International Journal of Trend in Scientific Research and Development (IJTSRD)

Volume 4 Issue 4, June 2020 Available Online: www.ijtsrd.com e-ISSN: 2456 – 6470

Project Report on Maynard Operation Sequence Technique

Ankur, Mr. Manish
Dronacharya College of Engineering, Gurugram, Haryana, India

ABSTRACT How to cite this paper: Ankur | Mr.

I did my 6 weeks industrial training at Maruti Suzuki India Ltd, Gurugram in Manish "Project Report on Maynard
the Assembly 1 Department under Production Division. Operation Sequence Technique"
Published in
The entire duration I was in the Assembly-1department. The first Week in the
International Journal
dept. office itself for M.O.S.T. study & techniques, then for the major part of
of Trend in Scientific
June in Knuckle Sub Assembly Area & subsequent 4 Weeks on Line-4 & office
Research and
of the department.
Development
Overall my project has been related to the standardization of man power for (ijtsrd), ISSN: 2456-
fluctuating production volumes of IGNIS (YJC) model & improvement in HPV. 6470, Volume-4 | IJTSRD31411
Majority of the time has been engaged in videography & subsequent M.O.S.T. Issue-4, June 2020,
analysis of the work stations. pp.1248-1256, URL:
www.ijtsrd.com/papers/ijtsrd31411.pdf
I have finished two projects in my tenure. Man Power Reduction was the basic
principle underlying the M.O.S.T. project done.
Copyright © 2020 by author(s) and
International Journal of Trend in Scientific
Research and Development Journal. This
is an Open Access article distributed
under the terms of
the Creative
Commons Attribution
License (CC BY 4.0)
(http://creativecommons.org/licenses/by
/4.0)

INTRODUCTION
MARUTI SUZUKI INDIA LIMITED - COMPANY PROFILE :
Maruti Suzuki India Limited (MSIL, formerly Maruti Udyog
Limited), a subsidiary of Suzuki Motor Corporation of Japan,
is India’s largest passenger car company, accounting for over
54% of the domestic car market. They offer a full range of
cars from entry level Maruti 800 & Alto to stylish hatchbacks
like A-star, Swift, Wagon-R, Estillo and sedans like DZire, SX4
and the Sports Utility vehicle Grand Vitara. Since its
inception, MSIL has produced and sold over 7.5 million
vehicles in India and exported over 500,000 units to Europe
and other countries. The turnover for the year 2007-08
stood at Rs.79762 Crores , Yen 449 Billion, $4.512 Billion
and Profit after Tax at Rs. 17308 Million .

Date of Incorporation

February 1981
Incorporated as Maruti Udyog Limited

October 1982
As a Joint Venture between the Indian Government and
Suzuki Motor company, JAPAN

Type of Industry:

Automotive: The company designs and manufactures
motor cars.

Key Representative:

Mr. Kenichi Ayukawa, Managing Director and CEO

Revenue:

Rs.77,326 million ; USS $5.5 billion (2017

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Employees: D. Placement

40000 employees This parameter is used to analyze actions at the final stage
of, in object's displacement to align, orient and/or engage the
COMPANY SHARES object with another object befoi0e control of the object is
1. PROMOTERS 56.21% relinquished.
2. FI/BANKS/INSURANCE 5.72%
3. MUTUAL FUNDS/UTI 5.66 % E. Move Controlled
4. NON- INSTITUTIONS 7.15% This parameter is used to analyze all manually guided
movements or actions of an Object over a controlled path.
LIST OF TERMS
1. HPV: Man hours per vehicle F. Process Time
HPV= Workforce x Number of hours per shift/ Number of This parameter is used to account for the time for work
vehicles produced controlled by electronic or mechanical devices or machines,
not by manual actions.
2. Work Content
Operator time =∑ (Online + OfSline + Move) G. Alignment
This parameter is used to analyze manual actions following
3. Cycle Time the Move Controlled or at the conclusion of Process Time to
Operation Time =∑ (Online + Auto Cycle) achieve the alignment of objects
4. Online
H. Fasten
Time of manual activities done by Operator when machine is
This parameter is used to establish the time for manually or
not running
mechanically assembling one object to another, using the
=Longest/Critical Path time of the activities done in parallel
fingers, hand or a hand tool.
5. Offline
=Time of manual activities done by Operator when machine I. Loosen
in running This parameter is used to establish the time for manually or
=∑ (Time of the activities done in parallel) mechanically disassembling one object from another using
the fingers, hand or a hand tool.
6. Move
=Walking time of operator from Work Center to Next Work J. Cut
Center in Multi Machine /stage Working This parameter covers the manual actions employed to
separate, divide or remove part of an object using a
7. Auto Cycle sharp-edged hand tool such as pliers, scissors or a knife.
= Auto Cycle /Process time or machine controlled time
K. Surface Treat
8. Through Put Time This parameter covers the activities aimed at removing
=∑ (Cycle time of all operations on Critical Path for the unwanted material or particles from, or applying a
Product) substance, coating or finish to, the surface of am object.

