Gallery: India's insane Suzuki factories
By the time you've read this story, this plant will have made 40 cars
Posted: 10 Apr 2013
The modern plant at Manesar couldn't be more different. Clean, spartan, roomy. Plenty of natural light filtering through the roof. Underestimate what is possible out here at your peril - there's no room for prejudice. The new site is state-of-the-art, developing manufacturing techniques that Western manufacturers copy. The welding line is 100 per cent automated, at a cost of nearly £21 million, and the constant improvements are mind-blowing.
Each employee is encouraged to make suggestions about the way things can be enhanced. Nothing new in that - most manufacturers do the same. But the scale is the difference. One bloke (and it is mostly men) suggested shortening the battery clasp. That saves 18 pence per car. Big deal. But, overall, that has saved Maruti Suzuki £31,000 a year.