A

Report
on

INDUSTRIAL TRAINING AT MARUTI

SUZUKI

TITLE: OPTIMIZING BILLET CUTTING

OPERATION

DEPARTMENT OF MECHANICAL ENGINEERING

HBTU KANPUR

SUBMITTED TO: SUBMITTED BY:

PROF (Dr.) S.K.S YADAV ARYAMAN PAINULY
PROF (Dr.) S.K. SINGHAL ROLL NUMBER: 210110015
CERTIFICATE OF COMPLETION

1
 ACKNOWLEDGEMENT

I would like to express my heartfelt gratitude to everyone

who made my training at Maruti Suzuki a valuable and
enriching experience.

Firstly, I extend my sincere thanks to my mentors, Mr. Dhiraj

Kapoor San (DPM), Mr. Ajay Mendiratta San (DVM), Mr.
Rohit Shukla San (GM), Mr. Vishu Chauhan San, Mr.
Rameshwar San, and Mr. Sanjay Singh San, for their
invaluable guidance, support, and insights throughout the
training. Their expertise and encouragement helped me
gain practical knowledge and skills that will bene it my
professional growth.

I am also deeply thankful to Dr. Anand Kumar (HOD, MEd),

Dr. S.K.S. Yadav (Faculty In charge: Training) from my
university for their continuous support and guidance,
which played a crucial role in facilitating my learning
experience.

I am grateful to Maruti Suzuki and my university for

providing me with this opportunity to grow and learn in
such a prestigious environment.

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 TABLE OF CONTENTS
TITLE PAGE NO.
CERTIFICATE 1
ACKNOWLEDGEMENT 2
HISTORY 04-08
PLANTS 09-11
PRINCIPLES 12
POWERTRAIN PLANT 13-14
TRANSMISSION PLANT 14-17
FORGING SHOP 18-22
PROCESS FLOW 23-24
PRODUCTS 25
PROJECT 26-32
CONCLUSION 33
BIBLIOGRAPHY 34

3
 A BRIEF HISTORY OF MARUTI SUZUKI
Founding and Early Years
Maruti Suzuki India Limited (MSIL), formerly known as Maruti Udyog
Limited, is one of the leading automobile
manufacturers in India. It was founded in 1981 as
a joint venture between the Government of India
and Suzuki Motor Corporation, a Japanese
automobile and motorcycle manufacturer. The
primary objective behind establishing Maruti Udyog was to develop an
affordable, ef icient car that would cater to the growing needs of the middle
class in India.
The 1970s marked the beginning of India's ambitious plans to develop an
indigenous automobile industry. Sanjay Gandhi, the younger son of then-
Prime Minister Indira Gandhi, envisioned producing a small car for the
Indian masses, which led to the conception of Maruti Udyog. However,
following Sanjay Gandhi's untimely death in 1980, the project stalled
temporarily. In 1981, the Government of India revived the project and
entered a collaboration with Suzuki Motor Corporation, leading to the
establishment of Maruti Suzuki.
The Launch of the Maruti 800
One of the most iconic models in the
company’s history, the *Maruti 800*, was
launched in 1983. This compact car
revolutionized personal transportation in
India, providing millions with access to
affordable and reliable vehicles. It was based on the Suzuki Alto and became
synonymous with India’s car-buying culture. The launch of the Maruti 800
was a pivotal moment, as it became a symbol of economic growth and
modernization, marking the start of a new era in the Indian automotive
industry.
With a 796cc engine, the Maruti 800 was fuel-ef icient, easy to maintain, and
extremely affordable compared to other vehicles available at the time. This
made it an instant success. Maruti Udyog quickly became a dominant player

4
in the Indian car market, capturing the aspirations of the middle-class
population.
Expansion and Growth
After the initial success of the Maruti 800, the company steadily expanded its
product lineup. The late 1980s and early 1990s saw the introduction of other
models, such as the *Maruti Omni, a multi-purpose van, and the **Maruti
Gypsy*, a rugged off-road vehicle, which became popular with military and
law enforcement agencies.
Throughout the 1990s, India witnessed liberalization of its economy, which
spurred further growth for Maruti Suzuki. The company bene ited from
increased competition and foreign investment, becoming more ef icient in
production and diversifying its product range. In 1993, Maruti launched the
*Maruti Zen*, another hatchback model that gained immense popularity.
By the early 2000s, Maruti Suzuki had established itself as the leading car
manufacturer in India, capturing over 50% of the market share. The
company's reputation for building reliable, fuel-ef icient, and affordable
vehicles helped it secure a loyal customer base.