9. Effective Working Time L. Measure

=Content of Work in Minutes for Individual Operator in a This parameter includes the actions employed in
Day. determining a certain physical characteristic of an object by
=Average Content of Work in Minutes for a Group or Cell using a standard measuring device.

Content of Work for Group (Mins) M. Record

= ------------------------------------------------ This parameter covers the manual actions performed with a
No. of Operators pencil, pen, marker, chalk or other marking tool for the
purpose of recording information.
LIST OF PARAMETER
A. Action Distance N. Think
This parameter is used to analyze all spatial movements or This parameter refers to the eye actions and mental activity
actions of the fingers, hands and/or feet, either loaded or employed to obtain, information (read) or to inspect an
unloaded (loaded means carrying an object, unloaded means object, including reaching to touch, when necessary, to feel
the hands are free). the object.

B. Body Motion WHAT IS PRODUCTIVITY IMPROVEMENT

This parameter is used to analyze either vertical motions of Productivity Improvement implies optimum utilization of
the body or the actions necessary to overcome an resources to get maximum output.
obstruction or impairment to body movement.
Parameters Affecting Productivity
C. Gain Control 1. Line Efficiency=(Effective Working Time – Stoppage)/
This parameter is used to analyze all manual motions Effective Working Time)
(mainly finger, hand and foot) employed to obtain complete 2. Line Balancing Efficiency: ∑(Cycle time of each
manual control of an object and release the object after station)/(No. of stations xTmax)
placement.

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A Balanced line is one in which the time wasted at each WHY MOST
station is almost constant. What is M.O.S.T and How is it different from Time study?
250
M.O.S.T is an advanced work measurement system
which has evolved from time study.
200

150
In M.O.S.T,

An operation is divided into a sequence of basic motions,
100 which

are not operation specific
50

Time is assigned to these motions
0
Summation of the time gives total time required for the
22R 22L 23R 23L 24R 24L 25L 25 26
operation
250

Time Study finds the time for completing a operation or
42
44
42
a set of operations using a stop watch
42 35 67
200 50

55 45
50
50 57
Advantages
150 42
50
Quantifies time lost in waste motions.
100 54
30 100
Eliminates the inaccuracies of Time Study.
140 150
133 137 50 135
50
110
How M.O.S.T data is used?
70
40
58

Standard times calculated are used for Line balancing
0
22R 22L 23R 23L 24R 24L 25L 25 26 using Process Designer Software.

Actual time taken and a Target time obtained from
As can be seen from the graph of the imbalanced line, MOST can be displayed at each station for focused
operators at 24R and 25L will be idle for a long time as they implementation of MPS activities.
have less work load. Instead, the line may be balanced so
Benchmarking of operations possible across Models,
that every operator has almost equal work load. This will not Lines & Plants.
only reduce idle time but will also reduce manpower as the
LAYOUT OF LINE 4(ASSEMBLY SHOP 1)
work from a particular station can be distributed to other
station taking care of precedence of tasks. This will lead to a
situation as shown in the first graph. The line is balanced and
one station has been reduced.

