ONLINE SERVOMOTOR INSULATION

CHECKING THROUGH ISOMETER

INTERNSHIP REPORT
SUBMITTED IN PARTIAL FULFILLMENT OF REQUIREMENTS FOR THE AWARD OF
THE DEGREE OF

BACHELOR OF TECHNOLOGY
ELECTRICAL ENGINEERING

BY
DHEERAJ YADAV
(Univ. Roll No . 21001002019)

UNDER THE SUPERVISION OF

FACULTY COORDINATOR MENTOR/SUPERVISOR

DR. NARESH KUMAR MR. SANJAY KUMAR

ASSISTANT PROFESSOR SENIOR MANAGER
DCRUST, MURTHAL MARUTI SUZUKI INDIA LTD

DEPARTMENT OF ELECTRICAL ENGINEERING

FACULTY OF ENGINEERING & TECHNOLOGY
D.C.R. UNIVERSITY OF SCIENCE & TECHNOLOGY
MURTHAL, SONIPAT, HARYANA (INDIA) – 131 039
(June 2025)
Type your text
 ACKNOWLEDGEMENT

We are highly grateful to the Hon'ble Vice-Chancellor Deenbandhu Chhotu Ram

University of Science and Technology, Murthal, Sonipat for providing us this
opportunity to carry out the present Internship work.

The constant guidance and encouragement received from Dr. Surender Dhaiya
Professor & Chairperson, Dept. of Electrical Engineering. Deenbandhu Chhotu
Ram University of Science and Technology, Murthal, Sonipat has been of great
help in carrying out the present work and is acknowledged with reverential thanks.
We would like to express a deep sense of gratitude and thanks profusely to our
Faculty Coordinator, Dr. Naresh Kumar (Assistant Professor), Dept of Electrical
Engineering, Deenbandhu Chhotu Ram University of Science and Technology.
Murthal, Sonipat and Mr. Sanjay Kumar (Senior Manager) Without his able
guidance, it would have been impossible to complete the Internship in this manner.
The help rendered by Dr. Ravi Lathwal (Assistant Professor). B.Tech. Internship
Coordinator, Department of Electrical Engineering Deenbandhu Chhotu Ram
University of Science and Technology, Murthal, Sonipat for his wise counsel is
greatly acknowledged. We also express our gratitude to other faculty members of
Department of Electrical Engineering.

DCR University of Science & Technology, Murthal Sonipat for their intellectual
support throughout the course of this work
Finally, we are indebted to all whosoever have contributed in this internship work
Finally, I would like to express my gratitude to Maruti Suzuki as a whole for
providing me with this incredible opportunity. The experience I gained during my
internship has been invaluable. I feel that I have gained a deeper understanding of
the subject matter and valuable skills that will serve me well in my future career.
Sincerely ,

Dheeraj Yadav

[i]
 DECLARATION
I hereby certify that the work which is being presented in this internship report
entitled ONLINE SERVOMETER INSULATION CHECKING THROUGH
ISOMETER in partial fulfilment of requirements for the award of degree of
BACHELOR OF TECHNOLOGY in ELECTRICAL ENGINEERING, submitted to
the Dept of Electrical Engineering, Faculty of Engineering & Technology,
Deenbandhu Chhotu Ram University of Science & Technology Murthal, Sonipat
(Haryana) is an authentic record of my own work carried out during a period
from January 16TH to May 16TH under the supervision of Mr. Sanjay Kumar (
Senior Manager ). The matter presented in this Internship work has not been
submitted to any other University/Institute for the award of B Tech or any other
Degree/Diploma

Dheeraj Yadav (21001002019)

This is to certify that the above statement made by the candidate in correct to the
best of my knowledge & belief.

Signature of Faculty Signature of

Coordinator Dr. Naresh Supervisor/Mentor Mr. Sanjay
Kumar Kumar
(Assistant Professor) ( Senior Manager )

[ii]
CERTIFICATE

[iii]
 PREFACE

Industrial training is one of the best methods to make students familiar with the
modern techniques, latest equipment & methods used in various industries.
During industrial training, students visit various companies and make
themselves familiar with the practical aspects of the production method

This training has provided an unmatched experience and opportunity to gain

practical knowledge which has increased my level of thinking and taught me art
of dealing with different kinds of people in all walks of life. The training has
improved my theoretical and practical concepts of automotive technology

The well planned, properly executed and evaluated industrial training helps a lot
in inculcating good work ethics. It provides a medium between the students and
the industry in order to develop the awareness of industrial approach to problem
solving based on broad understanding of plant.

[iv]
 ABSTRACT

This report presents a detailed analysis of the process of online insulation

checking in servomotors using an isometer. As servomotors play a crucial role
in precision motion control systems, ensuring their insulation integrity is vital for
operational reliability and safety. Traditional offline insulation testing often
requires machine downtime, which hampers productivity. To address this
limitation, the use of isometers enables continuous, real-time monitoring of
insulation resistance without interrupting motor operation.
The report explores the working principle of isometers, which function by
detecting insulation degradation through resistance measurement to earth or
ground. Key benefits of this method include early fault detection, prevention of
unplanned breakdowns, and extended equipment life. The methodology
adopted for online testing is described, highlighting safety protocols and setup
considerations.
Case studies and practical observations support the advantages of integrating
isometers in industrial automation systems. The findings emphasize the
importance of proactive maintenance strategies in modern manufacturing
environments. This approach ensures efficiency, reduces downtime, and
contributes to the overall health of electrical machines through detection of the
isssues and making it work and check it continuously .