The Transition to Maruti Suzuki

In 2003, the company rebranded itself as *Maruti Suzuki India Limited*
(MSIL), further cementing the relationship between the Indian and Japanese
partners. Over the years, Suzuki increased its equity stake in the company,
and by 2007, the Government of India divested its remaining stake, making
Maruti Suzuki a fully Suzuki-controlled subsidiary.

5
The 2000s were also marked by the launch of some of the company’s most
successful models. The *Maruti Swift*, introduced in 2005, became a game-
changer in the premium hatchback segment, appealing to younger buyers
and further broadening the company’s customer base. The Swift combined
style, performance, and affordability, which resonated well with the Indian
market.
Technological Advancements and Innovations
As Maruti Suzuki grew, the company began to focus on
improving its technological capabilities, introducing
advanced features, and adopting global best practices in manufacturing. In
the 2010s, Maruti Suzuki began producing
cars with advanced safety features, such as
airbags, ABS (Anti-lock Braking System),
and structural reinforcements that
complied with international safety norms.
The company's *Suzuki Connect* platform,
launched in 2018, brought telematics and connected car technologies to the
Indian market, offering features like remote vehicle monitoring, driving
behaviour analysis, and emergency noti ications.
In terms of fuel ef iciency, Maruti Suzuki has been a pioneer in introducing
small, fuel-ef icient petrol and diesel engines, including Suzuki's innovative
*K-Series engines*. These engines offered a balance of power, ef iciency, and
reduced emissions, aligning with the company’s focus on eco-friendly and
affordable cars.
Product Line and Specialization
As of 2023, Maruti Suzuki has produced a diverse
range of vehicles, catering to different segments of
the Indian market, including hatchbacks, sedans,
SUVs, and multi-purpose vehicles (MPVs).
Maruti Suzuki's specialization lies in producing
affordable, fuel-ef icient cars tailored for Indian road conditions and
customer preferences.

6
 It delivers all through 2 sales channels, namely,
Arena and Nexa.
Manufacturing and Production Milestones
Maruti Suzuki operates several manufacturing
plants across India, including in Gurugram and Manesar in Haryana, and
Hansalpur in Gujarat. Together, these plants have a production capacity of
over 1.5 million vehicles per year. The company has also focused on ensuring
that its manufacturing processes are environmentally friendly, with several
plants being ISO 14001 certi ied for environmental management.
As of 2023, Maruti Suzuki has produced over 25 million cars since its
inception. This makes it the largest car manufacturer in India by volume and
one of the largest globally.
Export Market
While Maruti Suzuki’s primary market has always been India, the company
began exporting vehicles in 1986. It initially exported the *Maruti 800* to
neighbouring markets, and later expanded its export footprint to Europe,
Latin America, Africa, and Southeast Asia.
In recent years, the company has increased its focus on the export market,
with models like the Baleno, S-Presso, and Alto being popular in countries
outside India. Maruti Suzuki exports to over 100 countries and has become
a key player in Suzuki’s global supply chain.
Sustainability and Electric Vehicles
As the world moves toward greener transportation, Maruti Suzuki has
committed to reducing its carbon footprint and developing eco-friendly
vehicles. The company has introduced several mild-hybrid models,
incorporating Suzuki's SHVS (Smart Hybrid Vehicle by Suzuki) technology,
which enhances fuel ef iciency and reduces emissions.
Maruti Suzuki is also working on electric vehicles (EVs) for the Indian
market. In collaboration with Toyota, the company is expected to launch its
irst all-electric vehicle by 2025. The government’s push towards electric
mobility, along with Maruti Suzuki’s plans to build EVs, shows the company’s
commitment to staying ahead in the industry’s transition to cleaner
transportation.
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 Challenges and Future Outlook
Despite its tremendous success, Maruti
Suzuki has faced challenges over the years,
including increased competition from
global players like Hyundai, Tata Motors,
and Kia. The rising cost of raw materials,
emission regulations, and the shift towards
electric vehicles have also presented challenges.
To maintain its leadership in the Indian market, Maruti Suzuki has focused
on innovation, customer satisfaction, and expanding its product portfolio.

8
 PLANTS
Maruti Suzuki is India’s largest car manufacturer, and to meet its growing
demand and maintain leadership, the company has developed a robust
network of manufacturing plants across the country. These plants are
strategically located to ensure ef icient production, logistics, and distribution
to both domestic and export markets. Below is an in-depth look into Maruti
Suzuki’s current manufacturing facilities, as well as upcoming developments
that will shape the company's future.
1. Gurugram Plant (Haryana):
The Gurugram plant is Maruti Suzuki’s oldest
and one of its most signi icant production
facilities. Established in 1983, this plant played
a crucial role in the company’s early growth. It
has an annual production capacity of around
700,000 units. The plant is highly integrated,
producing everything from engines to car body
parts.
Key Features:
 Spread over 300 acres, it includes three fully operational assembly
lines.
 It manufactures popular models like the Alto, Wagon R, Ertiga, and S-
Cross.
 The plant also has dedicated facilities for training, research, and
development (R&D) and is instrumental in Maruti's technological
advancements.

