Presently planning for establishing a new plant at Indian roads. TATA Motors, the first company with having over more than million Stock Exchange in September company having operations lining in year 2008, it acquires Jaguar and launched Nano, people’s car in budget. And making jointVenture in India in 2007. Tata bus manufacturing Company, producing over billion models in South Korea’s economy.
It is the leader of motors and liesamong the top three in passenger vehicles and utility vehicle segments. Its the second largest bus manufacturers, using production value upto 92, 519 crores (USD 20 billion) in 2009-10. Now, it is present all over the country spread across Jamshedpur (Jharkhand), Patna, (Uttarakhand) and Dharwad , Gujarat). Over 5. 9 million Tata vehicles are producing from India’s engineering sector to be listed in 2004. It has also emerged as an international in the UK, South Korea, Thailand & Spain. producing star cars such as Land Rover from Ford Motors & in company. Fiat Group & Tata Motors announce established Motors acquires 21% stake in Hispano Cay. In 2004, it acquired the Daewoo Cond largest truck makers Unit (PCBU) and both the business flourished at large .
JAGUAR LAND ROVER
TATA MARCOPOLO MOTORS
TATA MOTORS (THAILAND)
TATA MOTORS EUROPEAN TECHNICAL CENTRE
TAL manufacturing solutions
HV transmission and HV axles
TML DISTRIBUTION CO
TATA MOTORS FINANCE
CLIMATE AND CULTURE AT TATA MOTORS
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THE TATA WAY
The TATA is still an emerging market because, although demand and consumption are going up, there are still too many bottlenecks in the system – both with regard to infrastructure and to processes.
A lot of productivity and time go into trying to go around or over obstacles, and that really saps one’s capacity and ability to do things. Some tasks that may take just one day in a more mature market, here may take one week or one month. Even then, the process is fraught with a lot of uncertainty and challenges and, therefore, a leader’s productivity drops very substantially
The vision and the aggressive stance that Tata Motors has taken, most particularly in the last 10 years or so, to break out of the normal growth pattern and to look at opportunities in the market as they emerge. We then try to convert those opportunities into real business.
Tata Motors has a very strong, spectacular and wide base of Indian loyalty, and that is helping us substantially in creation of products. We build small to very large trucks. We build bulk passenger carriers like buses, small and large. We build passenger vehicles and multi-utility vehicles. The range is vast; and, therefore, to see that you maintain a strong position, you need to spend a lot of time, effort and money to maintain that leadership position.
There is strong concept of trusteeship, not ownership, throughout all the companies. Mr Tata heads the Tata Group by virtue of being trustee of those trusts and not as the owner – and that perspective permeates throughout the management levels within the company.
This is one dimension to how we manage. The second is that the founder, when he started setting up businesses, had the very devolutionary idea that, whatever comes from society, should go back to the society in some form or the other. That means you hold in trust what you are getting from the society, and you give it back to the society.
Thus, Tata has a very different kind of culture or ethos, if I may say so, and this permeates the entire Tata Group, which leads to better corporate governance. Under this approach, there are better ethical values, different ways of doing things and better records of showing concern for society.
There is a greater caring for people and caring for things around our businesses. Tata’s values and group culture are unique, compared to other businesses, which also means that many times there are much greater problems and difficulties in getting things done.
THE CLIMATE OF CHANGE
The Tata group has always allied itself closely with the environment. With a comprehensive plan combat climate change, the group looks to strengthen the partnership
Tata Motors owes its leading position in the Indian automobile industry to its strong focus on indigenisation. This focus has driven the Company to set up world-class manufacturing units with state-of-the-art technology. Every stage of product evolution-design, development, manufacturing, assembly and quality control, is carried out meticulously. Our manufacturing plants are situated at Jamshedpur in the East, Pune and Sanand in the West and Lucknow and Pantnagar in the North.
UNITS UNDER TATA MOTORS
The Pune unit is spread over two geographical regions- Pimpri (800 acres) and Chinchwad (130 acres). It was established in 1966 and has a Production Engineering Division, which has one of the most versatile tool making facilities in the Indian sub-continent. It houses a Vehicle manufacturing complex which is one of the most integrated automotive manufacturing centres in the Country producing a large variety of individual items and aggregates. It is engaged in the design and manufacture of sophisticated press tools, jigs, fixtures, gauges, metal pattern and special tools, as well as models for the development of new ranges of automobile products. Its capabilities have enabled Tata Motors to introduce new products and improve existing ones without resorting to imports of dies or fixtures.