Balancing the line, however, is not an easy task as every

operation may have a predecessor, thereby meaning that
this operation cannot take place until the previous one has
been completed. For example, the parking cable must be AREA ASSIGNED: CHASSIS LINE (YJC)
fitted before the fuel tank is mounted on to the vehicle.

TECHNIQUE STUDY, LEARNING, IMPLEMENTATION &

ANALYSIS
TRIM: It is the area where mainly plastic components and
AIM OF PROJECT
light components are fitted.

STANDARDIZATION OF MAN POWER FOR
FLUCTUATING PRODUCTION VOLUMES CHASSIS: It is the underbody region. Components such as

TO IMPROVE PRODUCTIVITY (HPV) engine, axle .etc. which have to be fitted under the floor are
mounted.
TOOLS USED
“M.O.S.T” FINAL: It is the area where components essential for the
(MAYNARD’S OPERATION SEQUENCE TECHNIQUE) customer are fitted.

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PROCEDURE FOLLOWED

First made variant sheet for each work station than done videography. After watching the videos, MOST sheets were
prepared, which calculated the standard time that should be taken by and operator to complete that particular task. The
actual time taken by the operator as per the video was also noted down

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MOST PROGRESS REPORT (12-06-2018 TO 16-06-2018)
L-4 CHASSIS LINE
T OT A L C OM P .
VARIENT YJC STATUS S HE ETS S HE ETS
S.NO. ST. NO
WORK SUMMARY 5 STR AC 5 STR NON-AC 7 STR NON-AC

1 18L1 Brake Pipe Clamping ♠ ♠ ♠ 1 1

2 18L2 Brake Pipe Clamping & Speed Nut Fitm ent
♠ ♠ ♠ 1 1
3 19L1 Axle SA Lt. ♠ ♠ ♠ 1 1
4 19L2 Rear Axle Mtg. Lt ♠ ♠ ♠ 1 1
5 19R1 Axle SA Rt. ♠ ♠ ♠ 1 1
6 19R2 Rear Axle Mtg. Rt ♠ ♠ ♠ 1 1
7 19 Rear Axle Loading ♠ ♠ ♠ 1 1
8 20R1 Water Pipe S/A ♠ ♠ ♠ 1 1
9 21L1 Harness Wire Clamping ♠ ♠ ♠ 1 1
10 21L2 Strut Mtg. ♠ ♠ ♠ 1 1
11 21R1 Rear Bumper & Mud Flap Mtg. ♠ ♠ ♠ 1 1
12 21R Strut Mtg. ♠ ♠ ♠ 1 1
13 23L1 Tender Lining ♠ ♠ ♠ 1 1
14 23L2 Fuel Pipe & Toe Hood Mtg. ♠ ♠ ♠ 1 1
15 23L Front Susp. Mtg. ♠ ♠ ♠ 1 1
16 23R1 Side S/A - Bracket S/A ♠ ♠ ♠ 1 1
17 23R2 Side S/A - Front Suspension ♠ ♠ ♠ 1 1
18 23R3 Mud Flap Mtg. ♠ ♠ ♠ 1 1
19 23R Ft. Susp. Mtg. ♠ ♠ ♠ 1 1
20 25R Fuel Tank Mtg. ♠ ♠ ♠ 1 1
21 26L Harness Wire Clamping ♠ ♠ ♠ 1 1
22 26R Fuel Tank Mtg. ♠ ♠ ♠ 1 1
23 27L Bracket Mtg. ♠ ♠ ♠ 1 1
24 28L Water Pipe, Fuel Pipe Clamping ♠ ♠ ♠ 1 1
25 28R Harness Wiring & Heat Protector Fiting ♠ ♠ ♠ 1 1
26 29L Engine Mtg. ♠ ♠ ♠ 1 1
27 29R Gromet & Seal Hose Fitting ♠ ♠ ♠ 1 1
28 30L Engine Mtg. ♠ ♠ ♠ 1 1
29 30R Drive Shaft Fitting ♠ ♠ ♠ 1 1
30 31L Muffler & Silencer Shaft Fitment ♠ ♠ ♠ 1 1
31 32L Pan Guard Mtg ♠ ♠ ♠ 1 1
32 32R Clutch Clamp & Clutch Cap Mtg. ♠ ♠ ♠ 1 1
33 33L Front Light & Grill Mtg. ♠ ♠ ♠ 1 1
34 33M Marking & Ins. ♠ ♠ ♠ 1 1
35 33R Steering Joint ♠ ♠ ♠ 1 1
36 34L Ventilator Mtg. & Carpet Adjustment ♠ ♠ ♠ 1 1
37 34R Ventilator Mtg. & Carpet Adjustment ♠ ♠ ♠ 1 1
38
39
TOTAL SHEETS 37 37