2. Manesar Plant (Haryana):

The Manesar plant, located about 25 kilometers
from Gurugram, is one of Maruti Suzuki's most
modern and ef icient plants. Operational since 2007,
this facility was built to handle the increasing
demand for Maruti’s vehicles. The Manesar plant currently has a production

9
capacity of over 800,000 units annually, split across three fully automated
assembly lines.
Key Features:
 The plant produces models such as the Swift, Baleno, and Dzire, which
are some of Maruti's best-selling vehicles.
 It houses some of Maruti Suzuki’s most advanced production
technologies, including robotic assembly and eco-friendly practices to
reduce emissions and waste.
 A strong focus on automation ensures high precision and consistency
in vehicle production.
3. Suzuki Motor Gujarat Plant (SMG) (Gujarat):
Located in Hansalpur, Gujarat, this plant represents
a signi icant milestone for Maruti Suzuki, as it is
wholly owned by Suzuki Motor Corporation and acts
as a supplier to Maruti Suzuki India Limited. The
Gujarat plant started operations in 2017 and is
primarily focused on producing small cars for both domestic and export
markets.
Key Features:
 The plant currently has a production capacity of 750,000 units
annually with plans for expansion.
 SMG plays a vital role in the company’s export strategy, with models
like the Baleno and Swift produced here for international markets.
 This plant operates on green manufacturing principles, with rainwater
harvesting systems, solar energy initiatives, and a focus on energy
ef iciency.
4. Maruti Suzuki Research and Development Center, Rohtak (Haryana):
Maruti Suzuki's *Rohtak R&D Centre* is a state-of-
the-art facility located in Haryana, India. It was
established to focus on the development, testing, and
validation of new vehicles and technologies, including
safety and emission standards. Spread over *600
acres*, it houses advanced labs for crash testing, engine development, and
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vehicle performance evaluation. This center plays a crucial role in Maruti
Suzuki’s innovation and product development, especially for
the Indian market.
5. Upcoming Manufacturing Plants:
Kharkhoda Plant (Haryana):
To keep pace with growing demand, Maruti Suzuki is
setting up a massive manufacturing facility in Kharkhoda,
Haryana. The construction for this plant began in 2022, and it is expected to
be operational by 2025. This plant will be one of Maruti’s largest production
hubs.

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 COMPANY’S PRINCIPLES
3M: MUDA, MURI & MURA
 MUDA: Waste
 MURI: Overburden
 MURA: Unevenness
Muda, Muri & Mura are Japanese terms that refer to the three categories of
waste found in a business. Understanding each is key to implementing
proper lean manufacturing processes.

3K: KIMERAARETA, KIHON DORI & KICHIN TO MAMORA

 KIMERAARETA: What has been decided
 KIHON DORI: Exactly as per the standard
 KICHIN TO MAMORA: Must be followed
3K means “What has been decided must be followed exactly as per the
standard”. This concept is displayed prominently at workplace across
company.

3G: GEMBA, GENGITSU & GEMBUTSU

 GEMBA: Go to the spot
 GENGITSU: Check facts and igures
 GEMBUTSU: Examine the object
3G is method used to gather fact about problem of gap. Whenever a
problem occurs there are facts related with it, these facts are product on
which problem occurs, place where problem is reported and when problem
is reported.

5S: - SEIRI, SEITON, SEISO, SEIKETSU & SHITSUKE

 SEIRI: Sort
 SEITON: Set in order
 SEISO: Shine
 SEIKETSU: Standardize
 SHITSUKE: Sustain
5S describes how to organize a workspace for ef iciency and effectiveness
by identifying

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 MARUTI POWERTRAIN PLANT
The MPT (Manufacturing, Powertrain, and Transmission) plant at Manesar,
operated by Maruti Suzuki, is one of the key facilities focused on producing
engines and transmission systems. This plant is critical to the company’s
overall production ecosystem, supporting the assembly of various Maruti
Suzuki models.
Key Features of Maruti Suzuki's MPT Plant in Manesar:
1. Location and Signi icance:
Situated within the broader Manesar manufacturing complex, this plant
complements the vehicle assembly lines at the site.
It specializes in the production of engines and transmission units, which are
integral to the manufacturing process of cars like the Swift, Dzire, Baleno,
and others.
2. Production Capabilities:
The MPT plant has a substantial annual production capacity, capable of
manufacturing over 1 million engines and transmission units.
The facility is responsible for producing both petrol and diesel engines,
though in recent years, Maruti Suzuki has phased out its diesel engine
production to focus on more ef icient and environmentally friendly petrol
and hybrid engines.
3. Powertrain Manufacturing:
The plant produces advanced K-series petrol engines, which are known for
their fuel ef iciency, lightweight construction, and adherence to stringent
emissions standards like BS6.
The engines produced at this facility power a wide range of Maruti Suzuki’s
best-selling models, ensuring smooth performance and reliability.
4. Transmission Systems:
In addition to engines, the plant also manufactures manual and automatic
transmission systems, which are used across different models, from
hatchbacks to sedans and SUVs.

