Published on January 30, 2014
TATA NANO MANUFACTURING Khushiyon ki chaabi
Agenda I. II. III. IV. V. VI. History Introduction Technical specification The Strategy Supplier relation Assembling
Ratan Tata was the chairman of the TATA company since 1991 to 2012. It is diversified in 90 companies like Tata steel, Tata salt, Tata chemicals, Tata motors, Titan, Tata Telecom etc… This company is serving INDIA for over 130 years This company continuously upgrades technology with tie ups & collaboration with global companies
THE SEEDS OF DREAM The dream stared when Ratan Tata saw a family of four people (Husband, wife & two children) going on two-wheeler on heavy rain in highly risky conditions…But in India it’s a very common scene. Mr. Ratan Tata said, “I observed families riding on two-wheelers - the father driving the scooter, his young kid standing in front of him, his wife seated behind him holding a little baby. It led me to wonder for such a car which is safe & affordable to any middle class family.”
INTRODUCTION • Tata Nano is a proposed city car — a small, affordable, rear-engined, four-passenger car aimed primarily at the Indian market. • Presented by India's Tata Motors at the 9th annual Auto Expo on January 10, 2008 at Pragati Maidan in New Delhi, India.
ABOUT PLANT • Situated in Singur West Bengal • Investment of 1500cr. rupees by Tatas. • Shifting cost of the plant from singur is around 500 cr. • Total area of plant is 1000acres out which 300 acres were alloted for assembling of various parts and rest 700 acres for manufacturing.
AIM OF MAKING • The project to create the world's cheapest car inspired by the number of Indian families with two-wheeled rather than four-wheeled transport.
TECHNICAL SPECIFICATION AND FEATURES • First car in india with rear engine and rear wheel drive. • Engine with 623cc • A 33bhp car • Having fuel efficiency 21.97km/ltr in city and 25.5km/ltr on highway. • First car with 2 cylinder non opposed petrol engine.
TECHNICAL SPECIFICATION AND FEATURES • • • • • Acceleration: 0-70 km/h in 14 seconds. Maximum speed: 105 km/h. Trunk capacity: 15 L. Front brake: disc Rear brake: drum
The Strategy • Tata divided the components into two types – proprietary designs and Tata Motors design. For proprietary design components. Tata went with established suppliers such as Bosch which supplies the engine management system and has significantly contributed to the future diesel engine.
The Strategy • For components and systems designed inhouse, Tata Motors chose suppliers with strong process capabilities who could give valuable suggestions and improve on the designs. Nearly everything has been sourced locally and the Nano will have 97% local content from day one. Tata’s suppliers were an integral part of not only the design and development process, but also purchasing.
Supplier Relation •E.Balasubramanian , head of sourcing for the project, was not a popular man with vendors and there were problem in order to get vendors to pare marging and persuade them to produce components at lower cost .
The vendors had to invest in new processes and methods to reengineer their products to specifications that were rigidly guided by cost , performance and regulatory compliances.
For example , P.K.Kataky , director of battery maker exide , was reported as saying that the company’s margin would be thin and it would start making money only after two or three years.
Getting suppliers ,who were mostly clustered in auto centres such as pune, chennai and delhi , to invest in singur , west bengal , which Tata motors had chosen for its small car plant , was difficult . “But now about 15-20 vendors would finish their plants along with Tata Motors”.
However A three-shift operation and consolidated purchasing with suppliers provided them with lots of relief.
List of suppliers to TATA Nano • • • • • • • Bosch Caparo Continental Delphi Denso Fag Ficosa 8. Freudenburg 9. GKN 10. Itw Deltar 11. INA 12. Johnson Controls 13. Mahle 14. Saint gobain
• • • • • • 15. TRW 16. Ceekay 17. Vibracoustic 18. Visteon 19. Z.f (friedrichshafen) A.G 20. Behr
SUPPLIED MATERIALS BY SUPPLIERS • BOSCH: A German based automotive company. • It supplies Gasoline injection system, starter, alternator, brake system.
• Caparo Vehicle Technologies (CVT) : A Europe based company. • it supplies Inner structural panels.
• Continental motors: it is a Europe based company. • It supplies fuel level sensor, gasoline fuel supply system.
• Delphi: an automotive parts company headquartered in Troy, Michigan, USA. • It supplies instrument clusters.