Over the years, this division has developed expertise in design and manufacture of automated dies, fixtures and welding equipment. Its large design group is fully conversant with state-of-the-art CAD facilities and manufacturing facilities comprising of light and heavy CNC machine shops, jigs boring room, plastic template shop, wood pattern and model pattern shop, five axis precision machine tools and laser control machines. To cope with such a diverse range, four assembly lines have been established, one each for MCVs and HCVs, LCVs, Utility vehicles and one for Passenger Cars (Indica and Indigo).
The Passenger Car Division in ‘ K’ block executes the entire process of car manufacture over five shops – the engine shop, the transmission shop, press and body shops, paint shop and the trim and final assembly shop. The shops are fully automated ensuring that there is minimal chance for error in the manufacturing processes.
After the car is completely assembled, it goes through several checks like wheel alignment, sideslip test, brake test, shower test, and a short test run before it is ready for dispatch. All systems such as materials management, maintenance and other activities are computerized, enabling smooth operations and minimum inventory needs.
The Electronics Division is engaged in the production of a wide variety of Machine Tool Controllers, PLCs, Test rig instrumentation, Servomotors, Proximity Switches. In addition, it has developed a number of components such as flashers, horns, timers that are used in Tata Motors’ vehicles.
Industry experts rate the fully automated Foundries at Chinchwad and Maval among the best, worldwide. The Iron Foundry at Chinchwad produced 37, 000 Tons of high precision castings in 2006-07 while the Iron Foundry at Maval produced 14000 Tons of spheroidal Iron castings in 2006-07. These include Cylinder Blocks, Cylinder Heads, Gear Box Housing, etc. To dispense with the need for outsourcing, an Aluminium Foundry with an annual capacity of 3, 300 tonnes has been established.
Tata Motors Lucknow is one of the youngest production facilities among all the Tata Motors locations and was established in 1992 to meet the demand for Commercial Vehicles in the Indian market. The state-of-the-art plant is strongly backed by an Engineering Research Centre and Service set-up to support with latest technology and cater to the complexities of automobile manufacturing. Fully Built Vehicle business, which is one of the fast growing areas of our business, is also established in Lucknow.
Our plant, rolls out commercial vehicles and is specialised in the designing and manufacturing of a range of modern buses which includes Low-floor, Ultra Low-floor, CNG & RE Buses.
The Lucknow facility also specialises in manufacturing HCBS (High capacity Bus System) buses.
In light of Company’s aggressive growth plans, we are currently in expansion phase and production at Lucknow would grow many-fold in near future. The expansion shall be in the areas of painting, welding, vehicle assembly & testing and utility services, driven by latest technology. To achieve these plans we invite people who have good Technical Knowledge, seek Challenging Opportunities and have a Drive for Engineering Excellence to come and partner us in our journey.
The Company has set up a plant for its mini-truck Ace and the passenger carrier Magic (based on the Ace platform) at Pantnagar in Uttarakhand. The plant began commercial production in August 2007. This is the company’s fourth plant, after Jamshedpur (commercial vehicles), Pune (commercial vehicles and passenger vehicles) and Lucknow (commercial vehicles). The plant is spread over 953 acres, of which 337 acres is occupied by the vendor park.
State-of-the-art facilities include weld shops, paint shops, engine and gear box shops and assembly lines. The Company has invested over Rs. 1000 crores in the plant. Vendors for the vehicle have made additional investments to set up their plants in the vendor park adjoining the plant. The operation has generated about 7500 direct and indirect jobs in the plant, among vendors and service providers in the area.
Tata Motors’ plant for the Tata Nano at Sanand, in Ahmedabad district of Gujarat, marks the culmination of the Company’s goal of making the Tata Nano available to hundreds of thousands of families, desirous of the car a safe, affordable and environmental friendly mode of transport. The capacity of the plant, to begin with, will be 250, 000 cars per year to be achieved in phases, and with some balancing is expandable up to 350, 000 cars per year. Provision for further capacity expansion has also been incorporated in this location.
Built in a record time of 14 months starting November 2008, the integrated facility comprises Tata Motors’ own plant, spread over 725 acres, and an adjacent vendor park, spread over 375 acres, to house key component manufacturers for the Tata Nano.
In line with latest world-class manufacturing practices, the Tata Nano plant has been equipped with state-of-the-art equipment. They include sophisticated robotics and high speed production lines. Conscious of the critical need of environment protection, the plant has energy-efficient motors, variable frequency drives, and systems to measure and monitor carbon levels. These are supplemented with extensive tree plantation, sustainable water sourcing through water harvesting and ground water recharging and harnessing solar energy for illumination.
