PROJECT REPORT

(June-July 2015)

SCRATCH DETECTION AND

REDUCTION

Under the Guidance of Submitted

by-
Mr. AS Bhatnagar Vikrant Wadhwa
(Mentor) AU120030305009P
 B.tech AE
Ansal University

DECLARATION

I hereby declare that the project work is an authentic record of my own

work carried out at Maruti Suzuki India Limited, Manesar as a part of 45
days summer training as a student of B.Tech-AE, Ansal University,
Gurgaon.

Under the guidance of Mr AS Bhatnagar, during

1st June, 2015 to 15th July, 2015.

Vikrant Wadhwa

Roll no.-AU120030305009

Date: ____/____/________ Mr AS
Bhatnagar
(Mentor)
ACKNOWLEDGEMENTS

First of all I would like to state that this project has been great learning
experience in my life. Through this training at Maruti Suzuki India
Limited, Manesar, Haryana, I gained valuable insights into the
production process followed at a world class car factory, especially
related to the Assembly Shop and various quality control measures
and their management carried out in automobile industry.

I feel immense pleasure in showing my gratitude to all people who

have made my training successful by offering help and guidance.

I am deeply indebted to Mr.AS Bhatnagar, Mr. Vivek Tiwari and

Mr.Vikas Sharma (Assembly shop-Manesar B) for providing me this
opportunity and their valuable time in carrying out this project
whenever required.

Needless to say, without their support and active guidance, this

training and thus this report would not have been possible.
 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 them familiar with the practical aspect 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 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.
 ABOUT COMPANY

The decade of 1980's has been a watershed moment for Indian

economy in many ways, putting it firmly on the path of modernization
& technological advancements. At the end of technology spectrum was
the start of India's satellite program, with the launch of short-lived
Insat 1A in April 1982. At the other was color television, which made its
debut in India in time for the ninth Asian Games that were held in
1982. And in between, there was India's first modern car- the ionic
Maruti 800.

The 800 rolled out of the factory of Maruti Udyog Limited in December
1983 & changed not just India's automobile industry but also the way
people commuted & travelled. Maruti Udyog was established as a
public sector undertaking(PSU) In 1981 to manufacturer cars, following
the nationalization of late Sanjay Gandhi's Maruti motors limited in
1980.

Maruti Udyog limited (MUL) was established in February 1981, through

the actual production commenced in 1983 with the Maruti 800, based
on the Suzuki Alto kei car which at the time was the only modern car
available in India, its only competitors- the Hindustan Ambassador and
Premier Padmini- were both around 35 years out of date at that point.
Through 2004, Maruti Suzuki has produced over 5 Million vehicles.
MarutiSuzuki's are sold in India and various several countries,
depending upon export orders, under the brand name Suzuki.

MSIL, a subsidiary of SMC, Japan is the passenger cars& Multi-Purpose

Vehicles (MPVs) producer in India accounting for almost 52% of the
total industry sales. The company formerly known as Maruti Udyog
Limited was incorporated as Joint Venture between Government of
India & SMC Japan on 24th February, 1981. The first car was rolled out
from its Gurgaon facility on 14thDec, 1983. Since then it has sustained
its leadership position in Indian car market.

COMPANY MISSION
The Leader in the Indian Automobile Industry.
Creating Customer Delight and Share Holders wealth.
A Pride of India

LEADERSHIP PERCEPTION
By market share & brand equity.
By operational practices.
By people strategy.

A PRIDE OF INDIA
As a corporate citizen.
Products.
People.
Practices.
CUSTOMERS VALUES
Customer obsession
Fast, flexible, first mover
Innovation & creativity
Networking & partnership.

MSILs ACCOLADES
2007 India customer satisfaction index Award
2007 India Initial Quality Study
200NationalAwardforExcellenceCorporate Governance
2010 NHRDH Trailblazer Award for HRD Excellence
2011 Hall of Fame award for single handily changing the face of
Indian automobile Industry by Car India.
 2012 Golden Peacock Award for Occupational Health & Safety
Performance in Automobile Sector.

