicle

Check chassis number as per Match the chassis number

VI check sheet
check centre locking All door should be locked or Centre locking not working
unlocked

Check seat recliner Operation should be smooth Seat recliner lever not
working

Check rear bumper Check by pulling outside Fitment related defect

check wheel housing clip 3- clips should be visible Fitment related defect

Check door glass operation All door glass should be

working

Check ORVM Check for operation and Scratch and fitment related
scratch and fitment defect

Check all doors child lock Check child lock by locking

and unlocking

Check high mount stop lamp Check for fitment Fitment related defects

Check licence lamp Should be present on above Fitment related defects

the number plate
Check cabin lamp Check for fitment and should Fitment related defects
be glow Not glowing

2.3 HEADLAMP ADJUSTMENT

The optical lens itself, which is designed to accurately focus all types of vehicle headlamp,
and is fully adjustable in the vertical plane; achieved by mounting it to a vertical column. The
measurement travel of the optical lens is between the heights of 500mm and 1500mm, which
allows for the testing of all vehicles up to and including heavy goods vehicles. Finally, at the
top of the lens mounting column is a mirror or laser which allows the headlight tester to be
aligned with the longitudinal axis of the presented vehicle.

Adjust the headlamp on the position as shown in the monitor e.g., to centre of the green
rectangle. A headlamp beam tester is a means to check both the orientation and intensity of a
vehicle headlamp to ensure that it meets a minimum standard for the country of use of the
vehicle. A headlight tester comprises a fully adjustable single optical collimated light lens
assembly which is rail mounted and designed to prevent any distortion of the optical lens
supporting structure during general use, such as when aligning the lens to the vehicle or
manoeuvring the assembly along the rails.

A feature often included as part of such a tester is a method by which the intensity of
the beam can be measured. This is achieved with a light meter or Lux meter which is
incorporated within the assembly itself. This can be used to not only measure the intensity of
the dipped beams but also to measure and compare the full beam intensity.

2.4 SIDESLIP TESTING

Sideslip can be defined as the vehicle is running on a straight path at a speed of 2-3 km/hr.
with straight steering than the deflection in the path of the vehicle in 1km is called the
sideslip which is not more than 3m in a km.

In vehicle dynamics, slip angle or sideslip angle is the angle between a rolling
wheel's actual direction of travel and the direction towards which it is pointing (i.e., the angle
of the vector sum of wheel forward velocity and lateral velocity). For a free-rolling wheel this
slip angle results in a force parallel to the axle and the component of the force perpendicular
to the wheel's direction of travel is the cornering force. This cornering force increases
approximately linearly for the first few degrees of slip angle, then increases non-linearly to a
maximum before beginning to decrease.

2.4.1 CAUSES OF SIDESLIP

A non-zero slip angle arises because of deformation in the tire carcass and tread. As the tire
rotates, the friction between the contact patch and the road results in individual tread
'elements' (finite sections of tread) remaining stationary with respect to the road. If a side-slip
velocity u is introduced, the contact patch will be deformed. When a tread element enters the
contact patch, the friction between the road and the tire causes the tread element to remain
stationary, yet the tire continues to move laterally. Thus the tread element will be deflected
sideways. While it is equally valid to frame this as the tire/wheel being deflected away from
the stationary tread element, convention is for the co-ordinate system to be fixed around the
wheel mid-plane.
 Sideslip tester

2.4.2 EFFECT

The ratios between the slip angles of the front and rear axles (a function of the slip angles of
the front and rear tires respectively) will determine the vehicle's behaviour in a given turn. If
the ratio of front to rear slip angles is greater than 1:1, the vehicle will tend to understeer,
while a ratio of less than 1:1 will produce oversteer. Actual instantaneous slip angles depend
on many factors, including the condition of the road surface, but a vehicle's suspension can be
designed to promote specific dynamic characteristics. A principal means of adjusting
developed slip angles is to alter the relative roll couple (the rate at which weight transfers
from the inside to the outside wheel in a turn) front to rear by varying the relative amount of
front and rear lateral load transfer. This can be achieved by modifying the height of the roll
centers, or by adjusting roll stiffness, either through suspension changes or the addition of
an anti-roll bar.

2.5 APPEARANCE INSPECTION

Appearance inspection is done visually for the car parts to verify according to model and
variant, fitted and working properly. Appearance inspection can be done for all exterior as
well as interior parts. Appearance include a wide range of check points which cover the
whole car by inspecting visually.
Appearance inspection include scratch and dents related defects also

Some checkpoints in appearance inspection

Centre locking
Door inspection
Variant specification
Bumper fitment
Seat sliding
Seat recliner
Body level difference with respective parts
Trunk inspection
Fuel lid inspection
Cabin lamp fitment
Wiper fitment
Windshield
Pillar mouldings
Sash and sill for dent and scratch
ORVM working
Door glass working
Head lamp appearance
Door trim
Child lock working
Balance wt. fitment
Roof moulding
Glove box inspection
Tyre nut torqueing
Scuff fitment
 DECLARATION

I hereby declare that the project work entitled (VEHICLE INSPECTION PROCESS
STANDARDIZATION) is an authentic record of my own work carried out at (Vehicle
Inspection, Department, Manesar-B Plant, Maruti Suzuki India Limited) as
requirements of project semester training (One semester Industrial Training) for the award of
degree of B.Tech (Mechanical Engineering), POORNIMA UNIVERSITY, under the
guidance of (Mr. Deepak Pathria), during (20 Jan. to 30 April 2016).

PRAVEEN SINGH
(2012PUSETBMEX01395)

Date: __27/04/2016_
Certified that the above statement made by the student is correct to the best of my knowledge

Mr DEEPAK PATHRIA
(Manager VI-MB)

ACKNOWLEDGEMENT

It is my pleasure to be indebted to various people, who directly or indirectly contributed in

the development of this work and who influenced my thinking, behaviour, and acts during the
course of study.

I express my sincere gratitude to MR. DEEPAK PATHRIA, worthy Principal for

providing me an opportunity to undergoesP summer training at VEHICLE INSPECTION,
DEPARTMENT, MANESAR PLANT-B, MARUTI SUZUKI INDIA LIMITED.

I am falling short of words for expressing my feelings of gratitude towards him for
extending their valuable guidance about Inspection Standards , critical reviews of
project and the report and above all the moral support he had provided me with all stages of
this training.

PRAVEEN SINGH