Presented By

Jeetesh Kumar
ITM Chennai

PCBU

TATA MOTORS

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COMPANY PROFILE
TATA MOTORS

PASSENGER CAR BUSINESS UNIT AT PUNE

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Plant Layout
T.Axle Offices ETP Press Engine Materials
Comp House

CVBU
BIW

LPG Yard

Paint Shop

Assy. Shop

Sub Stn.

Pump House
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Plant Profile: PCBU Pune

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MANUFACTUING PROCESS

Committed Human Resource

Stamping

Transaxle & Heat Treatment

Material Resources

BIW

Pretreatment, coat & Painting Vehicle Assembly

Engine

Efficient Machinery & Equipment

Dispatch

Enabled Processes

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MANUFACTUING PROCESS
Transaxle & Heat Treatment + Engine:
Engine machine shop This is where the five most critical parts of the engine are
made: cylinder block, cylinder head, crankshaft, camshaft and connecting rod.

Engine assembly The five critical parts and outsourced components are brought
together here.

Engine testing Diesel and petrol engines are checked separately in testing cubicles
and test beds for power, fuel efficiency, smoke, torque and leaks.

Transaxle shop
Transaxle is the correct term, according to engineers, for what the rest of the world understands as a gearbox. The transaxle shop at the Indica is divided into six areas: soft machining, heat treatment, hard machining, housing, assembly and testing.
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MANUFACTUING PROCESS
Stamping The vehicle begins to take shape. The pieces are automatically moved to one of two large, stamping presses with dies moulded into various shapes. Over 5,400 tons of pressure used to transform into a specific body part.

Body-In-White (BIW) Welding Shop containing 326 robots who position stamped body parts and accurately weld them together to form the vehicle body, called a Body-In-White. Team Members attach hinges, doors, hood and trunk.
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MANUFACTUING PROCESS

Paint
Body moves into the Paint Shop for the nine-hour painting process. The vehicle rotates 360 degrees in a unique electrocoat bath. Robots apply primer, a base coat using one of 15 different water-based paint colors. Paint Shop is an environmentally-controlled area, Team Members must wear special overalls and gloves to protect themselves and the paints finish The Paint Shop has over four miles of conveyor systems to move the vehicle bodies through each different process. After drying, the freshly-painted vehicle body heads to General Assembly.
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MANUFACTUING PROCESS
General Assembly General Assembly houses approximately 1,150 Team Members. The painted vehicle body moves where wires, brake controls, and other parts are connected in the vehicle, under the hood, and trunk. The doors are taken off early and sent to another area where speakers, power windows, door seals and other parts are installed. In the chassis area, the underside of the vehicle is completed and the engine and drive train are connected to the body. After the tires, battery, front and rear glass, and seats are installed, the doors are reattached to the vehicle. Oil, engine coolant, gasoline and other vital fluids are added, and then the vehicle is started for the first time. A roll booth tests the braking system and vehicle is driven on a twomile test track to check for rattles or other issues.
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A shower test checks for leaks and once a vehicle meets all quality standards it is ready to be shipped to a dealer Quality Quality checks are built into each step in the production process. Each vehicle has to pass a series of stringent tests, including satisfactory performance on a two-mile test track. Tata Motors is the first Indian company that has implemented DELMIA solutions from end-to-end. DELMIA solutions at Tata Motors have enabled the assessment of equipment and logistics planning in a virtual world. Through the 3D simulation of assembly processes and tests, such as clash, interference or tool accessibility, the finer details can also be ironed out in advance.
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JOURNEY TOWARDS ENERGY EXCELLENCE THE METHODOLOGY

Benchmarking Enhanced Capacity Utilization through Technology up gradation Energy Audits Energy Conservation through low cost automation Thermography :An Innovative way of Energy Conservation Energy Conservation through Process Optimization Energy Conservation through rework elimination.

TEP : Energy Conservation, An Attitude of mind & not the effort.

Sustainability through Continual Improvement
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BENCHMARKING

Inputs from M/s Harbor & Associates(USA) on various Automobile Manufacturing aspects such as: - Level of Automation - Quality norms and standards followed internationally - Throughput Study of processes and practices followed in similar industries Information sharing with domestic and international players .

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Capacity Utilization
Introduction of Various new Models on Indica Platform
Indica : Base Model

Tata Indigo

Indica Sports

Indica Estate

City Rover

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Energy Conservation through low cost automation

Underbody spray application (Automatic)

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TEP
TOTAL EMPLOYEE PARTICIPATION

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CONCLUDING THIS PRESENTATION

Tata motors is the flag bearer of the Indian manufacturing industry, being the first Indian manufacturing company to have its own indigenously manufactured passenger car and being the first to make forays into the global market. It is a showcase for the whole industry with world class process management techniques being incorporated .This has been proved as they booked a turnover higher than Honda motors this fiscal, to become the 2nd in industry after Maruti Suzuki.

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