Established in 1945, the Jamshedpur unit was the Company’s first unit and is spread over an area of 822 acres. It consists of four major divisions – Truck Factory, Engine Factory, Cab & Cowl Factories. The divestments in March 2000 hived off the Axle and Engine plants into independent subsidiaries viz. TML Drivelines Limited, respectively.
The Truck Division boasts of two assembly lines. The main assembly line, measuring 180 m in length has 20 work stations with a vehicle rolling out every 8 minutes. The other line is dedicated to special purpose vehicles and for meeting the requirements of the Indian Army. The uniqueness of the Factory lies in its possession of
Advanced facilities for manufacturing long members comprising of a set-up of 5000 Tones Hydraulic press line, cut-to-length line for strip preparation purchased from M/s Kohler of Germany and a Camber Correction line.
Facility for hot forming of axle halves with a 3000 tone press and heating furnace.
Flexibility in manufacturing frames with an off line Proto-typing facility.
The Cab & Cowl Factory is equipped with state-of-art facilities like Centralized Paint Shop and Automated painting set up, Robot painting, BIW Fabrication of day & sleeper cabs for trucks, Articulates (Tractor/ Trailer), BIW Fabrication of Cowls for buses, and other miscellaneous applications.
The fully equipped Foundry, that the unit is supported by, supplies high-grade SG Iron castings for automobile components and excavators, and is rated as one of the cleaner, better and highly automated foundries in the world. It has an annual capacity of 42, 000 MT of Good castings and makes, both, Gey and SG cast Iron casting. It manufactures all critical automobile castings e. g. Cylinder Block, Cylinder Head etc. It has a sophisticated Kunkel Wagner High Pressure Moulding line of a rated production capacity of 90 moulds/ hour. This is supported by a sand cooler and sand mixer from Kunkel Wagner. Its melting shop has Medium Frequency Induction Furnaces for melting and Channel Furnaces for holding. The pouring is done by a Channel Press Pour coupled with a Steam Inoculation Dispenser. The core shop has a state-of-the-art Cold Box Machine, making four cores per minute. It has elaborate sand and metallurgical laboratories. In 1993 the foundry was ISO 9002 certified by the Bureau Veritas Quality International, which was later followed by the more stringent QS 9000 certification from the BVQI in the year 2000. Currently it is certified as TS: 16949 by BVC.
The Engine Factory is responsible for the in-house manufacture of Tata 697/497 Naturally Aspirated and Turbo Charged engines, and the 6B series engines manufactured at Tata Cummins.
As one of the most modern forging set-ups in the Country, the Forge Division is equipped with a semi-automated forging line with 40, 000 mkg Beche Hammer and state-of-the-art presses from Kurimoto of Japan. It produces critical forgings like crankshafts, front axle beams and steering parts for the automobile plant. The new forging line, installed in April 1984, has the capacity to forge front axle beams at 90 sec per piece and crankshafts at 120 sec per piece. Mechanical presses help produce a variety of heavy forgings. The sophisticated FIDIA digit 165 CC Graphite Milling Machine links shop floor machines to the design workstation. The Forge has been certified as ISO 9002 and QS 9000 by the BVQI.
TATA MOTORS DRIVELINES LIMITED
TML Drivelines Limited., a wholly owned subsidiary of Tata Motors, is currently the market leader in medium and heavy commercial vehicles axles in India with an installed capacity of over two lakh axles per annum. The Company’s product range includes Front Steer axles- both live and normal, Rear Drive axles and dummy/ trailer axles. It is currently the sole suppliers of M&HCV axles to the Jamshedpur and Lucknow plants of Tata Motors.
TML Drivelines Limited has state-of-the-art manufacturing facilities for making all major Axles components such as Front Axle Beam, Stub Axles, Front & Rear Wheel Hubs, Differential, Axle Gears (Crown Wheel, Pinion, Bevel Gear & Shaft Gear), Banjo Axle Beam, Swivel Heads, Constant Velocity Shafts etc. For being in the forefront of cutting edge technology, TML Drivelines Limited has proven skills in manufacturing axles from component level to assembly & testing. As a TS 16949 company, TML Drivelines Limited encourages and continuously supports its vendor base to upgrade their Quality Management System to TS 16949.
TML Drivelines Limited was established on 13th March 2000 as a major subsidiary of Tata Motors by taking over operations of Tata Motors’ erstwhile Gearbox Division. It is a leading manufacturer of automotive transmissions, components and engineering applications for a wide range of medium and heavy commercial vehicles. The Company has a capacity of producing 94, 000 gearboxes per year which is being enhanced to a capacity of 120, 000 Gearboxes per year. It provides products and services of superior quality, matching with the current economic and business trends in medium and heavy commercial vehicle markets. The Quality System of TML Drivelines Limited is certified under ISO/ TS-16949. In the environmental and safety front, it was ISO 14001 certified in 2004 and OHSAAS-18001 certified in 1999.
