Case Study Automotive · Manufacturing

3x faster EOT crane maintenance.

Client
Maruti
Maruti Suzuki India Ltd
Sector
Passenger Vehicle Manufacturing
Location
Manesar / Gurugram, Haryana
India
Deployment
EOT Crane Maintenance Bays
Outcome

Measurable impact across the operational footprint.

3X
Productivity uplift

Maintenance tasks completed 3× faster than the scissor lift workflow.

10X
Operational cost reduction

Cut energy draw, breakdown repairs, and complex-maintenance spend.

25 ft
Safe working height

Integrated stairway + J-hook stabilisers certified by the EHS team.

01 · The Challenge

A scissor lift that slowed every maintenance window.

Maruti Suzuki runs a continuous, high-throughput paint + assembly operation at scale. EOT cranes service the line around the clock, and their maintenance must happen at heights of up to 25 feet without disrupting vehicle flow.

The maintenance team had standardised on a scissor lift for at-height tasks. It worked, but it was beginning to cost more time and money than it saved.

Maruti site

Y Group access equipment on site

02 · The Solution

Fitout Master with J Hook — purpose-built for EOT crane access.

Y Group’s Fitout Master replaces the scissor lift with a lightweight, mobile, corrosion-resistant platform engineered specifically for EOT crane maintenance. The J-hook stairway makes climbing with tools safe and compliant with Maruti’s internal EHS standards.

It installs in minutes, folds down for storage, and needs no plugged-in power source to stay at working height.

Key features deployed
  • check_circleLightweight aluminium construction — two-person deployment, no forklift needed
  • check_circleCorrosion resistance — reliable in paint-shop and shop-floor conditions
  • check_circleQuick assembly — stands up in minutes, no specialist tools
  • check_circleIntegrated stairway with J-hook — safe tool carry at 25 ft working height
  • check_circleEHS-approved — replaces the rejected monkey-ladder standard
  • check_circleZero continuous-power requirement — unlike the scissor-lift predecessor

Maintenance productivity increased by 3X and operational cost dropped 10X—the Fitout Master gave our EOT crane team a safer, simpler way to work at height.

Maintenance Leadership · Maruti Suzuki India Ltd.
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