PROJECT REPORT

PRODUCTION OF CAR SEATS

CAR SEAT

CONTENTS

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

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.

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.

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.

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!

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.

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.

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

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.

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.

‘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.

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.

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. 

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).

PU SHOP PROCESSES

STATION 1

MOULDING STATION 2

RELEASE AGENT SPRAY STATION 3

MOULD CLEANING STATION 4

DEMOULDING STATION 5

CRUSHING

COMPONENTS USED IN ASSEMBELY OF SEATS• M8• M10• KNOB• BUCKLE• HANDLE• PROTECTOR• ROD• RUBBER WASHER

UNSAFE ACTS

MAKING SAFETY DEVICE INOPERATIVEREMOVING GUARDSUNSAFE LOADING LIFTING TOO HEAVY LOADSOVERLOADINGUNSAFE SPEEDUSING HANDS TO FEEDUSING DEFECTIVE TOOLS