13
This includes the production of 5-speed manual transmissions as well as
automated manual transmission (AMT) systems, which Maruti Suzuki has
been popularizing in India for its affordability and ease of use.
5. Technological Advancements:
The MPT plant employs advanced automation and robotic technologies to
maintain high standards of precision and ef iciency in engine and
transmission production.
Continuous quality checks and sustainability measures are integrated into
the production processes to ensure minimal wastage and adherence to eco-
friendly manufacturing practices.
6. Role in Maruti Suzuki’s Strategy:
The MPT plant at Manesar plays a pivotal role in ensuring that Maruti Suzuki
maintains its competitive edge in the small car segment by producing
ef icient and reliable powertrains at a large scale.
With a focus on fuel-ef icient engines and low-cost production, the plant
helps Maruti maintain its leadership in the Indian automobile market,
particularly in the affordable car category.
Sustainability Initiatives:
The Manesar MPT plant, like other Maruti Suzuki facilities, adheres to green
manufacturing practices. It incorporates measures like energy-ef icient
machinery, recycling, and waste minimization.
The plant also implements water conservation methods and is gradually
adopting more eco-friendly technologies to reduce its carbon footprint. It has
a water treatment plant and a waste management facility.

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 TRANSMISSION PLANT
The Maruti Suzuki MPT (Manufacturing, Powertrain, and Transmission)
Transmission Plant at Manesar is a state-of-the-art facility dedicated to
producing a wide range of transmission systems for Maruti Suzuki’s vehicles.
This plant plays a critical role in supplying gearboxes, both manual and
automated, that are used across various models, from hatchbacks to sedans
and SUVs.
Overview of the MPT Transmission Plant:
The plant is an advanced facility equipped with modern technologies and
automation processes, ensuring high precision and ef iciency in
transmission manufacturing. It primarily focuses on manual transmissions
(MT) and automated manual transmissions (AMT).
Key Areas and Shops at the MPT Transmission Plant:
1. Gear Manufacturing Shop:
 This shop is responsible for the production of gears, which are critical
components in any transmission system.
 High-precision CNC (Computer Numerical Control) machines and gear
hobbing machines are used to cut and shape the gears.
 The facility ensures that each gear meets strict tolerance levels to
ensure smooth functioning of the transmission system.
 The gear manufacturing process includes heat treatment and inishing
to ensure durability and optimal performance under various driving
conditions.
2. Transmission Assembly Shop:
 This is where the different components of the transmission, such as
gears, shafts, and synchronizers, are assembled into fully functional
transmission units.
 The assembly shop uses robotic arms and automated assembly lines
to ensure precise itting of parts, minimizing human error and
increasing ef iciency.
 Transmission units are assembled with a focus on both manual and
automated systems, depending on the model they are intended for.

15
  For the AMT (Automated Manual Transmission) units, electronic
control modules (ECM) and actuators are integrated during the
assembly process.
3. Machining Shop:
 This section is dedicated to machining parts like shafts and housings
for the transmission systems.
 Using high-speed machining centers, the shop ensures that all parts
are manufactured with high accuracy to ensure a smooth assembly
process.
 Parts undergo multiple stages of milling, drilling, grinding, and
polishing to achieve the exact speci ications required for the
transmission unit.
4. Testing and Quality Control Shop:
 Every transmission unit undergoes rigorous quality checks and testing
before it is dispatched for vehicle assembly.
 The testing shop uses sophisticated testing rigs that simulate real
driving conditions to evaluate the performance of the transmission
systems.
 Tests include load testing, vibration analysis, and durability testing to
ensure that the transmission can handle varying loads, road
conditions, and driving styles without issues.
 AMT units are tested for their automated shifting accuracy, response
times, and overall performance under different conditions.
5. Heat Treatment Shop:
 The heat treatment process is critical for improving the strength and
durability of transmission components, especially gears and shafts.
 The plant’s heat treatment shop uses induction heating and hardening
processes to enhance the toughness of components, ensuring they can
withstand wear and tear over the vehicle’s lifespan.
 The heat-treated parts are then cooled and tempered in a controlled
environment to achieve the desired mechanical properties.
6. Paint Shop (For Transmission Cases):

