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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
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
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