Engine Downsizing Engine Downsizing –– A Kaizen Approach A Kaizen Approach

–– Amit Gautam Amit Gautam Engine Design & Development Engine Design & Development

Maruti Suzuki India Ltd, IndiaMaruti Suzuki India Ltd, India2222ndnd Jun 2010 Jun 2010

Presentation Outline

2. Engine downsizing concepts & Market Trends

3. Key Challenges

4. Exploration of Options

5. The evolution of new engine

6. Summary

1. Maruti Suzuki India Ltd & Indian market Scenario

Introduction to Maruti Suzuki

•Maruti Suzuki India Limited (MSIL, formerly Maruti UdyogLimited), a subsidiary of Suzuki Motor Corporation ofJapan, is India's largest passenger car company

•Market leader in Indian Automotive industry since last 26years.

• Largest Engg, Research, Design & Development centre ofSuzuki Motor Corp outside Japan

Maruti Suzuki Sales in FY 2009-10

3302

8

4938

3

1013

25

7794

8

6331

90

5113

96

9931

5

7592

8

3932

7489

1475

75 7002

3

050000

100000150000200000250000300000350000400000450000500000550000600000650000

A1 C A2 A3 MUV Export

FY 2009-10 FY2008-09

Our Achievements this fiscalOne Million sales :Highest ever Annual sales

Highest ever exports sales

In FY 2009-10 (Total Sales)• Maruti sells 10,18,365 units. Growth(28.6%)

• A2 grows by 23.8%• A3 grows by 30.8%.

• C segment up by 30%. Export s more that double : Up by 110.8% at

1,47,575 units.

Industry Sales FY 2009-10

8668

58

7146

55

3149

5824

4030 20

1399

1604

22

7067

746

041

3421

9

2519

6

6133

2

5019

5

5336

1343

8

1013

385

81

0

75000

150000

225000

300000

375000

450000

525000

600000

675000

750000

825000

900000

MSIL Hyundai Tata Motors GM Ford Honda MM Toyota

FY 2009-10 FY 2008-09

During FY 2009-10 (Domestic Passenger cars)

• Maruti Suzuki up by 21.3%. Industry up by 25.2%. Others up by 30%• Hyundai up by 29.1%, Honda up by 22.2% ,

• Tata up by 25.5%, Toyota up by 18.1%, GM up by 53.5%.

• Maruti Suzuki market share : 53.3% (55%)

“Build our engineering capability to Conceive, Design and Develop Carsto delight the Indian Consumer and establish Maruti as a

Design Hub of SMC”

ERDDERDD

Capability Development From “Facelift to Full Body Change”

Facility Augmentation

Manpower Augmentation,Training and Development

R&D Vision & Approach

Presentation Outline

1. MSIL & Indian market Scenario

2. Engine downsizing concepts & Market Trends

3. Key Challenges

4. Exploration of options

5. The evolution of new engine

6. Summary

Engine Downsizing

World wide Trends

Engine Capacity Reduction

Turbo Charging

Super Charging

Hybrid Vehicles

Engine Downsizing

Constraints

Engine CapacityReduction

Turbo Charging

Super Charging

Hybrid Vehicles

•Cost Up

•Cost Up•Nascent Technology

•High Cost•Parts Availability

•New parts•Limited options

Driving Forces

• Legislation Driven Reduction in Tax Duty for vehicles <1200cc

24% 16%

• Customer Driven

Engine Downsizing

Price Reduction of Vehicle

Fuel Economy

Indian Perspective

Indian Perspective

Based on the Driving forces and prevailingIndian conditions, The Downsizing in termsof Capacity Reduction works out to be themost feasible solution

Concepts and Industry Trends

Engine Downsizing

Concepts

“Engine Downsizing is the technique used toachieve the similar performance withenhanced fuel economy and reduction inemissions”

“Whatever the case, downsizing results in anincreased engines’ power and/or torquedensity, which serves one main objective:Fuel Consumption reduction”

Engine Downsizing

Concepts

• Downsizing permits Increasing engines power and torque (to respond to new market demands or to

compensate for vehicle weight increase) without increasing cylinder capacity.

Reducing engines’ capacity at same power.