16
  The transmission cases and housings are treated in the paint shop to
ensure corrosion resistance and durability.
 After machining, the cases undergo a thorough cleaning process to
remove any debris or oil, followed by electrostatic powder coating to
ensure uniform coverage.
 The coating ensures protection against rust, especially for vehicles
used in harsh environments.
Other Notable Features of the Plant:
1. Automation and Robotics:
The plant is heavily automated, with robots performing many of the tasks
that require high precision, such as assembling the synchronizers and gears
into the transmission system.
2. Logistics and Material Handling:
The plant uses automated guided vehicles (AGVs) for internal logistics,
moving parts between different sections of the plant.
This not only improves ef iciency but also minimizes the chances of human
errors during the material handling process.
3. Energy Ef iciency and Sustainability:
The transmission plant is designed with energy ef iciency in mind. It
incorporates several green practices, such as the use of energy-ef icient
lighting and recycling systems for waste materials.
The facility also has rainwater harvesting and solar power generation
systems, contributing to Maruti Suzuki’s larger sustainability goals.

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OVERVIEW OF FORGING SHOP AND PROCESSES AT THE
TRANSMISSION PLANT

The forging shop is equipped with advanced machinery and follows strict
procedures to produce high-strength components. The forging process
typically involves billet cutting, hot forging, cold forging, isothermal
annealing, and shot blasting to re ine and strengthen metal parts.

1. Billet Cutting:

 Billet is the raw material, usually made of steel

or other metals, which is prepared for forging.
Billets are long cylindrical or square pieces of
metal.
 In the billet cutting process, the billet is cut
into smaller, speci ic lengths according to the size required for the
component being forged.
 Precision shearing machines or sawing machines are used to cut the
billets accurately, ensuring minimal wastage of material.

2. Hot Forging:

Hot forging is the process of shaping metal at high temperatures (typically

between 950°C to 1250°C for steel) to make it more malleable and reduce
the risk of cracking during deformation.
In the hot forging process:
 The billets are heated in a furnace until they reach the required forging
temperature.
 Once heated, the metal is placed in forging dies where high-pressure
mechanical or hydraulic presses are used to shape the metal into the
desired form.
 Hot forging is used for making large and complex parts such as gears,
shafts, and hubs, which need high strength and toughness.
 The heat reduces the material’s resistance to deformation, allowing
the material to low into the shape of the die with precision.

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3. Cold Forging:

Cold forging is a process where the metal is shaped at room temperature.

While it requires higher pressure than hot forging, it offers several
advantages such as improved surface inish, better dimensional accuracy,
and increased strength due to strain hardening.
In cold forging:
 The billet is cut to size and then fed into forging dies at room
temperature.
 High-pressure presses (with tons of pressure) shape the billet into the
desired form without the application of heat.
 Cold forging is generally used for smaller, less complex parts like
fasteners and smaller transmission components where precision and
surface inish are more critical.

4. Isothermal Annealing:

After forging, the metal parts undergo a process known as isothermal

annealing to reduce internal stresses, re ine the microstructure, and improve
the mechanical properties of the parts.
Isothermal annealing involves heating the forged part to a temperature
where recrystallization occurs, and then cooling it slowly in a controlled
environment, typically at a constant temperature.
This process:
 Improves the ductility and toughness of the parts.
 Helps in re ining grain size, leading to better mechanical properties
such as fatigue resistance and impact strength.
 Is used particularly for gears and shafts, where uniform mechanical
properties are crucial for performance under high loads.

5. Shot Blasting:

Once the forging and annealing processes are completed, parts undergo shot
blasting to remove scale, rust, or any residue left on the surface due to forging
and heat treatment.

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Shot blasting machines use small metallic pellets (shots) ired at high
velocity to clean and polish the surfaces of the forged parts.
This process:
 Ensures a smooth surface inish free from impurities.
 Enhances the appearance and prepares the parts for further
machining or inishing processes, such as coating or assembly.
 Also helps in improving the fatigue strength of the components by
introducing compressive stress on the surface, reducing the likelihood
of cracks or failures.

6. Post-Forging Machining (Secondary Process):

After forging and shot blasting, the components are often sent for secondary
machining to achieve precise dimensions and tight tolerances required for
transmission parts.
CNC (Computer Numerical Control) machines and other precision tools are
used to perform drilling, milling, grinding, and inishing processes to achieve
the inal shape and speci ications of the part.

