A peek into the engineering culture that helps Maruti Suzuki stay light, even as vehicles get cleaner, safer, and more complex.
12 Jun 2025 | 1189 Views | By Kiran Murali and Ketan Thakkar
In the era of more powerful engines and stricter safety and emissions standards, Maruti Suzuki’s ability to shed weight without compromising on quality has become a defining trait of its engineering approach. At the heart of this lies a quiet but powerful Japanese philosophy: ‘Sho Sho Kei Tan Bi’, which ...
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In the era of more powerful engines and stricter safety and emissions standards, Maruti Suzuki’s ability to shed weight without compromising on quality has become a defining trait of its engineering approach. At the heart of this lies a quiet but powerful Japanese philosophy: ‘Sho Sho Kei Tan Bi’, which translates to Smaller, Fewer, Lighter, Shorter, and Neater.
“It’s not just a slogan—it’s the DNA of how we design and manufacture vehicles,” said C V Raman, former CTO and executive committee member of Maruti Suzuki, during his keynote address at the Autocar Professional Lightweighting Conference 2025.
This philosophy underlines every design decision, where each part, no matter how trivial, is assigned a weight target, often calculated down to the gram level. It’s not limited to Maruti’s in-house R&D team either.
“This has to be adopted by all stakeholders—our suppliers, vendors, and even our manufacturing partners. Lightweighting is a shared responsibility,” Raman emphasized.
Swift Case Study: A Legacy of Losing Weight, Gaining Value
If there’s one product that showcases this philosophy in action, it’s the Maruti Suzuki Swift.
Launched in 2005, the first-generation Swift tipped the scales at 980 kg. Over four generations, even as it added airbags, met tighter emission standards, improved NVH, and introduced a new platform and engine architecture, Maruti managed to maintain or reduce its weight.
“The third generation came down to 845 kg, and the latest generation, even with six airbags and BS6 Phase 2 compliance, weighs just 900 kg,” Raman noted.
That’s a remarkable feat when viewed against the broader industry trend, where electrification, connectivity, and safety additions are significantly increasing vehicle weights. It underscores Maruti’s ability to reengineer components, swap materials, and rethink design hierarchies—without compromising safety, features, or comfort.
Precision by Practice
The Swift’s weight reduction journey involved:
• Increased use of high tensile steel
• Replacing metal fuel tanks with plastic alternatives
• Swapping cast iron for aluminum in structural parts
• Leveraging lightweight interior trims and seat structures
These are not one-time changes, but rather part of a continuous improvement loop, where lightweighting is integrated into the development lifecycle from the concept stage, claims Raman.
“Every engineer has to strive for this—it's part of their KPIs. Even a one-gram reduction on a single part, when multiplied across millions of vehicles, adds up to enormous fuel efficiency and CO₂ benefits,” he explained.
A Model for the Industry
While other OEMs are just beginning to incorporate design-for-lightweighting frameworks into their processes, Maruti Suzuki has already systematized it across generations of vehicles. The ‘Sho Sho Kei Tan Bi’ model is not just about shedding mass; it’s about engineering discipline and cultural alignment.
It’s a model that ensures India’s largest carmaker remains frugal, efficient, and ready for the demands of the future—whether it’s meeting CAFE norms, enhancing range for hybrids and EVs, or lowering the environmental footprint of each vehicle.
As powertrains grow heavier and emissions targets grow tighter, Maruti Suzuki’s commitment to make every gram count may well be its lightest, yet strongest competitive edge.