PRODUCTION

Production is the process of manufacturing the Good/ Services. Ford India

the Maraimalai Nagar plant is now geared to achieve production efficiency and quality
ranking with the world's best. This is important for consumers, who expect high-quality
products which are price-competitive with major Indian brands.

Ford is already conducting pre-production test building of its new car in the plant facility
and will be gearing up in the fourth quarter 2009 toward the start of volume production in
the new year.

Construction work has been painstakingly conducted throughout the expansion project to
avoid disruption of existing production at the plant. Although that was a key challenge,
Ford believed it was the best policy to redevelop its existing plant complex rather than
building a "green field" plant requiring additional land.

Ford has yet to reveal details about the new small car to debut as the expanded plant's first
new product.

"The wait is almost over," Boneham said. "We are on target and this is a quantum leap for
Ford India."

Ford is targeting the heart of the Indian car market and expanding its production capacities
accordingly - with output potential of 200,000 vehicles annually.
 The production process are

Blanking

Stamping

Body Shop

Paint shop

TCF (Trim-Chase-Final)

Quality

Engine Plant

BLANKING
In blanking process raw materials are converted into blank sheets through various
steps.
STAMPING
 Semi-automatic press line moulds blank sheets into various body parts.
 Here two types of process is running Press line-1 & Press line-2
 Press line-1 is the semi-automatic process
 Press line- is fully automatic process
 Thorough checks for perfection in dimensions and surface quality.

BODY SHOP
 In Body shop assembling the parts to make a body of the car.
 Three process are there in body shop.
 Underbody
 Framing
 Closure
 70-80 Robos are working to make a body of the car for welding the parts.
 Entire shell checked with military precision for dimensions
 Subjected to stresses to check quality of welding. .

PAINT SHOP
 Cutting-edge technology creates a finish that's unaffected by rain or sunshine.
 Painting so complete that even underside gets full PVC coating for corrosion protection.
 Baking done to Ford's global paint specifications.

TCF (Trim-Chassis-Final)
 Interior taken care of before doors and seats come on in Trim zone
 In chasis area, professionals use high power tools to fit in engine, front suspension, bumpers
etc.
Once nuts and bolts are tightened to perfection, the car gets its wheels.
 Rolls into final line for remaining parts and filling of fluids.
ENGINE PLANT
In engine pant the car engine is fitted and checks the engine through the testing
methods.

QUALITY TESTING
 Stringent testing ensures every car is at its best, even in trying conditions.

PDI (PRE DELIVERY INSPECTION):

Testing of vehicle on real road conditions
The following are the various tests done to test the vehicle:
a. Speed test
b. Acceleration test
c. Vibration test
d. Oil level and water level checking
e. Electrical components checking
f. Air leakage test
g. Grease level checking
h. Road test

All Ford cars complies with Bharat III emission standards, notified by the Government of India.

Two main department in production

 MP&L (Material Planning & Logistics)
 Product Development

MATERIAL PLANNING & LOGISTICS

Material planning is the scientific way of determining the requirements of raw materials,
components, spares and the other items that go into meeting the production needs within
economic investment policies.

Here two departments plays vital role to supply the products to the production process
Materia Line supply.
This is used to supply the raw materials in the production line. For right time the right material
to carry out the production process without any stoppage.
Supply Chain Managemnt.
Supply chain managent is carry out the process of how to get parts into the Plant.

Product Development
Product development is the one of the most important for the company.
It introduces the new product for a recent trends.
Altering existing product by adding more features.

PRODUCTION MANAGEMENT STRATEGIES

Long range strategies
 Effective management of technology.
 Innovation in product management and process technology.
 Globalization in industry.
 Goodwill inside and outside the organization.
 An aggressive marketing strategy and risk taking ability.

Short range strategies

 Location and layout.
 Product selection and technology.
 Capital selection and investment.
 Flexible strategy of production.
 Standardization of design.
 Economy of size and variety.