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INTERACT ION MARUTI SUZUKI, NGK SPARK PLUGS
4 www.autotechreview.com
MARUTI SUZUKI | INNOVATION IS ABOUT PROGRESSIVE IMPROVEMENT
In the wake of stiffening competition in the Indian
market, car market leader Maruti Suzuki India
Limited (MSIL) has made a successful transition
over the past decade or so. From manufacturers of
small, simple passenger cars, MSIL is today tech-
nically competitive, and has produced segment-
establishing cars. The objective is to gain sus-
tainable leadership through innovating technolo-
gies and products.
We recently met CV Raman, Executive Direc-
tor (Engineering), MSIL to get an idea about the
company’s outlook towards innovation and sus-
tainability, and to know of things to come.
Innovation doesn’t necessarily mean some-
thing radical or breakthrough for MSIL, but pro-
gressive improvement. For a company that pri-
marily competes in cost-competitive segments
and caters to value-conscious consumers, every
new plan requires some amount of innovative
thinking. As a guiding principle, continuous im-
provement is a part of every process the company
undertakes. This approach encourages all employ-
ees to constantly think about ideas for the next
level of improvement, Raman said.
ONE, ONE, ONE
It was Osamu Suzuki, Chairman, Suzuki Motor
Corporation (SMC), who had introduced the
concept of ‘One, One, One’ – one gram reduction
for one part resulting in saving of one Rupee or
Yen. This concept, when applied to every manu-
facturing process, automatically results in inno-
vations leading to sustainability. It’s not just en-
gineers, who ideate weight reduction, but even
line workers suggest how material movement
can be made easier and less power-consuming,
ultimately leading to lower-costs. Following this
approach leads to small yet significant innova-
tions throughout the business model.
In recent times, the company has upped the
usage of high-tensile steel in car bodies to lower
weight and improve efficiency. The K-Series
engine too follows the lightweight philosophy
and features numerous technologies that lower
emissions. Other major innovations in the engine
included plastic intake manifold, offset crank-
shaft, lighter pistons, new valvetrain and thinner
cylinder sleeves. All these lead to a fuel-efficient
and clean engine and the fact that it is at par
with competition – in some cases cheaper – re-
flects sustainability.
Another focus area in terms of sustainability
is increased use of recyclable materials in vehi-
cles, leading to lower negative impact on the en-
vironment. The recyclable rate for the A-Star at
the time of its introduction was 87 %, while the
recoverable rate was 96 %, at par with global
standards.
REDUCING WEIGHT
From a lightweighting perspective, high-tensile
steel will continue to be an important material
for MSIL. Aluminium is being used in the power-
train but its extension to the vehicle body is not
on the short-term horizon. The reason is primari-
ly the high cost of the material, but the company
will continue to explore any further opportunities
in this area.
There is more focus presently on the shift to
plastic as in the case of air intake and fuel
tanks, which has already become widely
adopted. For example, in the new Alto 800’s
engine, the intake manifold has been changed to
plastic, replacing the earlier one in aluminium.
This has increased the volumetric efficiency and
lowered the weight.
Driving ahead MSIL’s innovation programme
will be the new R&D unit being set-up at Rohtak,
Haryana. The set-up will house a proving ground,
which will have a high-speed test-track and
more than 35 types of other test-tracks. These
tracks would span close to 40 km in length and
will offer various testing surfaces. The testing
facilities also will include many new inclusions,
which will eliminate the need for MSIL to send a
vehicle to Japan for many types of testing. Once
this set-up is ready, MSIL will be capable of
testing global products here and contribute in a
greater way to SMC’s product development.
Over the next two years or so, MSIL engineers
will have the ability to design, make, test, fit,
evaluate, improve and correlate design, both
physically and virtually, all in India. This is what
would help MSIL achieve better results from the
‘One, One, One’ concept, translating into sus-
tainable innovations.
TEXT : Arpit Mahendra
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autotechreview 5January 2013 Volume 2 | Issue 1
NGK SPARK PLUGS | TRANSFERRING TECHNOLOGY, LOCALISING PRODUCTION
In a short span of over five years in the Indian
automotive market, Japanese spark plug maker,
NGK Spark Plugs has made significant pro-
gress, with assured business from OEMs, and
also its foray into the aftermarket. The Indian
unit of the company started manufacturing
spark plugs in 2007 at its plant in Bawal,
Haryana. We caught up with Keiichi Okumura,
Managing Director, NGK Spark Plugs India Pvt
Ltd to know about the growth achieved, and the
company’s expansion plans.