SOCIAL RESPONSIBILITIES TAKEN UP AT TATA MOTORS
While making technological advancements, the social responsibilities are also taken up seriously. Tata Motors, Jamshedpur, plays an active role in serving rural communities surrounding its Works through various community centres. While striving to create a culture for self-help amongst the local populace, it has made significant progress in community and social forestry, sustainable development of wastelands, road construction, rural health and education, development of rural industries, water supply and family planning. A signatory to the UN Global Pact, it also takes various initiatives in human rights protection, labour standards, environmental issues, modern effluent treatment facilities, sanitation drives, soil and water conservation programmes, tree plantation drives, etc.
MARUTI SUZUKI LIMITED
MARUTI UDYPG LIMITED
Maruti is India’s largest automobile company. The company, a jointventure with Suzuki of Japan, has been a success story like noother in the annals of the Indian automobile industry. Today, Maruti is India’s largest automobile company. This feat wasachieved by the missionary zeal of our employees across the lineand the far-sighted vision of our management.
THE COMPANY MISSION
To provide a wide range of modern, high quality fuel efficientvehicles in order to meet the need of different customers, both indomestic and export markets.
THE COMPANY VISION
We must be an internationally competitive company in terms of our products and services. We must retain our leadership in India and should also aspire to beamong the global players.
THE FOCUS ON :
-Building a continuously improving organisation adaptable toquick changes
-Providing value and satisfaction to the customer
Company are discussed with the Union. The Sahyog Samiti, acollection of representatives of non-un organised employees, training programmes in Japan, Quality Circles, productivity-linked incentive schemes, and an ethos of discipline and teamwork, all contribute to the Maruti culture. Several measures of performance have made amply clear that Maruti has established a truly healthy work culture. They have metal project and performance targets since inception. Their productivity levels are constantly improving. The Company has had good labour relations with employees from the very beginning, and they have been successful in the export market. Yet, the Maruti culture is one that does not believe in resting on its laurels. The adhere to the spirit of Kaizen, which states that constant improvement is always possible. The most basic tenet of productivity that they hold is that ‘ Today should be better than Yesterday and Tomorrow should be better than Today”. Maruti Udyog Limited (MUL) was established in Feb 1981 through an Act of Parliament, to meet the growing demand of a personal mode of transport caused by the lack of an efficient public transport system. Suzuki Motor Company was chosen from seven prospective partners worldwide. This was due not only to their undisputed leadership in small cars but also to their commitment to actively bring to MUL contemporary technology and Japanese management practices (which had catapulted Japan over USA to the status of the top auto manufacturing country in the world). A licence and a Joint Venture agreement was signed between Government of India and Suzuki Motor Company (now Suzuki Motor Corporation of Japan) in Oct 1982. The objectives of MUL then were:
-Modernization of the Indian Automobile Industry.
-Production of fuel-efficient vehicles to conserve scarceresources.
-Production of large number of motor vehicles, which wasnecessary for economic growth. Core Value
-Fast, Flexible and First Mover
-Innovation and Creativity
-Networking and Partnership
-Openness and Learning
The leader in the India Automobile Industry, Creating CustomerDelight and Shareholder’s Wealth; A pride of India.
We have introduced the superior 16 * 4 Hypertech engines across the entire Maruti Suzuki range. This new technology harnesses the power of a brainy 16-bit computer to a fuel-efficient 4-valve engine to create optimum engine delivery. This means every Maruti Suzuki owner gets the ideal combination of power and performance from his car. Our other innovation has been the introduction of Electronic Power Steering (EPS) in select models. This results in better and greater maneuverability. In other words, our cars have become even more pleasurable to drive.
Spread over a sprawling 297 acres with 3 fully-integratedproduction facilities, the Maruti Udyog Plant has already rolled out over 4. 3 million vehicles. In fact, on an average, two vehicles rollout of the factory every minute. And it takes on an average, just 14hours to make a car. More importantly, with an incredible range of 11 models available in 50 variants, there’s a Maruti Suzuki made here to fit every car-buyer’s budget.