[v]
 TABLE OF CONTENTS
Acknowledgement i
Type your text
Declaration 3
Certificate 4
Preface 5
Abstract 6

CHAPTER 1 : Introduction 10-21

1.1 Historical background 10
1.2 Maruti Suzuki India : A Legacy in Motion 10
1.3 Footprints in the stock market 15
1.4 Maruti’s quality policy 15
1.5 Quality system 15
1.6 Employee quality measures 16
1.7 Various quality tools 20
CHAPTER 2 : Manufacturing Facilities at MISL 22-40
2.1 Press Shop 24
2.2 Weld Shop 30
2.3 Paint Shop 31
2.4 Assembly Shop 36
2.5 Vehicle Inspection 39
CHAPTER 3 : About the Project 41-
3.1 Objective 42
3.2 Working Principle 42
3.3 How it Works in Project 42
3.4 Tools and Component Used 43
3.5 Methodology 44
3.6 Observations 46
Chapter 4 : Challenges 48-50
4.1 Challenges 48
4.2 Benefits 50
Chapter 5 : Conclusion 51
References 52

[vii]
 LIST OF FIGURES

FIG 1 : Maruti Suzuki Gurugram Plant 21

FIG 2: MARUTI Manesar Plant 22

Fig 3 : Maruti Suzuki Engine Plant 23

Fig 4 : Press Machine 25

Fig 5 : Upper Die 26

Fig 6 : Lower die 26

Fig 7 : Steel Coils 27

Fig 8 : Stack of blank Panels 28

Fig 9 : Paint Shop 31

Fig 10 : Flow Chart of Pre –Treatment Process 33

Fig 11 : Flow chart of Electro Deposition Process 34

[vi]
[9]
 CHAPTER-1
INTRODUCTION

1.1 HISTORICAL BACKGROUND

The Manesar facility was established to support the international operations of

Suzuki Motor Corporation (SMC) and its Indian partner, Maruti Suzuki India
Limited (MSIL). Operational since February 2007, it is regarded as one of
Suzuki’s most advanced manufacturing plants worldwide. The plant
incorporates a high degree of automation and robotics, particularly in the
stamping, welding, and painting workshops, which significantly enhances
productivity and safety—especially in potentially hazardous areas where robots
are employed to reduce human risk.

Designed with flexibility in mind, the plant can manufacture various vehicle
models. It features automatic changeover systems, a centralized welding control
setup, CNC machines, and integrated tools that streamline the production
process. Initially, the plant had a production capacity of 100,000 units annually,
which has since expanded to 550,000 units per year

1.2 Maruti Suzuki India: A Legacy in Motion

Maruti Suzuki India began its remarkable journey in 1981, marking a transformative
moment in the Indian automotive sector. In 1982, the company took a major leap
forward by entering into a strategic joint venture with Japan’s renowned Suzuki
Motor Corporation (SMC), significantly strengthening Indo-Japanese industrial
collaboration.

This partnership laid the groundwork for numerous achievements over the years. By
2002, Maruti Suzuki India Limited had officially become a subsidiary of SMC,
cementing its long-standing relationship with the Japanese automaker. Today,
Maruti Suzuki stands not only as a leader in India’s car market but also as SMC’s
largest subsidiary globally in terms of sales and production volume. SMC currently

[10]
owns a 56.48% stake in the company, underscoring its strong influence and
commitment to the Indian market.

1980s Highlights
In 1981, the Indian government founded Maruti Udyog Limited with the vision of
developing a homegrown automobile manufacturer. A year later, this vision took a
significant leap forward through a partnership with Japan’s Suzuki Motor
Corporation. This collaboration laid the foundation for a series of iconic vehicle
launches, beginning with the introduction of the Maruti 800 in 1983—a car that
would go on to revolutionize personal transportation in India. The lineup soon
expanded to include other well-known models like the Omni and the Gypsy. As local
production ramped up, Maruti focused on building a reliable domestic network of
auto component suppliers, helping the company reduce its reliance on imports. The
brand also took its first steps into the global market by exporting 500 cars to
Hungary, marking the beginning of its international journey. By the end of the
decade, Maruti introduced the M1000, a sedan that broadened its product portfolio..

1990s Highlights
During the 1990s, the company made major progress in localizing the production of
components, further strengthening its manufacturing base. Suzuki deepened its
involvement by raising its stake in the venture to 50%, reinforcing the joint venture's
long-term commitment. This era also saw the launch of several successful models
tailored for the Indian consumer, including the Zen, Esteem, and WagonR. These
efforts, combined with expanding production capabilities and a growing customer
base, helped Maruti achieve important milestones in its journey to becoming a
market leader. Maruti Suzuki reached a significant achievement by producing its
one-millionth vehicle. To mark the occasion, the company donated a Gypsy
ambulance to Mother Teresa as a gesture of goodwill.

Developments in the 2000s

 The company expanded its services with the launch of Maruti Finance and
Maruti Insurance, enhancing customer convenience.
 It entered the stock market, getting listed on both the NSE and BSE.

[11]
  The popular Swift hatchback was introduced, quickly gaining consumer
attention.

 A new production facility was set up in Manesar, Haryana, increasing

manufacturing capacity.
 Maruti Suzuki began focusing on sustainability by rolling out vehicles
powered by CNG.
Its portfolio continued to grow with models like the Dzire and Eeco, strengthening its
market presence.

Key Achievements: 2011–2025

 Chairman R.C. Bhargava received the prestigious Padma Bhushan award
for his contributions to the industry.
 New models including the Ertiga, Ciaz, Brezza, and Ignis were launched,
catering to evolving customer needs.
 The company prioritized sustainability by adopting solar energy solutions
and introducing Smart Hybrid Technology.
 Maruti Suzuki celebrated a monumental milestone by surpassing 25 million
vehicles sold in India.
 In recent years, the brand introduced advanced models such as the Invicto,
Grand Vitara, and a next-gen Intelligent Electric Hybrid Vehicle aimed at
eco-conscious consumers.

[12]
 MODELS OF MARUTI SUZUKI CURRENTLY
BEING PRODUCED

1. HATCHBACK

[13]
2. MUV’s/SUV’s:

3. SEDAN :

4. VAN’s :

[14]
1.3 FOOTPRINTS IN THE STOCK MARKET

Maruti Suzuki enjoys a prominent position not only in the Indian automobile sector but also
in the country's financial markets. As a publicly listed entity, its shares are traded on both
the National Stock Exchange (NSE) and the Bombay Stock Exchange (BSE), reflecting
strong investor confidence. The company’s widespread presence is visible across Indian
roads, where its vehicles are frequently seen. It continues to dominate the passenger
vehicle segment and holds the distinction of being India's leading exporter of passenger
cars. In the financial year 2022–23, Maruti Suzuki achieved a significant milestone with a
turnover surpassing ₹100 billion, joining the ranks of a few elite manufacturers in the nation
to accomplish such scale.