Key Equipment in the Forging Shop:

Mechanical and Hydraulic Forging Presses: These presses apply the
necessary force to shape the metal during hot or cold forging processes. The
size of the press can vary depending on the size and complexity of the
component.
Induction Furnaces: These are used to heat billets to the required
temperature during the hot forging process.
Automated Billet Cutters: High-precision machines cut raw billets to the
desired length and shape before the forging process.
Shot Blasting Machines: Automated machines that ire metal shots at high
speed to clean the surfaces of the forged parts.
Heat Treatment Ovens: Used for isothermal annealing and other heat
treatment processes to relieve stresses and improve the metallurgical
properties of the forged components.
Quality Control
Throughout the forging process, components are subject to stringent quality
checks to ensure they meet the required strength, hardness, and dimensional
speci ications.

20
Ultrasonic testing, hardness testing, and visual inspections are used to
identify any laws or defects such as cracks, porosity, or improper material
low in the forged parts.

RAW MATERIAL

SCR40H3V2 is a high-strength alloy steel known for its robustness, wear

resistance, and durability. It is primarily used in applications requiring
superior toughness and the ability to withstand heavy mechanical stress.
This alloy typically contains elements like chromium, vanadium, and silicon,
which enhance its overall mechanical properties and performance.
Key characteristics of SCR40H3V2 include:
 High Strength: This alloy is capable of enduring high tensile stresses,
making it suitable for industrial use, especially in heavy machinery.
 Wear Resistance: The presence of chromium and vanadium ensures
that the material can resist wear and tear, even in harsh environments.
 Good Toughness: SCR40H3V2 maintains its structural integrity under
impact, making it ideal for tools, components, and machine parts that
face continuous mechanical stress.
 Heat Resistance: With a high level of heat resistance, this steel is used
in operations where it might be exposed to high temperatures without
losing its strength or deforming.
This material is commonly used in industries like automotive,
manufacturing, and heavy machinery, where durability and mechanical
resilience are crucial for performance and safety.
A typical composition of this alloy might look like:
 Carbon (C): ~0.35-0.45% – Provides hardness and strength.
 Chromium (Cr): ~0.9-1.2% – Increases wear resistance, corrosion
resistance, and toughness.
 Vanadium (V): ~0.15-0.25% – Enhances hardness, strength, and wear
resistance.
 Manganese (Mn): ~0.5-0.8% – Improves toughness and
hardenability.
 Silicon (Si): ~0.15-0.35% – Adds strength and toughness while
improving the steel's deoxidation during production.
 Phosphorus (P): ≤0.030% – A very small amount to limit brittleness.

21
  Sulphur (S): ≤0.030% – Kept to a minimum as higher sulphur content
can reduce the steel’s toughness.

BRANDS USED:

IMPORT (JAPAN)
 SANYO
 DAIDO
 OKAYA

DOMESTIC MARKET
 SUNFLAG STEEL

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 PROCESS FLOW INSIDE THE FORGING SHOP

PRODUCTION OF HIRA, ATSUNYU AND ITTAI GEARS

GEAR PRODUCTION
PRODUCTION
S.NO PROCESS MACHINE USED
RATE
Unloading of Raw Komatsu Gaur 115 Forklift, Daido
1
Material Overhead 1T Crane
Bar cutting as per
2 MANYO BILLET CUTTER 40 SPM
weight (Shearing)
20 SPM (
Induction heating HIRA,
3 KURIMOTO
of billets ATSUNYU) 10
SPM (ITTAI)
20 SPM (
Hot forging HIRA,
4 HFTP - 1600T
process ATSUNYU) 10
SPM (ITTAI)
Short Blasting to
5 SINTO 17.5 KG/MIN
remove scales
Isothermal
6 DAIDO 17.5 KG/MIN
anhealing
(BONDE)
Lubrication
Coating to reduce
7 RCD 9 SPM
friction between
component and
dies
Cold forging and
coining process
Manual Press/Komatsu 1000T/ AIDA
8 (Back taper and 9 SPM
630T
ITAYI GEAR is
obtained)

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 PRODUCTION OF 2-WHEELER, 4-WHEELER SHAFTS AND DOG GEAR

SHAFT & DOG GEAR PRODUCTION

S.NO PROCESS MACHINE PRODUCTION RATE
Billet cutting for
1 Circular Saw (TSUNE) 6 SPM
forging
2 Scale removal Shot Blast (SINTO) 17.5 KG/MIN
3 Lubrication Bonde (NIPPU) 17.5 KG/MIN
CFT Press (Kurimoto
4 Forging 20 SPM
1000T)
5 Anhealing Daido IA Furnace 17.5 KG/MIN
For Dog Gear Komatsu 630 T manual
6 9 SPM
coining/back taper press
For Dog gear back
7 Aida 250T manual press 9 SPM
taper

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 PRODUCTS

 Input Shaft: The input shaft receives power from the engine of the car
and transmits it to the counter shaft. It has gears and sleeves itted on
it of varying sizes for different speeds.

 Counter Shaft: The counter shaft is directly in contact with the input
shaft via gears and receives power from it and delivers it to the inal
gear which carries the differential mechanism.