The healthy growth has now prompted the
company to start planning an expansion at its
Bawal facility, by setting-up a new building in
the premises by 2014. With new production
machines, the company will scale up produc-
tion to an estimated 60 mn units per annum in
about 10 years from now, a three-fold growth
from the present output of 20 mn units per
annum. The present facility has enough area to
undertake expansions, and there is little chance
of the company looking at a new location,
Okumura said.
In the Indian OEM segment, the company’s
present marketshare is estimated at close to 50
%, while in the aftermarket it’s pegged at about
12 %. Given the fact that the company is pres-
ently only in its sixth year of operation in the
country, these figures are impressive.
ADVANCED TECHNOLOGY
Spark Plug technology has progressed significantly
in the past decade or so. In India, OEMs are re-
quired to use the resistor type spark plug in accord-
ance with the Government of India EMI (electro-
magnetic interference) regulation implemented in
2003. Demands such as longer life and increased
efficiency have encouraged many OEMs to adopt
newer technologies. One major contributor to the
quick growth in OEM business has been the intro-
duction of new engines by carmakers such as
Honda Cars India and Maruti Suzuki India, which
make use of better spark technology. In addition,
the company is supplying oxygen sensors to com-
panies such as Ford and Volkswagen.
The technology for NGK is primarily developed
in Japan, also helped by engineers from Europe
and the US. When asked about the possibilities of
such a set-up for India, Okumura said that the
technology for products such as spark plugs and
oxygen sensors is driven primarily by emis-
sion norms. These norms are mostly
based on the ones formed in Europe,
known as Euro emission norms.
Since India is yet to adopt the
Euro IV norm completely, future
norms can be met by adopting
the existing global technology for
Indian conditions. However, in the
coming years if NGK sees a scope in
this area it would definitely consider it, he said.
This would, however, call for government initia-
tives to improve fuel quality and emission norms
to be upgraded.
The aftermarket segment is also expected to
grow in the coming years. The company is already
running programmes to educate consumers and
mechanics to avoid swapping spark plugs with
those of a different technical specification as they
could damage the engine or ECU severely. With a
product portfolio comprising of platinum tip and
iridium spark plugs, Okumura believes NGK is
ready to cater to any future technical require-
ments from its OEM customers.
As the norms get stringent and consumer
demand for fuel-efficiency goes up, the demand
for these products will go up, pushing the
company closer to its target.
TEXT : Arpit Mahendra
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INTERACT ION FIEM INDUSTRIES
6 www.autotechreview.com
FIEM INDUSTRIES | ENGINEERING DIVERSIFIED INNOVATIONS
Fiem Industries, an automotive lighting major
is presently pursuing a strategy of diversifying
into new technologies and businesses. In a
major shift towards material technology, Fiem
has developed the sheet metal frame for the
upcoming electric car, Mahindra Reva NXR.
This is in addition to the supply order of the
headlamp and LED tail lamp to the vehicle.
Dr JK Jain, Chairman & Managing Director,
Fiem Industries Limited said in a recent inter-
action that the Reva NXR order reflects a
quantum leap for the company, as the technol-
ogy for developing this frame was home grown.
The company, as a matter of fact, is developing
a robust focus on R&D for the future. Instead of
going the widely
adopted route of
sourcing technology
from a foreign
partner, Fiem pres-
ently develops most
of its automotive
products in-house.
While the company
does have an agree-
ment with Ichikoh Industries of Japan, their role
was primarily limited to establishing the company’s
new plant and its manufacturing set-up in Sonepat
in accordance with Japanese guidelines. The
company established an independent R&D division
just about two years back and has been able to roll
out some commendable products since then.
NEW INNOVATION
One of the major new products developed by Fiem
includes a LED two-wheeler headlamp, first of its
kind in Asia. Some notable new orders, which
reflect the growing technical capabilities of Fiem,
include the supply of lighting solutions to Harley-
Davidson and Triumph
in India. Exports too are
a major area of focus
and the company is
already supplying to
some global models
such as a 600 cc +
Honda two-wheeler in
Thailand. Other export-
ed products include
complete trailer lamps among many others to Eu-
ropean customers.