1.4 MARUTI’S COMMITMENT TO QUALITY

Maruti Suzuki is deeply committed to customer satisfaction. This commitment is
pursued through continuous improvement in both products and services, guided
by the PDCA (Plan-Do-Check-Act) cycle, which is implemented across all
departments and functions of the organization..

1.5 QUALITY SYSTEM

The company's quality approach is inspired by Japanese manufacturing
philosophies, particularly the idea of embedding quality directly into products.
Supervisors and managers actively support employees through guidance and
training to enhance output and operational efficiency. Top leadership plays an
active role by reviewing quality control Developments in weekly meetings.

Maruti Suzuki underwent a comprehensive four-day audit conducted by AV

Belgium, an international auditing body affiliated with the International
Organization for Standardization (ISO). This audit covered key areas such as
customer focus, leadership practices, employee involvement, systematic
processes, performance tracking, and continual improvement.

[15]
1.6 QUALITY IMPROVEMENT MEASURE

Maruti Suzuki follows the Kaizen philosophy, which emphasizes continuous,

incremental improvement in products and processes. This approach is designed
to be simple and easy to implement, encouraging active participation from
employees at every level of the organization.
As part of this initiative, staff are invited to contribute suggestions for
improvements across all operational areas. Each year, employees submit over
50,000 improvement ideas, many of which are related to on-ground operations.
Maruti believes that this strong focus on ongoing quality enhancement plays a
crucial role in its sustained growth, especially as industry competition grows
more intense.

Kaizen Principle At Maruti

 Serves as a practical tool to drive quick improvements through the

PDCA (Plan-Do-Check-Act) methodology
 Supports Rule 4 of Maruti’s internal operational framework
 Improvement goals are aligned with the company's key performance
indicators (KPIs)

 Encourages a team-based approach to problem-solving and

innovation

[16]
Meeting Needs

• Community
• Shareholders
• Internal/External 3. Do
• Employee

2.
1. Customer Design 4. Feedback
Needs (Check)
(Plan)
• Cost
• Say-do / PK /
5. Improve
schedule (Act/Adjust)
• Quality / PPM
• Safety
• 5S
• TPM

Before, during and after the Kaizen, the Team Leader should:
 Planning and Preparation: Gather relevant data, allocate necessary
resources, and organize daily operational needs.

 Tool Management: Collect and return the Kaizen kit (if applicable) for
team use.

 Team Coordination: Review initial performance metrics with the team

and assign daily tasks.

 Active Participation: Be involved in every stage of the Kaizen process to

guide and support the team.

 Logistics and Communication: Work with maintenance teams and the

Kaizen facilitator to arrange any equipment movements.

 Progress Sharing: Create and present daily updates, and help prepare
for the final presentation.

 Post-Kaizen Follow-up: Contribute to developing and executing the

action plan to maintain and build on the improvements made.

[17]
DCRUST Maruti Suzuki

There are 5 basic steps:

1. Case of the business should be identified
2. Collect baseline data
3. Team should be selected
4. Set goals (measureable example: time
and number of ideas per person)
5. Kaizen activity should be supported

[18]
1.7 VARIOUS QUALITY TOOLS
 5S
 3M
 3G
 3K

5S

JAPANESE TERM AMERICAN TERM

3M

JAPANESE TERM AMERICAN TERM

MUDA WASTEFULNESS

MURA IRREGULARITY

MURI
OVERBURDEN

[19]
3G

JAPANESE TERM MEANING

GENCHI GO TO THE ACTUAL WORKSPACE

GENBUTSU SEE THE ACTUAL THINGS & FACTS

GENJITSU TAKE SUITABLE ACTIONS

3K

JAPANESE TERM MEANING

KIMERARETA KOTO GO WHAT HAS BEEN DECIDED

KICHIN TO MAMORU MUST BE FOLLOWED

KIHON DORI NI AS PER STANDARDS

[20]
 CHAPTER-2
MANUFACTURING FACILITIES AT MSIL
Maruti Suzuki operates two major manufacturing plants in India—one located in
Gurugram and the other in Manesar, both in the state of Haryana

GURUGRAM PLANT
The Gurugram facility comprises three fully integrated production units. While the
plant is officially designed to produce around 650,000 vehicles per year,
continuous enhancements—particularly through Kaizen-based improvements
implemented in the previous year—have increased its actual output to nearly
700,000 vehicles annually.

Fig 1. Maruti Suzuki Gurugram Plant

[21]
MANESAR PLANT OVERVIEW

The Manesar facility was established to support the international operations of

Suzuki Motor Corporation (SMC) and its Indian partner, Maruti Suzuki India
Limited (MSIL). Operational since February 2007, it is regarded as one of
Suzuki’s most advanced manufacturing plants worldwide. The plant incorporates
a high degree of automation and robotics, particularly in the stamping, welding,
and painting workshops, which significantly enhances productivity and safety—
especially in potentially hazardous areas where robots are employed to reduce
human risk.