PLANT JARGONS AND PRINCIPLES

POKA-YOKE : MISTAKE-PROOFING THE MANUFACTURING PROCESS

KAIZEN : IMPROVEMENT

PIKA-PIKA : SYSTEM MSIL USES TO ENSURE NO COMPONENT IS

MISSED ORWRONGLY FITTED BY THE OPERATOR ON THE
ASSEMBLY LINE

FUNDOSHI : A SHEET OF PAPER WITH ALL THE DETAILS OF THE PART

ON WHICH ITIS PASTED

MARU-A : PARTS OR JOINTS WHICH ARE EXTREMELY CRITICAL AND

ANY FAULTIN THEIR FITMENT CAN CAUSE LOSS OF LIFE

HINKAI : PROBLEMS DURING ASSEMBLY OF A MODEL

FUGAI : PROBLEMS DURING ASSEMBLY RELATED TO

MACHINES

VIN : VEHICLE IDIENTIFICATION NUMBER

PSN : PRODUCTION SERIAL NUMBER

EXP : EXPORT

DOM : DOMESTIC

PET : PETROL

DSL : DIESEL

MT : MANUAL TRANSMISSION

CVT : CONTINOUS VARIABLE TRANSMISSION

LDI: BASE DIESEL VARIANT VDI: MIDDLE DIESEL VARIANT ZDI:
TOP DIESEL VARIANT LXI: BASE PETROL VARIANT VXI: MIDDLE
PETROL VARIANT ZXI: TOP PETROL VARIANT

5S
SEIRI : PROPER SELECTION

SEITON : ARRANGEMENT

SEISO : CLEANING

SEIKETSO : STANDARISATION

SHITSHUKE : DISCIPLINE

3G
GENCHI : GO TO ACTUAL PLACE

GENBUTSU : SEE THE ACTUAL THING OR PROBLEM

GENJITSU : TAKE APPROPRIATE ACTION

3M
MURI : INCONVENIENCE
MUDA : WASTAGE

MURA : INCONSISTENCY

3K
KIMERARA KAYOKA : WHAT HAS BEEN DECIDED

KICHINTO MAMORU KOTO : MUST BE FOLLOWED

KIMI RARETA TORI : EXACTLY AS PER STANDARD

4M
MAN

MACHINE

MATERIAL

METHOD

3R

REDUCE
REUSE

RECYCLE
 FACILITIES AT MSIL

There are two manufacturing facilities in India, one in Gurgaon and the
other in Manesar, North India.

MSIL Snap shot

Equity Structure* 63% Suzuki, 37% with Public

Net Sales* Rs.4,86,055 million

Net Profit* Rs. 44,505 million

Sales* 12,92,415 units

Market Share* 46%

Manpower* over12,000 employees

Models* 14 models with over 150 variants

Joint Ventures* 20 joint venture for components

*subjected to change without any prior notice. T&C applied. All right reserved
under MSIL.
GURGAON PLANT:-
Gurgaon plant has three fully integrated plants. While the three plants
have a total installed capacity 650,000 cars per year, several
productivity improvements or shop floor Kaizens over the years have
enabled the company to manufacture nearly 700,000 cars per year at
the Gurgaon facilities. The entire facility is equipped with more than
150 robots; out if which 71 have been developed in-house. More than
50% of shop floor employees have been trained in Japan.
MANESAR PLANT:-

Manesar facility has been made to suit Suzuki Motor Corporation (SMC) and
Maruti Suzuki India Limited (MSIL) global ambitions. Rated high among Suzuki
best plant worldwide the plant was inaugurated in February 2007.
The plant has several in-built systems and mechanisms to ensure that cars
being manufactured here are of good quality. There is a high degree of
automation and robotic control in the press shop, weld shop and paint shop to
carry on manufacturing work with acute precision and high quality. In
particular, areas where manual operations are hazardous or unsafe have
been equipped with robots.
The plant is designed to be flexible; diverse car models can be made here
conveniently owing to automatic tool changers, centralized weld control
system and numerical control machines that ensure high quality and the use
of network integrated techniques so that no process is missed. The plant was
started with an initial capacity of 100,000 cars per year. This is now scaled up
to 550,000 cars per year.
DIESEL ENGINE PLANT:-