THE LOW COST MANAGEMENT ADVANTAGE
The acquisition cost is unfortunately not the only cost you face when buying a car. Although a car may be affordable to buy, it may not necessarily be affordable to maintain, as some of its regularly used spare parts may be priced quite steeply. Not so in the case of a Maruti Suzuki. It is in the economy segment that the affordability of spares is most competitive, and it is here where Maruti Suzuki shines. The recent Auto car Survey conducted in August 2004 bears testimony to this fact. In the Maruti Suzuki stable, the Omni has the lowest aggregate cost of spares followed by the Maruti-800. The Maruti-800 has the cheapest spares of any Indian car with a basket of just Rs. 23, 422. In the Lower Mid-size segment as well, price-consciousness is very high, where the cars have to be not only affordable on purchase price but also need to combine quality , drivability and have comfortable interiors. In this segment, the Maruti Suzuki Versa has scored particularly well with the lowest cost of spares in the segment. In the Upper Mid-sizes segment, the Maruti Suzuki Baleno has the segment’s lowest prices on a majority of the spares.
LOWEST COST OF OWNERSHIP
To be really happy with the car one owns, it should be easy on the pocket to buy and to run-which is why the cost of 21 ownership is so important. And here again, a Maruti Suzuki is a clear winner, as shown by the recent J. D. Power CSI study 2004. It is clear that a Maruti Suzuki delights you even when you run it for years. The 6 highest satisfaction ratings with regard to cost of ownership among all models are all Maruti Suzuki vehicles: Zen, Wagon R, Esteem, Maruti 800, Alto and Omni. They are proud to have the lowest cost of operation / km(among petrol vehicles) – the top 5 models are all Maruti Suzuki models: Maruti 800, Alto, Zen, Omni and Wagon R.
EMPLOYEE QUALITY MEASURES
Kaizen is based on the concept of making incremental improvements in our products. It incorporates a series of continuous small and simple improvements, which aim at involvingemployees at all levels. The Suggestion Scheme is based on the same principle. Under thisscheme, employees are encouraged to make suggestions forimprovement in any area of our operation. Over 50, 000suggestions are received from employees every year. Maruti has won the First place in
“ Quality Circles are groups of five to eight members from a particular work area who work as a team to identify priorities and solve work related problems in the area. We believe that it is this unwavering commitment to quality thatwill lead to the further growth of the organization as competition increases.
ISO 9001: 2000
At Maruti, our approach to quality is in keeping with the Japanese practice–“ build it into the product”. Technicians themselves in respect the quality of work. Supervisors educate and instruct technicians to continually improve productivity and quality. The movement of quality indicators is reviewed in weekly meetings by the top management.
In 2001, Maruti Udyog Ltd became one of the first automobile companies anywhere in the world to get an ISO9000: 2000 certification.
AV Belgium, global auditors for International Organization for Standardisation (ISO), certified Maruti after a four day long audit, covering varied parameters like Customer Focused organisation, Leadership, Involvement of people, Process approach, System approach to Management, Continual improvement, etc. 23
THEIR STRATEGY IS TO CAPTURE THE RURAL MARKET BY EMPLOYING WOMEN WHO BELONG TO THEIR LOCAL COMMUNITY THROUGH WHICH THEIR PRODUCT CAN REACH TO LOCAL CONSUMERS. THEIR STRATEGY IS TO PROVIDE WORK FOR WOMEN TO CREATE AWARENESS AMONG CONFINED CONSUMERS.
A product of poor quality requires repeated inspections, entails wastage in terms of repairs and replacements. “ Do it right first time”, is the principle followed to avoid wastage. To ensure quality, robots were devices and deployed especially where they reduced worker fatigue and were critical in delivering consistent quality. With consistent improvements in the plant the company was able to manufacture over 600, 000 vehicles in2006-07 with an installed capacity of just 350, 000 vehicles per year.
Home or work place; Safety takes First Place. This has been the motto of the company where safety is concerned. Maruti attaches great significance to safety of its people and strongly advocates that safety at work place adds to quality of the products and improves productivity of the plant significantly. In the Japanese manufacturing system, the central role is accorded, not so much to Quality, Productivity or Cost, but to Safety. When process flow, lay-out and systems are designed for maximum safety, they automatically contribute to better quality and productivity.
Maruti Exports Limited is the subsidiary of Maruti Suzuki with its major focus on exports and it does not operate in the domestic Indian market. The first commercial consignment of 480 cars were sent to Hungary. By sending a consignment of 571 cars to the same country Maruti Suzuki crossed the benchmark of 300, 000cars. Since its inception export was one of the aspects government was keen to encourage. Every political party expected Maruti Suzuki to earn foreign currency. Angola, Benin, Djibouti, Ethiopia, Europe, Kenya, Morocco, Nepal, Sri Lanka, Uganda, Chile, Guatemala, Costa Rica and El Salvador are some of the markets served by Maruti Exports.