For entrepreneurs and innovators in the mobility sector, few experiences are as enriching as a firsthand visit to an industry leader’s manufacturing facility. Recently, the winners of Maruti Suzuki NURTURE Cohort 2.0 had an invaluable opportunity to visit the Maruti Suzuki India Limited (MSIL) Manesar Plant – one of the largest and most advanced automotive manufacturing facilities in India. The visit offered first-hand insights into state-of-the-art manufacturing practices, lean production processes, automation in vehicle assembly and Maruti Suzuki’s approach to sustainability and workforce development. Following is an elaboration of the experiences and the key learnings picked up by the entrepreneurs during the visit.

 

Advanced Manufacturing Processes: Setting Industry Standards

The Manesar plant exemplifies cutting-edge manufacturing and thoroughly streamlined processes. The visiting entrepreneurs were introduced to Maruti Suzuki’s just-in-time (JIT) production system, which minimises inventory costs, reduces inventory costs and maximises efficiency by ensuring that the parts arrive exactly when needed.

Key learnings:

– Efficiency through Lean Manufacturing: Adopting lean principles can drastically reduce production costs, improve turnaround times and minimise waste, which can be the deciding factors for the success of any mobility startup.

-Automation for Precision: A high level of automation ensures precision, consistency and superior vehicle quality by minimising human error conspicuously.

 

Sustainable Manufacturing Practices

Maruti Suzuki’s Manesar plant exemplifies its commitment to sustainability with water recycling, zero-waste-to-landfill systems and solar energy usage, reflecting the company’s dedication to green manufacturing and reducing environmental impact.

Key learnings:

-Green Manufacturing: Sustainability is not just a corporate responsibility but provides a competitive advantage as well. Startups that incorporate eco-friendly practices from the beginning—such as using renewable energy or recycling materials—can appeal to environmentally conscious consumers and investors.

-Resource Optimisation: Meticulous management of resources through thoughtful means like water recycling and energy-efficient equipment can effectively reduce wastage.

 

The Role of Automation and Industry 4.0

The Manesar plant utilises robotics and automation across welding, assembly and quality control, embodying Industry 4.0 principles. Data analytics further helps enhance operational efficiency, product quality and maintenance.

Key learnings:

-Embrace Industry 4.0: The future of manufacturing is data-driven. By integrating IoT and AI-driven predictive maintenance, startups can improve efficiency, prevent costly downtimes and maintain high product quality standards.

-Flexible Automation: Maruti Suzuki’s use of robots extends beyond repetitive tasks, with some programmed to adapt to different vehicle models, demonstrating the flexibility of automation. This highlights the potential of adaptable automation to optimise operations across diverse product lines.

 

Workforce Development and Training

Maruti Suzuki’s Manesar plant invests in its workforce through dedicated training centres, ensuring employees are regularly skilled, reskilled and upskilled to stay updated with new technologies and processes.

Key learnings:

-Invest in People: In any high-tech production environment, a skilled and adaptable workforce is essential. Entrepreneurs should focus on building a knowledgeable and versatile team that can keep up with technological advancements.

-Encourage Lifelong Learning: With the pace of innovation in mobility accelerating, fostering a culture of continuous learning can help employees stay relevant and contribute meaningfully to a startup’s growth.

 

Quality Control and Assurance

Maruti Suzuki’s Manesar plant prioritises quality control at every stage, with automated systems inspecting components to ensure defect-free products, upholding the company’s reputation for reliability.

Key learnings:

-Prioritise Quality Control: In a competitive market, quality can be a decisive factor for customers. Entrepreneurs must establish rigorous quality checks from the outset to meet consumer expectations and build trust.

-Leverage Technology for Quality Assurance: Automating quality control tasks minimises errors, speeds up production and maintains consistency. By integrating smart quality assurance tools, startups can achieve higher standards and lower production costs.

 

Logistics and Supply Chain Management

Maruti Suzuki’s Manesar plant boasts top-class logistics and supply chain management, integrating seamlessly with suppliers and vendors and enabling rapid communication and just-in-time inventory management. This sophisticated supply chain setup helps minimise disruptions, reduce warehousing costs and ensure a steady material flow.

Key learnings:

-Efficient Supply Chain Design: A well-coordinated supply chain is essential for high-output manufacturing. Entrepreneurs should focus on establishing close relationships with suppliers and investing in robust inventory management systems.

-Adaptability: The ability to adapt supply chain processes based on demand and supplier dynamics emphasises the importance of flexibility. Mobility startups must design supply chains that can swiftly adjust to market changes or disruptions.

 

R&D and Innovation

Maruti Suzuki invests heavily in research and development, resulting in innovation in vehicle design, fuel efficiency and electric mobility. This ensures that the company remains competitive and responsive to consumer needs.  keeping it competitive. Entrepreneurs in the mobility sector are encouraged to prioritize R&D for long-

Key learnings:

-Prioritise R&D Investment: Innovation-driven R&D is key to staying competitive in the mobility space, particularly as trends shift towards electric and autonomous vehicles.

-Consumer-Centric Approach: For startups, building products that solve real customer problems is fundamental to success.