 ITTAI Gear: It is used as the 1st and 2nd gear on the counter shaft and
the 5th gear of the input shaft.

 ATSUNYU Gear: It is used as the 3rd and 4th gear of the input shaft.

 HIRA Gear: It is used as the 3rd 4th and 5th gear of the counter shaft.

 DOG Gear: It is press itted on the ATSUNYU Gear and is used for
meshing purpose.

 Final Gear: It receives power from the counter shaft and is attached to
the differential mechanism.

 Sleeves for low, high and 5th speed gears

25
 PROJECT

TITLE: OPTIMIZING BILLET CUTTING (SHAFTS) EFFICIENCY

PROBLEM STATEMENT:
As per the current standards, 20 specimens can be obtained from a single
rod. Increase it to reduce wastage and improve costs.

SPECIMEN DETAILS:

 TYPE: SCR40H3V2
 BRAND: DAIDO
 DIAMETER: 34 MM ± .5
 ROD LENGTH: 5523 MM ± 10

AREAS OF CONCERN:
 Reduction in waste from raw material
 Increase in the number of shafts obtained.
 Opting for higher ef iciency in process low.

MEASURES OPTED:
 Nesting and generating a genetic algorithm for cutting operation.
 Machine Optimization through updated G-code

NESTING AND GENETIC ALGORITHM:

Nesting in manufacturing, particularly in the context of machining, refers to

the process of arranging multiple parts or components to be cut from a single
sheet or material block in a way that maximizes material utilization and
minimizes waste. It is commonly used in industries such as sheet metal
fabrication, woodworking, textiles, and plastics.

Key Features of Nesting:

 Material Optimization: Nesting ensures that parts are placed
ef iciently, reducing scrap material and maximizing the use of raw
materials.
26
  Automated Software: Many manufacturers use nesting software to
automate the layout process, as it can handle complex shapes and
make optimal decisions quickly.

A genetic algorithm (GA) is an optimization technique inspired by the

principles of natural selection and genetics. It is used to solve both
constrained and unconstrained optimization problems and is particularly
useful for problems where the search space is large and complex.

MACHINE SPECIFIACTIONS:

TSUNE TK5C 101GL

 BLADE DIA: 14.0"

 Capacity: .6" to 4.33" Steel
 Carbide cap. Solid steel .98" to 3"
 Capacity cutting round tube: 5.12"
 Square tube: .6" to 4.33"
 Carbide saw diameter: 360mm/ 14"
 HSS saw diameter: 420mm/16.5"
 Saw head feed type: Hydraulic
 Material feed one stroke: 24"
 Shortest cut off (Part length): .4"
 Remnant length: 3.3"
 Blade speeds: 12-120 RPM
 Loading magazine: Incline type
 max bar length: 20'
 Main Saw motor: 15 HP
 Coolant tank capacity: 38 Gallons
 Operating Dimensions: 305" x 84" x 76" High
 Weight: 7,850 Lbs.
Shipping Dimensions
 machine = 8' 6" x 7' x 6' high
 bar feed = 15' x 5' x 4' 6" high

27
STEPS TAKEN:
 Generation of optimum length of work piece using nesting software.
 Generation of genetic algorithm for inding the appropriate cutting
pattern according to the lengths generated by nesting.
 Optimization of machine by updating the G-CODE running the CNC on
the TSUNE billet cutter.

GENETIC ALGORITHM:

import random
# Constants based on earlier info
rod_length = 5523 # Length of each raw material rod in mm
shaft_lengths = [262, 262.3, 262.5, 262.7] # Possible shaft lengths
desired_shafts_per_rod = 21 # Number of shafts to cut from each rod
total_rods = 47 # Total number of rods available

# Genetic Algorithm Parameters

population_size = 100
generations = 1000
mutation_rate = 0.05

# Function to initialize population

def initialize_population(pop_size, num_rods, num_shafts_per_rod):
return [[[random.choice(shaft_lengths) for _ in
range(num_shafts_per_rod)] for _ in range(num_rods)] for _ in
range(pop_size)]

# Function to calculate itness

def calculate_ itness(individual):
total_wastage = 0
for rod in individual:
rod_length_used = sum(rod)
wastage = rod_length - rod_length_used
total_wastage += wastage
return 100 / (1 + total_wastage) # Adjusted itness function based on
wastage minimization

28
# Function for selection based on itness proportionate selection (roulette
wheel)
def selection(population, itness_scores):
return random.choices(population, weights= itness_scores, k=2)

# Function for single-point crossover

def crossover(parent1, parent2):
crossover_point = random.randint(1, len(parent1) - 1)
child1 = parent1[:crossover_point] + parent2[crossover_point:]
child2 = parent2[:crossover_point] + parent1[crossover_point:]
return child1, child2