Designed with flexibility in mind, the plant can manufacture various vehicle
models. It features automatic changeover systems, a centralized welding control
setup, CNC machines, and integrated tools that streamline the production
process. Initially, the plant had a production capacity of 100,000 units annually,
which has since expanded to 550,000 units per year

Fig2 . Maruti Suzuki Manesar Plant

[22]
DIESEL ENGINE PLANT

Suzuki Power Trains India Limited operates a diesel engine manufacturing

facility in Manesar, which is Suzuki’s first plant in India and MSIL’s sole facility
dedicated to producing premium diesel engines and automotive transmissions.
This plant is part of a joint venture named Suzuki Power Transmission India
Limited (SPIL), with Suzuki Motor Corporation (SMC) holding a 70% share and
the remaining 30% owned by Maruti Suzuki India Limited (MSIL). The plant is
equipped with advanced automation technology and has an annual production
capacity of 300,000 engines. Quality control is rigorously maintained using
precision measurement equipment, ensuring that every unit meets strict
standards and is free of defects

Fig3 . Maruti Suzuki Engine Plant

[23]
DIFFERENT SHOPS IN MSIL

2.1 PRESS SHOP

The press shop marks the beginning of the vehicle manufacturing process and is
strategically positioned among the three welding units—Weld 1, Weld 2, and
Weld 3—to supply them with essential body components. It operates on a batch
production basis, in contrast to the continuous production lines followed in the
welding sections. To avoid any disruption in supply, the press shop keeps a
buffer stock that can support at least two days of production.
The welded body assemblies receive stamped parts from the press shop
according to their production schedules. These parts are classified into three
categories: A, B, and C. Category 'A' includes large body panels like roofs and
doors, which are produced internally by Maruti due to design confidentiality and
high tooling costs. Categories 'B' and 'C' consist of components that are

procured either through joint ventures or from third-party suppliers .

Process flow of Press Shop activity :-

el Blank Panel
Ste coil

Fig . Process Flow

 The Press Shop currently manufactures sheet metal parts for eight active
Maruti Suzuki models, along with one model for GM India, the Tavera.
 The blanking and stamping sections handle approximately 10,000
metric tons of steel each month, which breaks down to around 400
tons per day.
[24]
Machinery
 The facility is equipped with five transfer presses with capacities of 4000 tons,
3500 tons, two presses at 2400 tons each, and a 2000-ton press. These presses
handle multiple operations including drawing, trimming, piercing, bending, and
restriking. Additionally, there is one tandem line with a 1500-ton drawing capacity.

 Two coil processing lines operate here: a shear line (ROSL) and a blanking line,
supported by special purpose machines (SPM) with a capacity of 60 units.

 The total daily output amounts to around 55,000 strokes processed from 400 tons
of steel coils.

4000 Ton
transfer
press

Fig 4. Press Machine

[25]
Press Machine: The mass production presses used are continuous flow
transfer presses, where 4 to 5 dies are mounted on a single press. As the
sheet metal passes through the press, it undergoes stamping, trimming,
and piercing to produce complete panels. There are a total of 189 die sets
in use, including 15 sets for GM India (GMI). Each die set typically consists
of an average of four upper and four lower dies.

SMED: ―Single Minute Exchange of Dies‖ new concept being adopted. The
concept of SMED is being implemented to reduce die changeover time to
less than nine minutes. This rapid die exchange technique significantly
improves machine utilization and operational efficiency. Given the high cost
of press machines, minimizing idle time during die changes is crucial for
cost savings and productivity enhancement.

Fig5 . Upper die Fig6 . Lower die

[26]
Yield improvement: Yield, defined as the ratio of output panel weight to
input coil weight, is currently the highest among Suzuki Motor Corporation
(SMC) group companies, standing at 63.2%. Continuous modifications
have led to material savings of approximately Rs. 7.786 million as of
October 2009.
Key factors contributing to yield improvement include:
 Reducing the size of blanks to optimize material usage
 Recycling scrap material for producing smaller sheet metal parts

Steel Coils : Steel coils are the primary raw material used for manufacturing body
sheet metal components. These cold-rolled steel (CRS) coils vary in thickness from
0.65 mm to 0.8 mm and typically weigh between 1 and 4 tons each.

Fig 7 . Steel Coils

Coils are sourced both domestically and internationally, with a supply ratio
of approximately 60% local and 40% foreign. They are stored centrally
before being dispatched to the blanking and ROSL (Roll Over Shear Line)
areas according to production schedules.

[27]
Blanks
 Steel coils are fed into the blanking line, where they provide a

continuous flow of sheet metal to the cutting dies. This process shapes
the coils into blank sheets according to the production plan.
 These blanks are created through stamping or shearing and are stacked
sequentially to form large bundles.
 Once stacked, the blanks are transferred to press machines for further
processing into body panel shapes.

Fig 8 . Stack of Blank Panels

[28]
Panels

 The stacks of blanks are directed to the press lines, where they are

formed into various vehicle body panels.

 Through precision pressing, these blanks are shaped into specific panel

components required for vehicle assembly.

 The finished panels are then placed in pallets and delivered to the weld

shops, where they are used to construct the vehicle’s white bodies.

Panels re
stacked in
pallet
trolleys

Fig. Panels

[29]
2.2 WELD SHOP

In the weld shop, body panels produced in the press shop—along with smaller
components—are assembled to form the vehicle's structural shell, commonly referred
to as the ―white body.‖ Approximately 1,400 individual parts are joined through
welding to complete the body structure. The weld shop is equipped with the following
key systems and equipment:
Welding jigs
Spot welding guns
Kawasaki robotic welders
Hemming machines
Punching machines

PROCESS OUTLINE:
Underbody Assembly
This stage involves welding together several underbody components, including
the rear underbody, central floor panel, and front engine compartment panel.
These parts are positioned on a conveyor and joined to create the vehicle’s
underbody structure.
Main Body Assembly
Once the underbody is completed, the roof and side panels—previously
assembled on sub-lines—are welded onto it to form the main body. At this
stage, the chassis number is stamped on the cowl top, which is then welded to
the front section of the engine bay.
White Body Completion
Doors, the hood, and the rear hatch or trunk lid are bolted onto the main body
to complete the ―white body.‖ The assembled structure is then inspected for
any surface defects such as dents, burrs, or welding splatter. Identified issues
are corrected during this stage. Once the body passes inspection and any
necessary repairs are mades

[30]
2.3 PAINT SHOP

Fig 9 . Paint Shop

In the paint shop following processes are carried out: -

The paint shop is responsible for applying a uniform finish to the white body received from
the weld shop. All vehicle models are painted on a single production line, regardless of
variant. The painting process is divided into five main stages, each designed to ensure
surface preparation, corrosion resistance, and consistent paint application.