IGNIS (YJC) CHASSIS LINE (LINE 4)

PROCESS SHEET
PROCESS SHEET Date: 12-Oct-16

Model : YJC STN : FRAME S/A-2

VXI AMT P12
ZXI AMT P06

ZXI AMT P12

YJCVXI P06

YJCVXI P12

YJCZXI P06

YJCZXI P12
5AMTZDI+
5AMTZXI+

5MTZDI+
5AMTVDI
5MTZXI+
5AMT VXI

5AMT ZDI
5AMT ZXI

5MTVDI
5MTVXI

5MTZDI
5MTZXI
5MTLXI

S.NO PART NO. PART NAME AREA PROCESS

1 45810M66R00 FRAME COMP, FRONT SUSPENSION CHASSIS2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 PULLED UP BY TH E LIFTER TO THE TABLE

2 42311M66R00 BAR, FRONT STABLIZER CHASSIS2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 FITTED BVY HAND (MANUALLY)

FITTED WITH FRAME FOR THE STEARRING FITMENT

3 4850M66R00 BOX ASSY, STRNG GEAR CHASSIS2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 BY GUN

4 45201M66RA0 ARM ASSY,FRONT SUSPENSION,R CHASSIS2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 TAKE ARM FROM TROLLEY AND PLACE ON FRAME.

5 45202M66RA0 ARM ASSY,FRONT SUSPENSION,L CHASSIS2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 TAKE ARM FROM TROLLEY AND PLACE ON FRAME.

INSERT TEHNTORQUE ROD ON FRAME AND ALIGN

6 11910M66R00 ROD COMP,ENG RR TRQ CHASSIS2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 THEIR HOLES.

INSERT TEHNTORQUE ROD ON FRAME AND ALIGN

7 11910M66R50 ROD COMP,ENG RR TRQ CHASSIS2 1 1 1 1 1 1 THEIR HOLES.

HAND TIGHT THE BOLT ON BOTH ARMS. TIGHT THE

8 45853-74P00 BOLT,SPNSN ARM FR BUSHING CHASSIS2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 BOLTS WITH GUN.

TORQUE THE BOLTS WITH SET VALUE OF 95 NM

9 TORQUING CHASSIS2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 AND APPLY YELLOW MARK.

10 42441M74P00 BRACKET, FRONT STABLIZER BAR CHASSIS2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 FITTED BY GUN

11 42420M66R00 JOINT COMP,FR STABILIZER BAR CHASSIS2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 INSERT THE BAR JOINT ON STABLIZER BAR.

HANTIGHT THE BAR JOINT NUT. TIGHT THE NUT

12 08316M1010A NUT,STABILIZER JOINT CHASSIS2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 WITH GUN.

TORQUE THE NUTS WITH SET VALUE OF 50 NM AND

13 TORQUING CHASSIS2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 APPLY YELLOW MARK.

HAND TIGHT THE BOLT ON TRQ ROD. TIGHT THE

14 09113-12010 BOLT,TRQ ROD & SPNSN FRM CHASSIS2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 BOLT WITH GUN.

TORQUE THE BOLT WITH SET VALUE OF 93 AND

15 TORQUING CHASSIS2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 APPLY YELLOW MARK.

16 45851M66R00 COVER,TORQUE ROD CHASSIS2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 PRESS FIT THE COVER ON FRAME.