In line with its strategy of expanding the
product line, the company has developed some
LED search and fog lamps for four-wheelers and
higher applications. A strong grip on the two-
wheeler business allows the company to focus
and plan on expanding its four-wheeler business.
DIVERSIFICATION ON TRACK
The company has recently established a new divi-
sion to manufacture solar-based and normal LED
lamps for domestic and commercial purposes. The
technology for this division will be derived from
BrightLite Systems of Singapore, with which the
company has signed a technical agreement. Given
the shortage of electricity in India and the bene-
fits of LED technology, Jain expects the Solar &
Greenfield division to grow at a fast rate and
account for a significant share of the total
revenue in the coming years. Products from this
division include solar streetlamps, domestic LED
lamps and display signs for multiple applications.
Jain told us that the company is presently on a
fast-track growth path and they expect to close
FY13 with a revenue of just under ` 600 crore. In
the next three years or so, the revenues are ex-
pected to reach ` 1,000 crore and cross ` 2,000
crore in the following two years. The reason for ex-
pecting such fast-paced growth is the expanding
portfolio of products beyond lighting. This will not
only enable the company to get more business but
also offset the risks to a large extent.
The company’s strong focus on technology and
its ability to develop products conforming to
global quality standards are drivers of growth,
and justify its ambitious target of growing by
almost four-times in about five years. Developing
a component for electric vehicles requires high
technical expertise. By developing a critical com-
ponent such as the frame, Fiem has proven its
ability to develop technically-demanding prod-
ucts, which directly translate into higher values
and margins, an imperative for the revenue goal
to be achieved.
TEXT : Arpit Mahendra
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SPONSORED FEATURE
autotechreview 7January 2013 Volume 2 | Issue 1
The Automotive Research Association of India
(ARAI), established in 1966 at Pune, is a leading
automotive R&D organisation set up by automotive
industry with the Government of India. ARAI is affil-
iated to the Ministry of Heavy Industries and Public
Enterprises and is recognised by the Department of
Scientific and Industrial Research. It is an ISO
9001-2008, ISO 14001-2004, and OHSAS 18001-
2007 organisation, and is also accredited by Na-
tional Accreditation Board for Laboratories (NABL)
for its major certification facilities.
ARAI organises ‘Symposium on Internation-
al Automotive Technology’ biennially in associ-
ation with SAEINDIA, NATRiP and SAE Interna-
tional at ARAI, Pune. SIAT serves as an impor-
tant forum for sharing ideas and knowledge
concerning promising areas of automotive en-
gineering and technology, wherein eminent
experts and authors present keynotes and
technical papers in multiple sessions. Some of
the milestones of SIAT event include:
:: First edition of SIAT was organised in 1985
and it was then called “Symposium on
Indian Automotive Technology”
:: SIAT attained SAE status in 1996, and since
then it is called “Symposium on Internation-
al Automotive Technology”
:: Since its inception, SIAT has been witness-
ing growth in the areas of keynote paper
presentations, technical papers presenta-
tions, number of delegates, etc.
SYMPOSIUM ON INTERNATIONAL AUTO-
MOTIVE TECHNOLOGY (SIAT 2013)
The 13th edition of ‘Symposium on International
Automotive Technology’, i.e., SIAT 2013 is being
organised from 9-12 January, 2013. The theme of
‘SIAT 2013’, i.e. ‘Towards Safer, Cleaner & Quieter
World’, is in continuation with our previous edi-
tion’s theme “Sustainable Mobility –A Creative
Challenge”. This edition’s theme aligns with auto-
motive industry’s current need of R&D focus on
safety and environment.
Over 190 technical papers, including 40
keynote papers will be presented by eminent
experts from across the globe at this symposi-
um in various areas such as vehicle & struc-
tural dynamics, automobile air-conditioning &
HVAC, alternate fuels, automotive electronics,
CAE, CFD methodology, hybrid & electric vehi-
cles, emissions, power train, materials & man-
ufacturing, NVH, safety, global regulations,
and transmission etc. Symposium proceedings,
covering the technical papers, will be pub-
lished, besides Technical Reference Bulletin
containing technical articles, case studies and
product information.
Prominent highlight of SIAT 2013 will be
BRICS Session, which will be organised on 11
January, 2013. Herein, a panel comprising of
technical experts from BRICS countries will
discuss on ‘Challenges and opportunities in
global automotive technology areas ahead of
BRICS group’.