Main Stages of the Painting Process:

Pre-Treatment (PT):
In this initial step, the vehicle body is thoroughly cleaned to eliminate any dirt, grease, or
scale residues. It is then treated with a zinc phosphate (ZnPO₄ ) coating, which enhances
corrosion resistance and promotes better adhesion of the paint

[31]
  ED coat: In this stage, the vehicle body undergoes electro-
deposition using a 240V DC supply. This method ensures an even,
rust-resistant coating across the body. Once the ED layer is applied,
the body is cured in a baking oven to solidify the coating . 

 Sol-sealer and under coat: Gaps and seams left from the welding
process are sealed using a sol-sealer to make the body water-
resistant. An underbody coating is then applied to the wheel arches
and lower sections to protect against debris and moisture, reducing
the risk of rust or damage in those areas. 
 Intermediate coat: This layer is applied using automated spray
systems, specifically 10 Kawasaki robots. The intermediate coat acts
as a base for the final paint layer, enhancing adhesion and surface
smoothness. The vehicle is again passed through an oven for drying.

 Top coat: The final paint layer is applied using 20 Kawasaki robots.
Vehicles with metallic finishes receive two layers of top coat, along
with aluminum flakes to create a glossy metallic effect. This coat
defines the final appearance and provides durability ..


After the application of all paint layers, the vehicle body is carefully inspected for any
imperfections. Necessary touch-ups are carried out, and once the quality standards are
met, it is labeled as PBOK (Paint Body OK) and sent to the assembly line. The painting
process involves several key stages, including phosphate coating, electro-deposition (ED)
coating, intermediate coat (IC), and top coat application. While robotic systems handle the
exterior painting for consistency and precision, the interior areas are painted manually to
ensure complete coverage in hard-to-reach spots.

[32]
Pre-treatment (PT)

Before sending vehicle to painting process pretreatment is done.

SPRAY DEGREASING

SURFACE CONTROL

WR

Fig 10 . Flowchart of Pre-Treatment Process

ED PAINTING:

Electro-deposition (ED) painting involves immersing the vehicle in an ED

solution, where an electrical voltage of approximately 300 volts is applied to
ensure the paint adheres evenly to the surface. The ED bath consists of about
17% paint combined with water and specific additives (such as EDD and M).
The ED solution functions as an electrolytic medium. Prior to ED dipping, the
vehicle is subjected to pre-treatment, which includes phosphating. During
phosphating, a zinc phosphate layer forms on the vehicle’s body, enhancing
paint adhesion during electro-deposition. In the ED process, the vehicle body
acts as the cathode, while the paint particles carry a positive charge. When
current flows through the solution, the paint particles are attracted and
deposited uniformly on the vehicle until the desired thickness is achieved. This
method ensures precise and consistent paint application

[33]
 RINSING BY DIPPING

Fig.11 Flowchart of Electro-Deposition Process

ULTRAFILTRATION:

Ultrafiltration involves filtering and cleaning all rinse pipes and dip tanks to recycle
water efficiently. This process uses osmosis technology to purify the water,
ensuring minimal waste and continuous reuse

IC Painting:

Intermediate Coating (IC) involves applying three different colors: white, blue, and
red. The exterior surfaces of the vehicle are painted by robots, while the interior
areas are coated manually. The paint thickness is carefully monitored before the
vehicle proceeds to the IC curing oven, which operates at a temperature of
approximately 198°C, with a tolerance of ±5°C

TOP COAT Painting:

After passing through the second dry sanding stage, the vehicle undergoes top
coating, which consists of two layers: a base coat and a clear coat. A total of
eleven colors are used—eight metallic and three solid shades. Only the metallic
colors receive the clear coat. Similar to the IC painting process, robotic systems
apply paint to the exterior, while manual painting is done on the inside. Once
completed, the vehicle moves on to the final inspection stage before returning to
assembly

[34]
.

DRY SANDING

Sealing Line Repairs and Inspections

Before the sealing stage, certain body areas may require minor rectifications.
These include sanding the roof to smoothen the surface and repairing any
visible side imperfections. Once these repairs are completed, quality checks are
carried out to detect any remaining flaws such as:
 Marks left by the dosing process
 Imperfections from sanding

SOL Sealing Process

The SOL sealing line emphasizes the visual quality of the applied sealer.
Ensuring a clean and consistent appearance is a top priority. To achieve this,
operators use three distinct types of sealant guns, each suited for specific tasks:
 Pencil Gun – for narrow and precise sealing lines
 Flat Gun – for wider surface coverage
 Blind Gun – for areas with limited accessibility

Throughout this process, the following aspects are closely monitored to maintain
high standards:
 Accumulation of powder dust
 Presence of excessive sealer
 Pinholes in critical areas such as around the lamps
 Overall smoothness and consistency of the sealer application

[35]
2.4 ASSEMBLY SHOP
In the assembly shop the body is loaded on an overhead conveyor. As the
conveyor moves the body, fitments are made at various stations. There are
three Assembly Shops named ASSY-1, ASSY-2 and ASSY-3. Plant 2 and
Plant 3 have similar setup butin Plant-1 there are separate assembly lines for
separate models. The assembly shop has a continuous production system.
The assembly line can be subdivided into the followings: -

Trim line
The vehicle proceeds through a series of Trim workstations where team
members begin by installing weather stripping, moldings and pads. Then they
put in wiring, vents and lights. After an instrument panel, windows, steering
column and bumper supports are added, it starts to look less like a shell and
more like a car.

Chassis Line

This is where many safety-related items are installed. Things like brake lines,
torque,gas tanks and power steering are double-checked. The engine is
installed, along withthe starter and alternator. Then come suspension and
exhaust systems. Then wheel is mounted with the help of wheel nut fastening
machine

Final Line

From there the vehicle enters Final 1, which covers many interior items such
as the console, seats, carpet, glove box and steering wheel. This is also where
bumpers, tires and the battery are added, as well as finishing touches like
covers and vents. Then, Coolant, Brake oil, Power steering oil are filled and
also the A/C gas are charged.