17 09409M06322 CLIP,TORQUE ROD COVER CHASSIS2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 FIT THE CLIPS ON COVER.

18 42431M66R00 MOUNT, FRONT STABLIZER BAR CHASSIS2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 MOUNTED ON FRAME BY GUN

NOTE:

Prepared By Checked By Approved By

Control No. AS1-Z-72-C1 Rev no. 00

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 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
PROCESS SHEET Date: 12-Oct-16

Model : YJC STN : BRAKE DRUM S/A

VXI AMT P12

ZXI AMT P06

ZXI AMT P12

YJC VXI P06

YJC VXI P12

YJC ZXI P06

YJC ZXI P12

5AMT ZDI+
5AMT ZXI+

5AMT VDI

5MT ZDI+
5AMT VXI

5AMT ZDI
5MT ZXI+
5AMT ZXI

5MT VDI
5MT VXI

5MT ZDI
5MT ZXI
5MT LXI
S.NO PART NO. PART NAME AREA PROCESS

1 43402M68P01 HUB ASSY,REAR WHEEL CHASSIS2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 TAKE A HUB AND PLACE ON S/A JIG.

2 56310M62R00 SENSOR COMP,RR WHEEL CHASSIS2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 TAKE A SENSOR WIRE AND FIT ON HUB.

HAND TIGHT THE BOLT ON SENSOR WIRE.

3 01550M0612A BOLT,RR WHEEL SENSOR CHASSIS2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
TIGHT WITH GUN AFTER HAND TIGHTENING.

TORQUE THE BOLT WITH SET VALUE OF 11NM. APPLY

4 TORQUING. CHASSIS2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
RED MARK.

1 53002M68P10 BRAKE ASSY,REAR,L CHASSIS2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 TAKE BRAKE ASSY AND PLACE ON JIG.

TAKE PARKING CABLE AND INSERT IN BRAKE ASSY AND

2 54402M66R00 CABLE COMP,PARKING BRAKE,L CHASSIS2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
FIT IN LOCK OF BRAKE ASSY AND STUD.

HAND TIGHT THE NUT ON BRAKE ASSY STUD. TIGHT

3 08316M1006A NUT,PARKING CABLE CAP CHASSIS2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
WITH GUN.

4 53001M68P10 BRAKE ASSY,REAR,R CHASSIS2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 TAKE BRAKE ASSY AND PLACE ON JIG.

TAKE PARKING CABLE AND INSERT IN BRAKE ASSY AND

5 54401M66R00 CABLE COMP,PARKING BRAKE,R CHASSIS2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
FIT IN LOCK OF BRAKE ASSY AND STUD.

HAND TIGHT THE NUT ON BRAKE ASSY STUD. TIGHT

6 08316M1006A NUT,PARKING CABLE CAP CHASSIS2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
WITH GUN.

NOTE:

Prepared By Checked By Approved By

PROCESS SEQUENCE OF IGNIS (YJC)

FINAL LINE (LINE 4)
PROCESS SHEET Date: 13-Oct-16

Model : YJC STN : 43R

VXI AMT P12

ZXI AMT P06
ZXI AMT P12
YJC VXI P06
YJC VXI P12
YJC ZXI P06
YJC ZXI P12
5AMT ZDI+
5AMT ZXI+

5AMT VDI
5AMT VXI

5AMT ZDI
5MT ZDI+
5AMT ZXI
5MT ZXI+

5MT VDI
5MT VXI

5MT ZDI
5MT ZXI
5MT LXI

S.NO PART NO. PART NAME AREA PROCESS

1 CHECK FUNDUSHI OF VEHICLE FINAL1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

2 ABS HARNESS COUPLER CONNECTION WITH ACTUATOR. FINAL1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

FIT THE BRAKE OIL FILLING GUN ON BRAKE MASTER CYLINDER AND
3 BRAKE OIL FILLING. FINAL1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
PRESS SWITCH TO START FILLING.