Suzuki Power Train India Limited, the diesel engine plant at Manesar is
Suzukis first and MSILs perhaps the only plant design to produce
world class diesel engine and transmission for cars. The plant is under
a joint venture company, called Suzuki Power Train India Limited (SPIL)
in which SMC hold 70% equity with the rest held by MSIL.
This facility has an initial capacity to manufacture 100,000 diesel
engines a year. This will be scaled up to 300,000 engines per year.
The diesel engines manufactured at this plant will also be exported to
SMC companies across the world. This facility too has a high level of
automation. Final inspection of components is done through automatic
measuring and marking machines, which leads to a uniform and error
free production.
R&D Mission:-
To achieve full model development capability for global Suzuki models
by 2016, a fully-fledged R&D center is being developed at a total
investment of Rs. 2000 crores.
 MSIL (Manesar Plant)

MAIN UNITS AT MSIL-M

a. Press shop

b. Weld shop

c. Paint shop

d. Bumper paint & injection moulding shop

e. Assembly shop

f. Vehicle inspection

MARUTI PRODUCTION PROCESS

YARD/ CUSTOMER ASSEMBLY SHOP
VEHICLE INSPECTION PAINT SHOP
WELD SHOP
 BLANKING LINE

There are two blanking lines; ROSL (Rotary oscillatory shear line) for
rectangular sheets and the other employing die cutting for irregular shapes.
The rectangular sheets are obtained on ROSL while dies are employed to
obtain the required shape sheets. The sequence of operations on the
blanking line is as follows:-

Uncoiling
Cleaning
Levelling
Measuring
Shearing/cutting
Piling/stacking
 PRESS SHOP

Die spotting press M/C-200t

Tandem press line 2-200t
Transfer press line -30
Tandem press line -1200t

The press shop can be regarded as the starting point of a car manufacturing
process. The press shop has a batch production system whereas the plants
have a line production system. The press shop maintains an inventory of at
least two days. The weld shop as per their requirement picks the finished
body parts. These may be divided as A, B & C parts. A components are
large outer components, example-Roof, door panels, front hood etc. These
components are manufactured in the press shop at Maruti due to design
secrecy and huge investment requirements. B and C components are
manufactured by joint ventures or brought from vendors. The press shop can
be divided into:
 Raw Material Procurement
Blanking at Blanking Line
Stamping at Stamping Line

WELD SHOP

ROBOTS- 139
AUTOMATION LEVEL- 76 %

The body panels produced in the press shop and other small components are
joined here to give the white body or shell. In a typical car body about
1400 different components are welded together. The joining process is
resistance spot welding predominantly.

The weld shop has following facilities:

Welding jigs
Spot welding guns
 Hemming machine
Punching machine

PROCESS OUTLINE
The shop has different lines for different models, each of which is further
divided into three parts:

THE UNDER BODY

Here different under body panels are welded together. These comprise of
rear under body, central under body and front engine room panels. These
under body panel are prepared on sub lines starting from singular
components. The sub lines have specific jigs for each. Finally these under
bodies are put on the conveyor and are welded together to give under body.

MAIN BODY

The chassis number is punched on the cowl top and it is welded to the front
engine room panel. As the body moves on the conveyor roof and side body
panels are welded to it to give the main body. The side body panels are
prepared on the sub lines.

WHITE BODY

The doors, hood and back door are attached on the main body with the help
of bolts and screw to the main body to make it a white body. The body is
checked for dents, burr and spatter and these defects are repaired.

After inspection and repairs the body is called WBOK that is white body OK. It
is sent to paint shop thereafter.
 PAINT SHOP

Fully automatic process

18 Robots with 10 colours

In the paint shop following processes are carried out:-

Pre-treatment: the body is thoroughly washed to remove dirt and oil

scales.
ED coat: this is done by electric deposition method. After applying the
ED coat body is baked in ovens.
Final coat: for metallic coating, double coats are applied and
aluminium flakes provide the shine to metallic paint. This is also done
by spray painting method.
The PBOK i.e. Paint Body OK is sent to the assembly shop.

ASSEMBLY SHOP

There are three assembly shops at MSIL, Manesar, namely, Assembly Plant-
Manesar A (AS-MA), Assembly Plant-Manesar B (AS-MB)and Assembly Plant-
Manesar C (AS-MC).

AS-MA: Production of Ciaz (YL-1) and Swift Dzire (YP-8 NB).

