MARUTI SUZUKI | INNOVATION IS ABOUT PROGRESSIVE IMPROVEMENT · Managing Director, NGK Spark Plugs...

INTERACT ION MARUTI SUZUKI, NGK SPARK PLUGS

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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

4-11_News_ATR_jan'13.indd 44-11_News_ATR_jan'13.indd 4 03-01-2013 12:45:5503-01-2013 12:45:55

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.



INTERACT ION FIEM INDUSTRIES


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.



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


INTERACT ION CONTINENTAL


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


MARUTI SUZUKI | INNOVATION IS ABOUT PROGRESSIVE IMPROVEMENT · Managing Director, NGK Spark Plugs...

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