4 TIGHT CLAMP OF DEG TANK HOSES. FINAL1 2 2 2 2 2 2 TIGHT THE CLAMP WITH PLIER AND APPLY BLUE MARK.

5 TORQUING OF AIR CLEANER. FINAL1 4 4 4 4 4 4 SET VALUE 8.5 NM.

6 AIRBAG SCAN FINAL1 SCAN THE AIRBAG IN VTS SYSTEM

CHECK THE COIL POSITION IN CONTACT COIL WINDOW & APPLY

7 CONTACT COIL CHECK 1 FINAL1 CHECK MARK

8 CONTACT COIL LOCK REMOVAL 2 FINAL1 BREAK THE LOCK TAB OF CONTACT COIL

TORQUING OF WHEEL NUT & APPLY RED MARK ON WHHEL NUT &
9 STEERING WHEEL NUT TORQUING. FINAL1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 COIL WINDOW

CONNECT THE HARNESS COUPLERS AND APPLY RED MARK. PRESS FIT
10 48150M66R20-C48 MODULE ASSY,AIRBAG FINAL1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
IN VEHICLE.

11

NOTE: Process change from date-10-Nov-2017

1
Process addition from date-20-Nov-2017
2

Prepared By Checked By Approved By

Control No. AS1-Z-72-C1 Rev no. 00

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 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
Here the process is divided into smaller parts and total most time of the work station is calculated.eg In the above sheet we
have calculated the most time of work station 19R2.The main process carried out is rear axle mounting. Similarly most time of
all the work station is calculated. After calculating the most time, graph is made with station no on the x axis.

Than graph between video time and station no is made.

After it the graph between video and most time is made

After the graph standardization of manpower for fluctuating production volumes is calculated

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 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
PROCESS SEQUENCE OF IGNIS (YJC)
TRIM LINE (LINE 4)
PROCESS SHEET Date: 16/11/2016

Model : YJC STN : 11R

VXI AMT P12

ZXI AMT P06
ZXI AMT P12
YJC VXI P06
YJC VXI P12
YJC ZXI P06
YJC ZXI P12
5AMT ZDI+
5AMT ZXI+

5AMT VDI
S.

5AMT VXI

5AMT ZDI
5AMT ZXI

5MT ZDI+
5MT ZXI+

5MT VDI
5MT VXI

5MT ZDI
5MT ZXI
5MT LXI
PART NO. PART NAME AREA PROCESS
NO

1 01551M1025A BOLT,ENG MTG LH(BODY TO MTG) TRIM2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 Fit the hand tight bolt eng mounting
2 01551M1025A BOLT,ENG MTG RH(BODY TO MTG) TRIM2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Fit the hand tight bolt eng mounting
3 08316M1010A NUT,ENG MTG LH(BODY TO MTG) TRIM2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Fit the hand tight nut eng mounting
4 08316M1010A NUT,ENG MTG RH(BODY TO MTG) TRIM2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Fit the hand tight nut t eng mounting
5 11610M66R00 MOUNTING COMP,ENG RH TRIM2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Fit the mounting comp. ENG RH
6 11610M66R50 MOUNTING COMP,ENG RH TRIM2 1 1 1 1 1 1 Fit the mounting comp. ENG RH
7 11620M66R00 MOUNTING COMP,ENG LH TRIM2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Fit the mounting comp. ENG LH
8 11620M66R50 MOUNTING COMP,ENG LH TRIM2 1 1 1 1 1 1 Fit the mounting comp. ENG LH
9 23830M66R00 PIPE COMP,CLUTCH OIL RH TRIM2 1 1 1 Fit the pipe comp ,clutch oil RH
10 27978-68P00 CLAMP,CLUTCH OIL PIPE NO.1 TRIM2 1 1 1 Fit the clamp ,clutch oil no.1
27978-68P30
11 1 CLAMP,CLUTCH OIL PIPE NO.2 TRIM2 1 1 1 Fit the clamp ,clutch oil no.2
27978-55R00
Fit the bolt hood switch tight ,torquing with
12 09115-06005 BOLT,HOOD SWITCH TRIM2 1 1 1 1 1 1 1 1 1 1 1 1
blue marking
13 37225M66R00 SWITCH ASSY,HOOD TRIM2 1 1 1 1 1 1 1 1 1 1 1 1 Fit the switch assy ,hood
14 72420M66R00-5PK GARNISH COMP. FR HOOD RH TRIM2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Fit the garness comp .FR HOOD RH
15