AS-MB: Production of Swift (YP-8 HB), Swift Dzire (YP-8 NB) and YRA
(not launched yet).
 AS-MC:Production of Celerio (YL-7 HB), Alto800 (YE-3 HB) and AltoK10
(YE-1 HB).

AS-MB was the department assigned to me.

AS-MB has following Sub-Assemblies:

FDSA -Front Door Sub-Assembly

RDSA -Rear Door Sub-Assembly
IPSA -Instrument Panel Sub-Assembly
EGTM -Engine Transmission Sub-Assembly
EGSA -Engine Sub-Assembly
RASA -Rear Axle Sub-Assembly
FIAL -Fiat Line

Apart from the Sub-Assemblies, the main assembly line is divided into
following parts:

Trim Line 1
Trim Line 2
Chassis or Overhead Line
Final Line 1
Final Line 2
Vehicle Inspection
Assembly Touch-up

Each line is further divided into stations which are used to uniquely identify
any part of the line.

There are total 294 stations in AS-MB.

 PROCESS OUTLINE

FDSA-Front Door Sub-Assembly: Both left and right front doors are
removed from PBOK from paint shop and assembled 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 from PBOK from paint shop and assembled 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, glove box, etc. are installed here.

EGTM-Engine Transmission Sub-Assembly: Engine and

transmission are coupled together on this line. Some other engine
components are also fitted on this line.

EGSA-Engine Sub-Assembly: Front suspension mounting, Half axles,

Radiator, Intercooler (only in diesel), Front suspension system,
Stabilizer bar, Steering rack, Torque rod, etc. are fitted on to the engine
and engine and front suspension mounting here and the engine is sent
to the chassis line.
RASA-Rear Axle Sub-Assembly: On the rear axle, 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.

FIAL-Fiat Line: Diesel engines supplied by Fiat Power train, Pune are
assembled here. Parts like A/C compressor, alternator, VSV, Air filter,
etc. are fitted here.

Trim line 1: PBOK (Paint Body OK) from the paint shop comes to the
Assembly plant 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.

Vehicle Inspection: Various tests are carried on the car to ensure

optimum quality and customer satisfaction. Tests carried out are:

i. Toe-in test
ii. Toe-out test
iii. Shower leakage test
iv. Acceleration test or Drum test
v. Headlamp focus test
vi. Brake test
vii. Turning radius test
 viii. Final Drive test

Scratch Detection and Reduction

In this project, under the guidance of Mr. AS Bhatnagar, various scratch
locations were identified, their pattern studied and the root causes were
identified. Different locations had different reasons causing scratches, and
thus different suggestions and possible solutions were thought of.

WHAT ARE SCRATCHES?

Scratches are marking on the surface of a body with a sharp or pointed object. They are
indentified on the PBOK (Paint body OK) of the car, caused by human error,
machine error or there combination. Scratches are usually limited to painted
layer, a scratch is caused when a sharp object removes the paint from the
body in form of a thin line, and however, in extreme cases it can be
accompanied by a dent or paint removal of a large area too. Scratches in this
project refers to minor scratches, caused mainly by human error and are
mainly limited to locations near which operator fits some component with a
torque gun or limit wrench. Exceptions were there but very rare.

Scratches are very critical if

penetrated deep in the
body, and can cause fatal
accidents as the stress
concentration is very high
near the scratch.
How a Scratch can be Removed
A scratch can be removed using these three simple steps.

1. Assessing the damage.

2. Preparing the area for repair.
3. Repairing the paint surface.

Assessing the Damage

a) Determine if the scratch is actually a scratch and not just
something on the surface of the paint- Look at the area close up and
inspect whether you have a scratch or just debris on the car. Sometimes
what appears to be a scratch is actually a raised line of material from an
impact. This occurs when car contacts another bumper or any object
whose coating is softer than your car paint. These imperfections require
much less work to remove.

b) Establish the depth of the scratch- After you have actually

determined that you do have some scratches that need repair, you need
 to figure out how deep the scratch is. This will determine how you
approach repairs. Scratches to the clear coat can be easily fixed by
following these steps. Your car has 4 main layers: clear coat, colour,
primer and steel. If the scratch is only as deep as the clear coat or colour,
it will be much easier to remove. If you can see a different colour or steel,
the scratch is deep and might be more difficult to repair.

c) Look for other areas to repair at the same time- While you may
have one scratch that is bothering you enough to start a repair, it is a
good idea to look for any other areas that could be repaired at the same
time.