• Denso: a global automotive components manufacturer headquartered in the city of Kariya, Japan. • It supplies Windshield wiper system.
FAG Kugelfischer • FAG: A German based company manufacturing ball bearings. • It supplies rear wheel bearings.
• Ficosa: It supplies Rear-view mirrors, interior mirrors, manual and CVT shifters, washer system .
• Freudenberg: a town in the, in North RhineWestphalia, Germany. • It supplies Engine sealing.
• BEHR GmbH & Co: German corporation • It supplies engine cooling systems and HVAC for the luxury version.
• ZF Friedrichshafen: a town on the northern side of Lake Constance in southern Germany, leading worldwide supplier of driveline and chassis technology. • It supplies Chassis components, including tie rods
• Vistoen: a U.S based company. • It supplies air induction system.
• Vibracoustic: it supplies Engine mounts.
• TRW: an American corporation. • It supplies break systems.
• Saint-Gobain: a French multinational corporation, headquartered on the outskirts of Paris . Originally a mirror manufacturer, it now also produces a variety of construction and high-performance materials. • It supplies glazing.
• Mahle GmbH: a german based company headquartered in Stuttgart. • it supplies Camshafts, spin-on oil filters, fuel filters and air cleaners .
• Illinois Tool Works (Itw): a U.S based company. • It supplies Outside and inside door handles .
• Johnson Controls: a U.S based company. • It supplies seating systems.
Assembling • Development began in: 2003 • Scheduled to roll out in: 2008 • The Nano was originally to have been manufactured at a new factory in: • Singur (census town, less than 5000 people, 75% working men on non-agricultures, and 400km2/citizen) • West Bengal (state in eastern of India, with 3rd fastest growing economy in India, best power infrastructure, includes Kolkata city)
Assembling Reportedly manufacturing Nano at: • Pantnagar (town and university campus) • Uttarakhand (state in northen of india, policies for generous tax benefits for investors) And a mother plant has been proposed for: • Sanand Gujarat (largest business in india, 1st nationwide gas-based thermal electricity)
Assembling • The new Nano Plant could have a capacity of 500,000 units, compared to 300,000 for Singur. • Gujarat has also agreed to match all the incentives offered by West Bengal government.
Assembling • As of August 2008, material costs had risen from 13% to 23% over the car’s development
Tata Nano at Sanand, Ahmedabad • The capacity of the plant, to begin with, will be 250,000 cars per year • expandable up to 350,000 cars per year • spread over 725 acres
Now, lets see, How do they do it…??
Assembling • The plant is divided into 5 shops (/sections): – Weld shop – TCF shop – Power train shop – Paint shop – PDI SHOP
WELD SHOP – Also known as BIW Shop (BODY IN WHITE). – Here the different parts are welded together and the whole structure of the car is built. – This shop plays very important role in framing the body shell. The press panels are transported from Bhuj and Pune plant.
WELD SHOP – It has three main assemblies, which includesUB(under body), ML(Main line or main frame) and MF(metal finish) where different welding processes of » Projection welding » CO2 welding » MIG welding » Stud welding » Spot welding
TCF Shop (TRIM CHASSIS FITTING) • Also known as ASSEMBLY SHOP – assembly works like Engine, – Suspension, Tyres, Lights, Dashboard etc. fitment is carried out.
POWER TRAIN SHOP • This shop is divided into Power Train and Engine shop. Here various operations related to Engine, Gear Trains etc. are performed. • It consists of – Engine Assembly Shop – Transaxle Assembly Shop – Engine Dressing Line • In Engine assembly the various components of the Engine are assembled into a single unit and sent for the various tests.
PAINT SHOP • The TAIKISHA paint shop is the beauty parlors of the car plant. This shop paints the car in various shades. It takes 18 steps spread over less than 10 hours to accomplish the task. • Here in Paint shop: – – – – Colour and appearance Covering of gaps between the weld joints Corrosion resistance Smothering of sharp corners
PDI SHOP (Pre-Delivery Inspection) • PDI is the final quality check, in this the overall checking of the vehicle takes place, in this the fitment is not done, only the outward checking is completed. The final QA OK of the vehicle is done here and after this the vehicle is sent for dispatch. • Parts which are checked are mentioned below:
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