16

17

18

19

20

NOTE: 1 Part no changed through ECN no-55R-0549

Prepared By Checked By Approved By

Control No. AS1-Z-72-C1 Rev no. 00

STATION DETAILS CHSSIS LINE (EECO)

EECO CHASSIS LINE
MODEL 5 STR AC 5 STR NON AC 7 STR NON AC ALL
TOTAL (LEFT) 1893.58 1893.58 1893.58 1893.58
TOTAL (RIGHT) 1588.51 1588.51 1588.51 1588.51
OVERALL TOTAL(LT+RT) 3482.09 3482.09 3482.09 3482.09
STATION (130 VEH./203 Sec) 17.15 17.15 17.15 17.15
OVERALL TOTAL(5 Sec Extra) 3567.86 3567.86 3567.86 3567.86
STATION (130 VEH./203 Sec) 17.58 17.58 17.58 17.58
STATION (150 VEH./176 Sec) 19.78 19.78 19.78 19.78
OVERALL TOTAL(5 Sec Extra) 3581.01 3581.01 3581.01 3581.01
STATION (150 VEH./176 Sec) 20.27 20.35 20.35 20.32
STATION (175 VEH./158 Sec) 22.04 22.04 22.04 22.04
OVERALL TOTAL(5 Sec Extra) 3592.28 3592.28 3592.28 3592.28
STATION (175 VEH./158 Sec) 22.74 22.74 22.74 22.74
STATION (200 VEH./132 Sec) 26.38 26.38 26.38 26.38
OVERALL TOTAL(5 Sec Extra) 3613.99 3613.99 3613.99 3613.99
STATION (200 VEH./132 Sec) 27.38 27.38 27.38 27.38
STATION (220 VEH./120 Sec) 29.02 29.02 29.02 29.02
OVERALL TOTAL(5 Sec Extra) 3627.18 3627.18 3627.18 3627.18
STATION (220 VEH./120 Sec) 30.23 30.23 30.23 30.23
STATION (250 VEH./105 Sec) 33.16 33.16 33.16 33.16
OVERALL TOTAL(5 Sec Extra) 3647.90 3647.90 3647.90 3647.90
STATION (250 VEH./105 Sec) 34.74 34.74 34.74 34.74

@ IJTSRD | Unique Paper ID – IJTSRD31411 | Volume – 4 | Issue – 4 | May-June 2020 Page 1255
 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
INCREASE IN PRODUCTIVITY DUE TO DECREASE IN Apart from these the evident presence of
MANPOWER robots,fundamentals of Industrial Engineering and TQM in

Present production plan = 250 the industry, made me realize the importance of the subjects

Present manpower for above plan = 37 taught to us as a part of our curriculum.

As per MOST, man power required = 35

Thus total man power saving = 2 (just in Chassis area for Besides their was an increasing emphasis laid on man power
EECO) reduction , increse in labour productivity and labour cost
cutting.
CONCLUSION OF TRAINING SEMESTER
The 6 WEEKS stay at Maruti Suzuki India Ltd. Gurgaon has The industrial training over a period of six weeks is indeed
been a great learning curve which I will always cherish. very valuable as now I know how it is to work in the
I was able to see the concepts and the topics I have studied industry. Hence will go a long way to help me in my career.
being implemented that further enhanced my understanding
of them. BIBLIOGRAPHY
[1] INDSTRIAL ENGINEERING:- DR. AJAY BATISH
I was involved in an important project which was interesting [2] TRAINEE (AUTHIOR):- SAHIL
and concerned Productivity and thus I was able to learn
many different things in my six weeks tenure as well as go REFERENCE
into the depth of some. [1] wikipedia.org
[2] google.com

@ IJTSRD | Unique Paper ID – IJTSRD31411 | Volume – 4 | Issue – 4 | May-June 2020 Page 1256