Preparing the Area for Repair

 a) Wash and dry the car thoroughly- If your car is dirty during scratch
repair, that dirt could cause more scratches to be created. Pay particular
attention to the area you will be repairing. Spray the scratched area with
water, making sure to get any debris out of the scratch.

b) Sand the scratch lightly- Wrap 2000-grit wet/dry sandpaper around a

sanding pad and begin sanding. The goal is to sand just through the clear
coat and no further.

Sand in the direction of the scratch. You do not want to create opposing
scratches, which will only create more ridges and valleys in the paint
that need to be repaired.
Periodically rinse the area with water. This will allow you to better see if
you have gotten to the bottom of the scratch.
 If the scratch is slightly deeper than the clear coat, use 1500-grit
sandpaper initially to level the surface and then 2000-grit sandpaper to
remove the scratches made by the coarser sandpaper.
Avoid getting dirt or debris between the sandpaper and the vehicle.
This will cause scratching.

c) Rinse the area, making sure that it is clean and dry- Use good
quality and clean microfiber clothes to wipe dry the surface. Remember
that using old rags could simply cause more scratches on the surface of
your car.

Repairing the Paint Surface

a) Apply rubbing compound to the scratched areas- Do not turn on the
buffer quite yet but with a buffer pad spread the compound around the
area that is dull from sanding. Rubbing compound is an abrasive that
takes off a bit more of the paint surface but it also smoothes out the paint
surface, getting it ready to be waxed. Basically the rubbing compound is
used to take out the scratches from the sand paper.

b) Polish the area with the rubbing compound- Turn the buffer on its
lowest level and move it around for approximately 10 seconds. You need
to polish the rubbing compound relatively quickly, so that it does not dry
before being smoothed out.

Increase the speed to 2000 RPM and buff for 1 minute. You should be
moving the buffer from side to side and then moving downward slowly.
Continue until the dullness has faded but make sure not to go through
the paint layer. This might take up to 5 minutes depending on the
scratch and your speed and pressure.
 Do not buff in the same spot for more than a second. You will scratch
into the next layer if you buff in the same spot too long.

c) Wash the area once again- Use clean water and a towel to remove the
leftover compound residue from the paint surface. If the compound got in
any crevices, use a toothbrush to clean it out. Wipe off the leftover
rubbing compound immediately after buffing. The residue will adhere to
the paint and be more difficult to remove otherwise.
d) Wax the area to seal the paint you have repaired- Apply a good
quality carnauba wax to the surface and then buff the surface with a
random orbital buffer. Finish by washing the area one more time
and make sure that the repaired area is super shiny and repels water
easily.

Project: Scratch Data and Countermeasure

 Scratch Data (June, 2015)

S Location 1 2 3 4 5 6 7 8 9 1 1 1 1 1 1
No. 0 1 2 3 4 5
1. Right Side Sill - - - - - -
2. Left Side Sill - - - - - -
3. Right Side Fender - - - - - -
4. Left Side Fender - - - 1 - -
5. Pillar A Both Side - - - - - -
6. Pillar B Both Side - - - - 1 -
7. Pillar C Both Side - - - - - -
8 Right Wheel Housing - - - 1 - -
9. Left Wheel Housing - - - 2 1 -
10.
11.
Right Front Door
Left Front Door
- - - 4 4
- - - 2 1 SHUT DOWN 1
-
12. Right Rear Door - - - - 2 2
13. Left Rear Door - - - 2 - PERIOD 1
14. Right Quarter Body - - - 1 - 1
15. Left Quarter Body - - - 1 1 2
16. Left Housing I.P. Bolt - - - 1 - 1
17. Right Housing I.P. - - - - - -
Bolt
18. Roof - - - 1 - -
19. Hood (Bonnet) - - - - - 1
20. Back Door - - - - 2 1
21. C/M Hood - - - - - -
22. Fuel Lid - - - - - -
S Location 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3 Tot
No. 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 al
1. Right Side Sill - - 2 - - - - 2 4
2. Left Side Sill 2 - 1 - 1 - - - 4
3. Right Side - - 1 - - - - 1 2
Fender
4. Left Side Fender - - 1 1 1 - - 1 5
5.
6.
Pillar A Both Side
Pillar B Both Side
-
-
-
-
-
2
-
- W -
-
-
-
-
- W -
1
0
4
7. Pillar C Both Side - - - - - - - - 0
8 Right Wheel 1 - - - E - - - E - 2
Housing
9. Left Wheel
Housing
- - - 2 E 1 - 4 E - 10