# Function for mutation

def mutation(individual):
mutated_index = random.randint(0, len(individual) - 1)
for shaft in range(len(individual[mutated_index])):
individual[mutated_index][shaft] = random.choice(shaft_lengths)
return individual

# Genetic Algorithm
def genetic_algorithm(population_size, generations, mutation_rate,
num_rods, num_shafts_per_rod):
population = initialize_population(population_size, num_rods,
num_shafts_per_rod)
for gen in range(generations):
itness_scores = [calculate_ itness(individual) for individual in
population]
new_population = []

for _ in range(population_size // 2):

parent1, parent2 = selection(population, itness_scores)
child1, child2 = crossover(parent1, parent2)

if random.random() < mutation_rate:

child1 = mutation(child1)

29
 if random.random() < mutation_rate:
child2 = mutation(child2)

new_population.append(child1)
new_population.append(child2)

population = new_population

# Optional: Early stopping criteria if desired itness is achieved

best_individual = max(population, key=calculate_ itness)
best_ itness = calculate_ itness(best_individual)
if best_ itness >= 97.6: # Example threshold based on earlier info
break

best_individual = max(population, key=calculate_ itness)

best_ itness = calculate_ itness(best_individual)
total_wastage = sum([rod_length - sum(rod) for rod in best_individual])
return best_individual, best_ itness, total_wastage

# Running the genetic algorithm

best_solution, best_ itness, total_wastage =
genetic_algorithm(population_size, generations, mutation_rate, total_rods,
desired_shafts_per_rod)

# Output results
print(f"Best individual (Shaft lengths for each rod):")
for idx, rod in enumerate(best_solution):
print(f"Rod {idx + 1}: {rod}")
print(f"Best itness: {best_ itness:.2f}")
print(f"Total wastage for {desired_shafts_per_rod} shafts from {total_rods}
rods: {total_wastage:.2f} mm")

OUTPUT:
Best solution: [261.98, 262, 262, 262.1, 262.1 262.1, 262.1, 262.1, 262.1,
262.3, 262.3, 262.3, 262.3, 262.3, 262.5, 262.5, 262.5, 262.5, 262.3
262.3,262]

30
UPDATED G CODE:
%
O1001 (Program Number)
N10 G21 (Set units to mm)
N20 G90 (Absolute positioning)

(De ine the raw material length, desired shaft lengths, and chip loss)
N30 #100 = 5523 (Raw material length)
N40 #101 = 262.25 (Desired shaft length)
N50 #102 = 21 (Number of shafts to cut)
N60 #200 = 107 (Chip loss)

(Initialize the current position)

N70 #300 = 0 (Initial position)

(Calculate total length required for cutting 21 shafts)

N80 #400 = #102 * #101 + (#102 - 1) * #200 (Total length required including
chip loss)

(Start the cutting loop)

N90 WHILE [#102 GT 0] DO1
N100 G00 X[#300] (Move to current position)
N110 G01 X[#300 + #101] F200 (Cut to the desired shaft length)
N120 #300 = #300 + #101 + #200 (Update position for the next cut)
N130 #102 = [#102 - 1] (Decrement the shaft count)
N140 END1

(Move to safe position and end program)

N150 G00 X0 Y0 Z100
N160 M30 (End of program)
%

31
 OPTIMIZATION RESULTS:

RESULT
CATEGORY BEFORE AFTER
Specimens obtained 20 21
Length 263 262.2
Weight of Specimen 1869 Grams 1861.62 Grams
Total Material Weight 37380 Grams 39094.02 Grams
Waste in each rod 1451.5 Grams 120 Grams
Chip Wastage 398.5 Grams 3 Grams

OUTCOME:

The desired result was achieved however, the result is

optimized for an absolute length not taking tolerances
into account.

32
 CONCLUSION

My training at Maruti Suzuki has been an enriching and transformative

experience, providing me with invaluable insights into the automotive
industry. During this period, I had the opportunity to learn about the Work
Inspection Sheet (WIS), the core principles that drive the company’s success,
and the practice of Kaizen for continuous improvement. Additionally, I
gained practical knowledge in CNC operations and advanced manufacturing
techniques, which have signi icantly broadened my technical skill set.

I also had the chance to observe and participate in various audits, which gave
me a better understanding of maintaining quality and ef iciency in
production processes. This hands-on experience has not only enhanced my
technical abilities but also reinforced the importance of teamwork, precision,
and the pursuit of excellence in a professional environment.

I am deeply grateful to Maruti Suzuki for the opportunity to be a part of this

dynamic organization. The knowledge and experiences acquired during this
training will undoubtedly serve as a strong foundation for my future career.

33
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