[36]
Features

Different layout configurations are used in the assembly shops to streamline

material movement and minimize handling efforts. These layouts are
specifically designed to improve workflow efficiency and optimize space
utilization:
Straight-Line Layout – Car & Omni Line (Assembly Shop-1):
This is the most straightforward layout where the assembly process starts at
one end of the shop and finishes at the other, allowing smooth, linear
movement of materials.
U-Shaped Layout – Assembly Shops 2 & 3:
In this configuration, both the starting and ending points of the line are
positioned at the same end of the plant. This is typically done to simplify
logistics and reduce the need for multiple forklifts, making material handling
more efficient.
S-Shaped Layout – Esteem Line (Assembly Shop-1):
This serpentine-style layout is adopted to accommodate a longer assembly
process within a confined or square-shaped area.

PROCESS OUTLINE
FDSA-Front Door Sub-Assembly: Both left and right front doors are
removed on ABON and conveyed on this line Parts like out rear view
mirrors, speakers, locking mechanisms, window glasses, window
regulators and electrical connections are installed here.
RDSA-Rear Door Sub-Assembly: Both left and right rear doors are
removed on ABON and conveyed on this line. Window glasses,
window regulator switches, locking mechanisms, speakers etc. are
installed here.
IPSA-Instrument Panel Sub-Assembly: At this line, various dashboard
instruments, driving console, steering column, air conditioning vents,
ove box, etc. are installed.

[37]
EGTM-Engine Transmission Sub-Assembly: Engine and transmission
are coupled together on this line. Some other engine components are
also fitted on this line
RASA-Rear Axle Sub-Assembly: Rear drum brakes, rear wheel hub,
rear and brake lines are fitted and sent to the chassis line where the
rear axle is fitted to the vehicle body.
Trim line 1: From PBOK (Paint Body OK) of paint shop vehicle body
comes to the Assembly plant's ABOK with doors fitted. The doors are
removed and the main vehicle body comes to the Trim line 1 first.
Various components like wire harness, Washer tank, etc. are fitted
here.
Trim line 2: Instrument Panel, Relay box, Forward and Backward
sensors, etc are fitted here.
Chassis or overhead line: On this line, Engine, Front suspension,
Rear axle, Rear suspension, Fuel tank and other underbody
components are fitted. Wearing a helmet is compulsory on this line.
Final line 1: Seats, Wheels and tires, Bumpers, Headlights, taillights
are fitted and coolant and brake oil is filled on this line.
Final line 2: Battery, Battery tray, Doors, etc. is fitted on this line and
systems are checked at further stations.

[38]
2.5 VEHICLE INSPECTION
Before a vehicle is cleared for delivery, it undergoes a comprehensive inspection across several
specialized testing stations. Each station is designed to ensure that the vehicle meets all quality,
safety, and performance standards. The key tests include:

Toe-In Test – Verifies the alignment of the front wheels for proper steering and handling.

Slip Test – Checks for lateral wheel movement to detect alignment or suspension issues.

Headlamp Test – Ensures proper focus and alignment of headlights for optimal visibility.

Appearance Test – Examines the vehicle's exterior and interior for cosmetic defects such as
scratches, dents, or paint inconsistencies.

Drum Test – Simulates driving conditions to evaluate drivetrain and transmission performance.
Brake Test – Assesses the braking system's response, balance, and stopping distance.

Shower Test – Subjects the vehicle to high-pressure water to detect any water leakage through
doors, windows, or body seals.

Road Test – Involves actual driving to observe vehicle behavior, engine performance, suspension
comfort, and noise levels.

2.5.1 Inspection Procedure Overview

During inspection, the vehicle passes through each of the above testing stations in
sequence. At every station, various criteria are evaluated to ensure the vehicle
meets quality standards. Operators use a checklist to record any defects they
identify; if no issues are found, the station is marked as ―OK.‖ Once the vehicle
successfully completes the road test without any reported faults, it moves to the
final check conveyor, where it undergoes a thorough visual inspection.
If any defects are detected at any stage, the vehicle is redirected to the appropriate
repair section based on the nature of the problem, including:
 Assembly repair
 Welding repair
 Paint repair
 Engine assembly repair

[39]
VEHICLE FLOW IN MSIL

WELD SHOP-2.3 PRESS SHOP

PAINT SHOP- 3 PAINT SHOP- 2 PAINT SHOP- 1

KB MACHINE
ASSEMBLY SHOP- 3 ASSEMBLY SHOP- 2 ASSEMBLY SHOP- 1

KB ENGINE SHOP FINISHED VEHICLES YARD

CASTING FROM
VENDORSS
DISPATCHED

[40]
 CHAPTER-3

ABOUT THE PROJECT

In modern industrial environments, servomotors play a critical role in

automation, robotics, and precision machinery. One of the most common
causes of motor failure is insulation breakdown, often due to prolonged stress,
moisture ingress, or thermal aging. Traditionally, insulation resistance is
checked offline using a megohmmeter, which requires the motor to be
disconnected from the power source — leading to downtime and delayed fault
detection.

This project proposes and implements an online insulation monitoring system

using an isometer, allowing real-time detection of insulation degradation without
stopping the motor. An isometer continuously measures the insulation
resistance between live conductors and earth in an operational system. It can
detect both symmetrical and asymmetrical insulation faults, helping to prevent
unexpected breakdowns.

The system integrates an isometer into the servomotor's power line and logs
resistance values over time. When insulation resistance drops below a set
threshold, the isometer triggers an alert. This proactive approach enhances
predictive maintenance, reduces unplanned downtime, and ensures better
equipment safety and reliability.

Key components used in the setup include the servomotor, isometer device
(conforming to IEC 61557-8 standards), and optional interfacing with a PLC or
SCADA for logging and alarms. The implementation has shown that online
monitoring is effective for early fault detection, making it a valuable addition to
modern industrial maintenance strategies.