10.
11.
Right Front Door
Left Front Door
3
2
3
1
4
1
-
5
K 2
1
2
3
3
1
K -
-
26
17
12. Right Rear Door 3 1 1 - 1 1 - 2 12
13. Left Rear Door 2 1 1 2 E 4 1 2 E 5 19
14. Right Quarter - - - - - 1 - - 2

15.
Body
Left Quarter - 4 2 1
N - 2 2
N - 15

16.
Body
Left Housing I.P. - - - -
D - - -
D - 2
Bolt
17. Right Housing 1 - 1 - - - - - 2
I.P. Bolt
18. Roof - - - - - - - - 1
19. Hood (Bonnet) - - 1 - - 1 2 - 5
20. Back Door 3 2 2 5 2 1 3 - 21
21. C/M Hood 2 - - - - 1 - - 3
22. Fuel Lid - - - 1 - - - 1 2
 Scratch Data (July, 2015)

S Location 1 2 3 4 5 6 7 8 9 1 1 Tota
No. 0 1 l
1. Right Side Sill - - - - - 1 - - 1
2. Left Side Sill - - - 1 3 1 1 - 6
3. Right Side 1 1 3 - - - - - 5
Fender
4. Left Side Fender - 1 - - - - - 2 3
5.
6.
Pillar A Both Side
Pillar B Both Side
-
1
-
2
-
- W -
3
-
2
-
1
-
-
-
1
0
10
7. Pillar C Both Side - - - - - - - - 0
8 Right Wheel 1 1 - E 1 2 - - - 5
Housing
9. Left Wheel
Housing
1 2 1 E 1 1 - - - 6

10.
11.
Right Front Door
Left Front Door
1
1
3
1
1
2
K -
1
-
3
5
2
3
1
3
3
16
14
12. Right Rear Door - 2 - - - 9 1 4 16
13. Left Rear Door - 1 3 E 3 2 - - 1 10
14. Right Quarter - - - - - - 2 - 2

15.
Body
Left Quarter - - -
N - - - 1 - 1

16.
Body
Left Housing I.P. - - 2
D - - - - - 2
Bolt
17. Right Housing I.P. - 3 - - - - - - 3
Bolt
18. Roof - - - - - - - - 0
19. Hood (Bonnet) 1 4 - - - 1 1 - 7
20. Back Door 2 5 1 1 1 1 1 2 14
21. C/M Hood - - - - - - - - 0
22. Fuel Lid - - - - 1 - 1 - 2
 Conclusion

Scratches were indentified on the PBOK (Paint body OK) of the car, that were
caused by human error, machine error or there combination. Scratches are
usually limited to painted layer; however, in extreme cases it can be
accompanied by a dent or paint removal of a large area too. Root cause
areas were detected and there countermeasure were also suggested as per
the following table.

Countermeasures

S No. 1. 2. 3.
Station No. 31R 13R 14L
Process Fitting Of Back Brake and Clutch Sun visor Fitment
Door Lock (Latch) Pedal Fitment
Area T2.2 T1.2 T1.2
Model YP8 (HB/NB) YP8 (HB/NB) YP8 (HB/NB)
Countermea My cover should Sill cover should Sill cover should
be provided so be provided on be provided on
sure that no scratch both sides to both sides to
should occur near prevent prevent
the latch scratches. scratches.
Status Pending Pending Pending
 BIBLIOGRAPHY

Official website of MSIL:

http://www.marutisuzuki.com/company-at-a-glance.aspx
http://www.marutisuzuki.com/GujaratProjectInfo.aspx
http://www.marutisuzuki.com/annual-reports.aspx

Wikipedia:
https://en.wikipedia.org/wiki/MarutiSuzuki

Scratch Removal Technique:

http://www.wikihow.com/Remove-Scratches-from-Car