• Reducing capacity at same power permits reducing FuelConsumption Pumping losses reduction

Gases-to-wall heat transfer reduction

Friction losses reduction

Presentation Outline

1. MSIL & Indian market Scenario

2. Engine downsizing concepts & Market Trends

4. Exploration of options

3. Key Challenges

5. The evolution of new engine

6. Summary

Major factors

• Economical

Minimum investment in the existing facilities

Cost down vis a vis current engine

• Technical

Maximum Fuel Economy with the givenengine

Same Torque compare to existing engine

Key Challenges

Presentation Outline

1. MSIL & Indian market Scenario

2. Engine downsizing concepts & Market Trends

4. Exploring the options

3. Key Challenges

5. The evolution of new engine

6. Summary

Exploration of Options

Available & Probable Options

119611951298993Displacement(cc)

73.575.575.561Stroke (mm)

72717472Bore (mm)

G-BG-AG-YG-X

Probable OptionsAvailable OptionsDetail

Major affected parts

Option G-B• Crank Shaft• Conn ROd

Option G-A• Cylinder Block• Piston• Piston Rings

Exploration of Options

Detail Option G-A

Bore 71mmBore 71mmStroke 75.5mmStroke 75.5mmDisp. Volume 1195 ccDisp. Volume 1195 cc

G-YConnecting Rod

G-YCrankshaft

NewPiston / Piston Rings

G-X(22.5cc)/G-Y(25.5cc)Cylinder head

NewCylinder block

DetailComponents

Exploration of Options

Detail Option G-B

Bore 72mmStroke 73.5mmDisp Volume 1196 ccCrank throw 36.75 mm (Existing 37.75 mm G-Y)Conrod length 121.55mm (Existing 120mm G-Y)

New (G-Y base)Connecting Rod

New (G-Y Base)Crankshaft

G-XPiston / Piston Rings

G-XCylinder head

G-XCylinder block

DetailComponents

Exploration of Options

Layout of Option G-A (G-X Head)

Max CR with G-X Head

Layout of Option G-A (G-Y Head)

CR Less With G-Y Head

Layout of Option G-B (G-X Head)

Layout of Option G-B (G-Y Head)

Valve Hitting

Piston NG

Valve hitting

Presentation Outline

1. MSIL & Indian market Scenario

2. Engine downsizing concepts & Market Trends

4. Exploring the options

3. Key Challenges

5. The evolution of new engine

6. Summary

Evolution of New Engine

Kaizen Approach

The Definition Kaizen is the Japanese term meansContinuous improvement, taken from words Kaimeans Continuous and Zen means improvement.

Some term it as Change for betterment

Small change for continuous improvement

Final Option selected

GA with G-X HeadGA with G-X HeadBore 71mmBore 71mmStroke 75.5mmStroke 75.5mmDisp. Volume 1195 ccDisp. Volume 1195 ccCR CR 9.879.87

Evolution of New Engine

To have max CR for FE improvement

New Cylinder block with change on Sleeve only

Design of new Piston and rings

Minimal changes in the machine shop

No change in cylinder head, Crank Shaft

Evolution of New Engine

o Performance Curve (Existing & New)Perf 1.3 L

-40.0

-20.0

0.0

20.0

40.0

60.0

80.0

100.0

0 1000 2000 3000 4000 5000 6000 7000

RPM

Torq

ue N

m /

Pow

er K

w

0.0

200.0

400.0

600.0

800.0

1000.0

1200.0

1400.0

1600.0

1800.0

BSFC

1.3L Torque 1.3L Pow er 1.3L BSFC

Perf 1.2 L

-40.0

-20.0

0.0

20.0

40.0

60.0

80.0

100.0

0 1000 2000 3000 4000 5000 6000 7000

RPM

Torq

ue N

m /

Powe

r Kw

0.0

200.0

400.0

600.0

800.0

1000.0

1200.0

1400.0

1600.0

1800.0

BSFC

1.2L Torque 1.2L Pow er 1.2L BSFC

Presentation Outline

1. MSIL & Indian market Scenario

2. Engine downsizing concepts & Market Trends

4. Exploring the options

3. Key Challenges

5. The evolution of new engine

6. Summary

Summary

Evolution of New Engine

Increase in FE 11.5%

No changes in the In house machine shop

Max Torque achieved with reduced capacity

Tax Duty benefit 24% 16%

Cost Down to the company

End benefit to customer

Thank You