[41]
3.1 OBJECTIVE
The objective of this project is to implement an online insulation monitoring
system for servomotors using an isometer, enabling real-time detection of
insulation deterioration without interrupting motor operation. This aims to
enhance predictive maintenance and reduce unexpected equipment failures

3.2 WORKING PRINCIPLE:

The working principle of this project is based on continuous monitoring of the
insulation resistance between the live conductors and earth (ground) of a
servomotor using an ISOMETER device

An ISOMETER is an insulation monitoring device that:

1. Continuously checks the insulation resistance in unearthed (IT) systems.

2. Detects gradual degradation or sudden failures in insulation.

3. Triggers alarms when the insulation resistance falls below a predefined

threshold.

3.3 HOW IT WORKS IN THE PROJECT :

Connection to Servomotor:

1. The ISOMETER is connected between the live conductors (phases) of the

servomotor and the protective earth (PE).

2. It can be integrated into the motor control panel or monitoring system.

Monitoring Function:

1. The ISOMETER applies a low DC voltage (measuring voltage) between the

power lines and earth.

2. It measures the leakage current that flows due to insulation resistance.

3.Using Ohm’s Law , it calculates the insulation resistance in real-time.

Real-Time Analysis:

1. The device continuously compares the measured resistance with set

thresholds (e.g., 50 kΩ, 100 kΩ).

[42]
2. If the resistance drops below the threshold, it indicates deteriorating or faulty
insulation.

Alarm & Communication:

1. On detecting low insulation resistance, the ISOMETER triggers an alarm

(visual or audible).

2. In advanced models, it can send alerts to PLC/SCADA systems or

maintenance dashboards for predictive action.
3.4 Tools and Component used :
1. Isometer : This insulation monitoring device is designed for unearthed AC, DC, and
AC/DC systems, making it suitable for applications like servomotor insulation
monitoring.

2. Servometer : Servomotors are essential components in precision motion

control systems, often used in robotics, CNC machinery, and automation.

3. SCADA System : A SCADA system is used for real-time data acquisition and
monitoring of industrial processes, including servomotor performance and insulation
status.

4. PLC (Programmable logic Controller) : PLCs are used to automate control

processes and can interface with ISOMETERs and SCADA systems for integrated
monitoring.:

[43]
3.5 METHODOLOGY:
This section outlines the step-by-step process followed to implement and test the online
insulation monitoring system using an ISOMETER device in a live industrial environment.
System Overview :

A servomotor connected to a control circuit.

An ISOMETER (e.g., Bender IRDH575) integrated for continuous insulation

resistance measurement.

A PLC or SCADA system for data acquisition and visualization.

Communication interfaces (Modbus TCP/IP or RS48)

Installation Process :

Selection of Monitoring Point

Identify the critical servomotor(s) to be monitored

Choose an ungrounded or impedance-grounded system where online insulation

monitoring is suitable.

Connect the ISOMETER terminals across the line conductors (L1, L2, L3) and
earth/ground.

Ensure that the neutral is not directly grounded (ISOMETERs are designed for
ungrounded/IT systems).

Power Supply and Configuration

Provide the appropriate supply voltage to the ISOMETER (typically 24V DC or

230V AC, depending on model).

Program the device to set:-Warning threshold (e.g., 100 kΩ) , Alarm threshold
[44]
(e.g., 50 kΩ) , Configure output relays to interface with PLC or external alarms.

Integration with PLC/SCADA :

Communication Setup - Set up Modbus communication between the

ISOMETER and the SCADA/PLC unit.

Assign Modbus addresses for data registers such as insulation value, fault
status, and device diagnostics.

Data Logging and Visualization - Develop a SCADA interface to visualize real-

time insulation values.

Implement trend analysis charts, alarm histories, and event logs and Enable
automatic logging of readings at defined intervals (e.g., every 1 minute).

Testing and Monitoring

Baseline Measurement - With the motor in a healthy state, record initial

insulation resistance values.

Operational Testing - Run the servomotor under normal working conditions. And
Continuously monitor the insulation resistance via the SCADA system.

Fault Simulation (Optional) - For training or testing purposes, introduce a

controlled fault (e.g., artificial moisture or insulation degradation on a test
motor).

Safety Consideration :

Safety Considerations - Ensure all wiring and installation are performed with the
power isolated.

Documentation and Reporting :

Documentation and Reporting - All installation steps, parameter settings,

readings, and observations were recorded.

Maintenance of the Monitoring System - Periodic inspection of ISOMETER

3.6 OBSERVATIONS :
.

Baseline Readings :

Initial insulation resistance values for the healthy motor were in the range of 2
MΩ to 5 MΩ.

[45]
Resistance values were stable and did not fluctuate significantly under normal
load conditions.

Ambient temperature was recorded at 28–30°C with relative humidity of ~50%

Motor Start-up Behaviour.

During motor startup (when torque demand is high), a temporary dip in

insulation resistance was observed—typically dropping by 10–15% for a few
seconds.

Values returned to baseline within 30–60 seconds after stabilization.

Effect Of Ambient Condition :

On days with higher humidity (above 70%), insulation resistance dropped by

15–20%, even without any change in operating load.

Moisture ingress is known to reduce surface insulation, especially in motors

without proper IP-rated enclosures.

No alarms were triggered, but trend data suggested faster resistance

degradation in humid environments.

Continous Operation :

During 8-hour continuous motor operation, a gradual reduction in resistance

was noted, likely due to heat build-up in the windings.

After 6 hours of operation, insulation resistance reduced from 4.2 MΩ to 3.1 MΩ.

Alarm Trigger Event :

On Day 17, a low insulation resistance alarm was triggered at 48 kΩ (threshold

set to 50 kΩ).

Inspection revealed dust and moisture accumulation in the motor terminal box.

After cleaning and drying, insulation resistance recovered to 3.5 MΩ, and the
alarm cleared.

This validated the accuracy and usefulness of the ISOMETER system in real-
world scenarios.

Trend Analysis :

Data logs showed a clear downward trend in insulation values over time on
motors operating in high-dust zones.

Motors in clean, temperature-controlled environments showed little to no

[46]
degradation over the same period

This emphasized the importance of environmental factors on insulation health.

Response Time and Accuracy :

The ISOMETER responded to insulation resistance changes within 1–2

seconds.

