PROJECT REPORT

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PROJECT REPORT

• PRODUCTION OF CAR SEATS

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KRISHNA MARUTI LTD.
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CAR SEAT

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CONTENTS

• INTRODUCTION
• HISTORY
• CERTIFICATION
• VENDORS
• UNSAFE ACTS
• 6 F PRINCIPLE
• WELDING PROCESSES
• PU SHOP
• ASSEMBELY SHOP

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INTRODUCTION

• KML started its operations with only 1 model and
  a production capability of 40 sets/day. Today we
  manufacture 16 different models. Krishna Maruti
  Limited has a production capacity
  of400,000SeatingSystems/annum.Presently Krishna
  Maruti Limited produces 16 different Variants of
  seating systems of following Models WAGON R,
  ZEN, OMNI, MARUTI 800cc ALTO.

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INTRODUCTION CONTD.

• Krishna Maruti Limited is also India's first
  Company to use Robotic PU Plants. Both the PU
  Plants are Fully Automatic Robotic and are
  capable of producing Dual hardness Pads for
  better orthopedic comfort.

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INTRODUCTION CONTD.

• Krishna Maruti Limited has in-house Welding Shop
  for manufacturing Frames for Seating System This
  weld shop is equipped with CNC machines and
  conventional welding machines like Mig Welding,
  Resistance Welding.
• For painting of seat frames KML has fully
  automatic conveyorised Pretreatment Paint
  Plant. Water based paints are used in Shower
  Painting process.
• Assembly is performed on Conveyorised lines using
  SNIC 's technology.
• KML is capable of conducting test as per European
  Homologation and Japanese's Standards.

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HISTORY

• Krishna Maruti Limited is a Joint Venture Company
  of Suzuki Motor Corporation of Japan, Maruti
  Udyog Limited and Ashok Kapur Associates. The
  company has a technical collaboration with SNIC
  of Japan. Krishna Maruti Limited is South Asia's
  Largest Manufacturer of Seating Systems for
  Automobiles.KML started its building operation in
  Dec 1993. The Rs. 265 Million project was
  completed in a record time of 120 days!

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HISTORY CONTD.

• KML entered the auto interior manufacturing
  business with a single product (seating system
  for Maruti 800 CC Car) in year 1994. Today we
  manufacture 8 different products with over 100
  different models. We are India's First Total
  Auto Interior Group of Companies manufacturing
  all the requirements of auto interiors including
  Seating Systems, Rear View Mirrors, Head Rest
  Assemblies, Arm Rest Assemblies, Seat Trims
  (Covers), Injection Moulded Door Trims,
  Roofliners Moulded Carpets.

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CERTIFICATION

• Company has been certified as ISO 9002 in year
  1996 by TUV Bayran and QS 9000 in Year 1997 by AV
  Vincotte, Belgium.Towards our quest to become a
  World Class Company, we at KML commenced the TQM
  Mission jointly organized by CII and MUL since
  1998.At Krishna Maruti Limited we are totally
  committed to Quality Standards set by our
  customers. Our line rejection is less than 500
  PPM and we have achieved Zero MARU 'A' Defect.

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VENDORS

• SKH METAL-1
• SKH METAL-2
• GANDHI SPRINGS
• SI INTERPACK (TRIM)
• SI INTERPACK(PE COVER)
• KARAN AUTO
• SANDHAR
• SOL AUTO
• SWARAJ
• ESSMA
• AUTOMAX
• MODERN IND
• SAI SUPREME

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RAW MATERIALS USED

• At Krishna the basic raw materials used are
•  Polyurethane raw materials to produce moulded
  cushion pads -Polyols Isocynates.
• CRCA sheet metal components.
• Tubular lengths of various sizes.
• Water soluble black paints pre treatment
  chemical.
• PVC fabrics.Laminated  polyester cotton
  fabrics.
• Wire Spring
• Polypropylene for injection moulded components
• Hardware items.
• Various industrial consumables like mig wire,
  adhesives, safety items, spot welding electrodes
  etc.

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CONTD.

• Seat adjuster mechanism assemblies.
• Seat recliner mechanism assemblies.
• Rear seat lock assemblies.
• Automotive fabric.
• Treads.Substrate for roof headliner(rigid foam).
• Mirror sheets.
• Felt for moulded carpet.
• Needle punch fabric for moulded carpet.
• CRCE sheet.Non - woven fabric.Fasteners for
  various sizes.

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6-F PRINCIPLE

• Focused Focus towards customer delight,
  engineering infrastructure, cost consciousness
  and continuous improvements through '5 - S',
  'Kaizens', Quality Circle Meetings and Suggestion
  Meetings.
• Fast Fast system technological up - gradation
  and implementation.
• Flexible Flexible towards customer requirements.
• Friendly Creating friendly environment among
  customer, employees vendors.
• Firm Firmly adhering to laid down policies
  procedures
• Fun Achieving the targets in stipulated time.

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WELDING PROCESSES
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SPOT WELDING

• Spot welding is one of the oldest welding
  processes. It is used in a wide range of
  industries but notably for the assembly of sheet
  steel vehicle bodies. This is a type of
  resistance welding where the spot welds are made
  at regular intervals on overlapping sheets of
  metal. Spot welding is primarily used for joining
  parts that are normally up to 3 mm in thickness.

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SPOT WELDING
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MIG WELDING

• Gas Metal Arc Welding (GMAW) is frequently
  referred to as MIG welding.  MIG welding is a
  commonly used high deposition rate welding
  process.  Wire is continuously fed from a spool. 
  MIG welding is therefore referred to as a
  semiautomatic welding process. 

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MIG WELDING
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PROJECTION WELDING

• Projection welding is a variation of spot
  welding. Projections are designed in one part.
  These act as current concentrators for the
  welding process. When the two parts are mated
  together, these projections are the high points
  that first make contact. As the power is cycled,
  the projections simultaneously carry the current
  and are welded.
• Due to the efficiency of power transfer, thicker
  materials can be successfully welded. Materials
  as thick as 3 mm (0.125 in) can be successfully
  welded.
• Low carbon steels, low alloy steels, stainless
  steels, as well as aluminum can be welded using
  this process.
• Projections are usually semi-spherical or blunt
  conical type.
• Projection welding requires that the height of
  projections be controlled to within a range of
  0.075 mm (0.003 in).

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PROJECTION WELDING
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PU SHOP
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PU SHOP PROCESSES

• STATION 1
• MOULDING
• STATION 2
• RELEASE AGENT SPRAY
• STATION 3
• MOULD CLEANING
• STATION 4
• DEMOULDING
• STATION 5
• CRUSHING

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ROBOTICS
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MOULDING
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RELEASE AGENT SPRAY
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MOULD CLEANING
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DEMOULDING
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ROLLER CRUSHING
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VACCUM CRUSHING
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ASSEMBELY SHOP
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COMPONENTS USED IN ASSEMBELY OF SEATS

• M8
• M10
• KNOB
• BUCKLE
• HANDLE
• PROTECTOR
• ROD
• RUBBER WASHER

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FINAL PRODUCT
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UNSAFE ACTS

• MAKING SAFETY DEVICE INOPERATIVE
• REMOVING GUARDS
• UNSAFE LOADING
• LIFTING TOO HEAVY LOADS
• OVERLOADING
• UNSAFE SPEED
• USING HANDS TO FEED
• USING DEFECTIVE TOOLS

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THANK YOU