Maruti Suzuki’s Manesar facility crosses 25 Lakh production milestone


Car market leader Maruti Suzuki’s Manesar facility crossed the 25 lakh (2.5 million) production milestone this month.

Priced attractively at Rs.4.68 Lakh (Ex-showroom, Delhi), the Celerio Green is available on the VXi trim (Manual Transmission).

A glistening grey Swift Zxi was the 2.5 millionth vehicle that rolled out from the Manesar B Line.

Spread over 600 acres, the Manesar facility houses three plants, Manesar A, B and C with total annual capacity of 800,000 units. In addition, the Manesar campus also has the diesel engine plant and a suppliers park.

Explaining some of the salient features of the Manesar facility, Mr Rajiv Gandhi, Executive Director (Plants) says, “The Manesar facility achieved the 25 lakh production milestone in 7 years and 8 months. The Manesar plant manufactures some of the top selling models of the country like Swift, DZire and now Celerio. This milestone would be the fastest for any car manufacturing plant in the country.”

Expressing gratitude towards the employees, Mr Gandhi said, “We are overwhelmed by the enthusiasm of employees for their regular and active participation in forums like Suggestion Scheme and Quality Circles. While we achieve the milestone, we have successfully implemented several ideas from the employees on the important production pillars of productivity, cost, quality and safety.”

Recently, the Manesar facility received the CII 5S Excellence Award (Northern region) for its best practices in observing the acclaimed Japanese 5S philosophy which improves shop floor productivity and efficiency.

Like the Gurgaon facility, the three Manesar plants have several in-built quality checks and systems to ensure that cars being manufactured here are of top 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 precision and higher quality. Areas where manual operations are challenging and difficult are supported by automation and robotics.

Early this year, the Company also commissioned a 1mw mono-crystalline photovoltaic Solar Power Plant inside the Manesar facility. Set up at an investment of Rs 103 million, the 1MW photovoltaic solar power plant helps the Company offset CO2 emissions to the tune of over 1200 tonnes annually.

The Company’s twin facilities at Gurgaon and Manesar have together rolled out over 1.4 Crore (14 million) vehicles cumulatively.

Manesar Facilities

Smart statistics:

> Feb 2007 : “A Line” commissioned
(Capacity 300,000 units/annum)
> Sep 2011 : “B Line” commissioned
(Capacity 250,000 units/annum)
> Sept 2013 : “C Line” commissioned
(Capacity 250,000 units/annum)
> Total: 800,000 annually
> Total investment: in the range of Rs 5100 Cr.

Models manufactured:

> Over 1 million Swift
> Over 0.5 million A-star
> Over 0.7 million DZire
> Over 0.1 million SX4
> Over 45,000 Celerio

High points:

> Most modern facility
> Fully robotized Weld and Paint Shops
> High on energy conservation