The system’s alarm relay triggered consistently at the set thresholds, with no
false positives observed.

Accuracy was cross-verified using a handheld megohmmeter during offline

maintenance, and results were within ±10% deviation.

Operator and Maintainence Feedback :

Maintenance personnel reported increased confidence in the early detection of

faults.

Reduced need for manual insulation testing during shutdowns

Operators suggested extending the monitoring system to other critical motors..

[47]
 CHAPTER-4
CHALLENGES
4.1 CHALLENGES :

While implementing the online insulation monitoring system using an
ISOMETER, several technical and operational challenges were encountered.
These are explained below
Compatibility with existing system :

Problems : Many industrial motors and panels were already in operation with
grounded systems.
Challenge : ISOMETERs are designed for ungrounded (IT) systems, so
integrating them into grounded (TN or TT) networks required careful planning
and, in some cases, system modifications.
Solution : A dedicated ungrounded power source was created for the test motor
setup to enable proper functionality of the ISOMETER.

Electrical Noise and Interferance :

Problem : Servomotor drive systems generate electromagnetic interference

(EMI) and switching noise.
Challenge : Noise affected ISOMETER readings, leading to fluctuating
resistance values or communication errors with the PLC.
Solution : Proper shielding of cables, use of EMI filters, and isolated signal
grounding helped minimize signal distortion.

Environmental condition :
Problem: The motor operated in a dusty and humid industrial environment.
Challenge : These conditions caused occasional false alarms or reduced
resistance values.
Solution : Sealed motor enclosures and regular cleaning schedules were
implemented to keep terminals and sensors dry and clean.

[48]
Limited Technical Knowledge :
Problem: Maintenance staff were not fully familiar with ISOMETER operation or
Modbus communication protocols
Challenges: Misinterpretation of alarm signals or configuration settings led to
confusion during initial stages.
Solution : Conducted hands-on training sessions for staff on using and
troubleshooting the ISOMETER system.

Communication setup with PLC/SCADA :

Problem Difficulty in setting up Modbus RTU/TCP communication between
ISOMETER and the SCADA/PLC system.
Challenges Register mapping, baud rate mismatches, and device address
conflicts occurred frequently.
Solution : Referred to the ISOMETER’s technical manual for exact register
mapping and tested connections using Modbus simulation software before final
deployment.

Calibration and Sensitivity Issues :.

Problem Variations in insulation values were sometimes too sensitive, triggering
warnings even during acceptable conditions
Challenges Determining the correct alarm and warning thresholds without
generating nuisance alarms was difficult.
Solution Threshold values were gradually optimized based on motor behavior
trends and historical data.

Difficulty in Fault Localization:

Problem : While the ISOMETER could detect a drop in insulation resistance, it
could not identify the exact location of the fault.
Challenges: Required manual checking of cables, terminals, and windings to
isolate the issue.
Solution : This limitation was acknowledged, and fault location systems (e.g.,
EDS series from Bender) were recommended for future upgrades.

[49]
4.2 BENEFITS :

1. Continuous Monitoring (24/7 Real-Time Insight)

Insulation degradation can occur suddenly. Online systems continuously track
insulation resistance, enabling immediate detection of faults as they develop—
without needing scheduled downtime.
2. Predictive Maintenance
Online data helps detect early signs of insulation failure (e.g., gradual drop in
resistance values).

3. No Production Downtime
Traditional insulation testing requires equipment shutdown. Online monitoring
allows testing while the system is energized and running.Especially important in
industries where stopping production causes significant losses (e.g.,
pharmaceuticals, automotive, steel plants).

4. Improved Equipment Longevity

Regular feedback on insulation health prevents equipment from being pushed to
the point of catastrophic failure.
Extends the usable life of motors and associated components by avoiding stress
from hidden electrical faults.

5. Enhanced Safety
Reduced risk of electrical fires or shock due to deteriorating insulation.Alarms
can be configured to alert staff when resistance drops below safe thresholds,
enabling fast response.

6. Data Logging and Analysis

Integration with SCADA/PLC systems allows historical data tracking, enabling
engineers to spot patterns and potential risk areas over time.

7. Cost Efficiency
Reduces emergency maintenance costs and losses due to equipment damage. .

[50]
 CHAPTER-5
CONCLUSION
The project titled ―Online Servomotor Insulation Checking through ISOMETER‖
aimed to implement a real-time, non-intrusive monitoring system for assessing
the insulation health of servomotors in industrial environments. Through the
successful deployment and testing of the ISOMETER device, the project
demonstrated the critical importance of continuous insulation monitoring as part
of a predictive maintenance strategy.
Insulation failure is one of the most common and potentially catastrophic faults
in electrical motors. Traditional offline insulation tests, while effective, are limited
in their ability to detect real-time deterioration and require shutdowns, which are
not always feasible in continuous production environments. By integrating an
ISOMETER into the system, insulation resistance values were continuously
monitored without interrupting motor operation. This approach allowed for early
detection of insulation degradation, which in turn enabled timely maintenance
interventions, minimized downtime, and improved overall system reliability.
The project highlighted several key technical aspects, including :
 The importance of configuring correct warning and alarm thresholds.
 The need for compatibility with ungrounded or isolated systems.
 Challenges in PLC/SCADA integration and the need for skilled
personnel.
Despite facing challenges related to communication setup, environmental
interference, and calibration, the system proved to be both reliable and scalable.
These challenges were systematically addressed through proper engineering
practices and iterative testing.

In conclusion, the project successfully met its objectives and demonstrated the
value of online insulation monitoring using ISOMETERs in industrial automation
environments. This technology can be a valuable tool for maintenance
engineers, helping to improve uptime, reduce operational costs, and extend
equipment life. The project also contributes to the broader movement toward
Industry 4.0, where real-time monitoring and intelligent decision-making are
essential.

[51]
REFERENCES

 Maruti Suzuki Cars in India – ARENA, NEXA, TRUE VALUE and COMMERCIAL
chanels
 Global Suzuki

[52]
53 | Internship Report 2025 21001002019
54 | Internship Report 2025 21001002019