The countdown for SIAT 2013 has already
begun with the commencement of delegate
registration for the symposium. For further
details regarding online registration, please
visit http://siat.araiindia.com.
SIAT EXPO 2013
‘SIAT EXPO 2013’, an exposition is being organ-
ised concurrently at ARAI from 9-12 January,
2013, wherein, a spectrum of worldwide compa-
nies will showcase automotive products, equip-
ment, services and technology solutions in 201
stalls. This grand exposition will be open to auto-
motive personnel and interested public, and will
provide a great opportunity to share and dissemi-
nate information and conduct business.
TECHNOLOGY THEATRE
‘Technology Theatre’ is being organised as a
special event on 12 January, 2013. This event pro-
vides a platform for exhibitors to interact, share
ideas, present innovative strengths and explore
business opportunities through technical discus-
sions and presentations. Exhibitors stand to
benefit immensely from this event, as entry to
Technology Theatre sessions will be open to all
SIAT 2013 delegates, in addition to their exclu-
sively invited customers.
With an enriched experience of over 25
years and support of SAEINDIA, NATRiP & SAE
International, SIAT is a well established brand
in automotive arena. Also, it is one of the most
eagerly awaited events by the automotive fra-
ternity, as it provides a platform for interaction
& knowledge dissemination.
EVENT | 13TH SYMPOSIUM ON INTERNATIONAL AUTOMOTIVE TECHNOLOGY
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INTERACT ION CONTINENTAL
8 www.autotechreview.com
Diversified supplier of automotive parts and
systems, Continental has always been at the
forefront of innovation and technological devel-
opment. Through its focus on shaping the meg-
atrends of the automotive industry, the company
endeavours making accident- and injury-free
motoring, earth-friendly mobility and an intelli-
gent and networked road traffic, a reality.
The Executive Board of the company met in
Bangalore in November 2011. At a press meet
later, the € 30.5 bn German company (as of
2011) reaffirmed its faith in the Indian market,
announcing its intent to double revenues in the
country by 2016. The thrust towards that goal
would be led through operations plans and inno-
vations for the Indian market. Meanwhile,
despite global slowdown in key markets like
Europe, Continental has confirmed the sales
forecast of more than € 32.5 bn for fiscal 2012.
At the press meet, the company made two im-
portant announcements. It has won a mandate
from Mahindra Reva Electric Vehicles Pvt Ltd to
supply sophisticated electrical and electronics car
body components for its soon-to-be-launched,
Reva NXR. The deal includes Basic Function Con-
troller (BFC), immobilizer and remote keyless entry
for the Reva. The BFC, Continental stated, is de-
signed as part of a full set of scalable solutions
that can be used to implement body electronics
features in a wide range of cars, starting from
entry level models to luxury cars. This would
enable OEMs to upgrade effortlessly to meet
future requirements, the company said.
Secondly, the company also announced ex-
pansion at its plant in Manesar, Haryana that
produces instrument clusters for passenger ve-
hicles and two-wheelers, sensors for powertrain
and chassis including knock sensors, speed
sensors for engine and transmission. The
Manesar facility is now spread over 15,027 sq m,
more than double its existing size of 7,152 sq m.
Claude d’Gama Rose, Head of Continental
India and Managing Director of Continental Au-
tomotive Components India Pvt Ltd, reiterated
the company’s commitment to localising the
entire value chain in India. Increasing buying
power among the Indians, and the low passenger
car density in the Indian market (12 cars per
1,000 people) offers tremendous scope for vehi-
cles sales in the market, and that augurs well
for the company in the coming years, he said.
INTERIORS – STAYING CONNECTED
In the automotive world, one of the most talked
about subject today is connectivity through intelli-
gent communication and information manage-
ment. Within Continental, this is dealt by the Inte-
riors division, headed by Helmut Matschi, Member
of the Continental Executive Board and President
of Interior Division.
“Information management is about intelli-
gent driving. Within intelligent driving, you’ll see
there is a lot about connectivity, and HMI,”
Matschi said. Tomorrow’s vehicle will always
remain connected; they’ll be user-friendly, com-
CONTINENTAL | REAFFIRMS INDIA SIGNIFICANCE
(L-R): Claude d’Gama Rose, Helmut Matschi, Dr Ralf Cramer and José Avila
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