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Tata Motors providesworld-class manufacturing units

Manufacturing

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.

 

Jamshedpur

The Jamshedpur facility, Tata Motors' first, was established in 1945 to manufacture steam locomotives. It led the company's foray into commercial vehicles in 1954. It has been modernized through the decades, with a particularly intense scale in the last 10 years and has led the company's evolution into a manufacturer of global repute.

This world-class facility is equipped with:

  • State-of-the-art equipment and assembly lines to produce a truck every 5 minutes
  • Over 200 models, ranging from multi-axle trucks, tractor-trailers, tippers, mixers and special application vehicles, catering to civilian and defence requirements
  • 3D visualisation of new models
  • Engine assembly shop, capable of supplying upto 200 engines per day
  • Modern testing facilities

The plant manufactures Tata Motors' entire range of medium and heavy commercial vehicles, including the Tata Prima, both for civilian and defence applications - over 200 truck variants, ranging from multi-axle trucks, tractor-trailers, tippers, mixers and special application vehicles. Besides India, these vehicles are sold in South Africa, Russia, Myanmar, the SAARC region and the Middle East. On February 19, 2013, Jamshedpur Plant rolled out its two millionth truck.

The plant houses a world class Engineering & Research Centre. The centre is responsible for the conceptualisation and integration of Tata Motors' current and future truck range. The centre undertakes complex digital design through 3D visualization of new truck models, including that of its features and electrical systems. It also houses a comprehensive facility for benchmarking, prototype planning, vehicle assembly, chassis fabrication and a customisation unit. The testing unit also includes engine performance testing, indoor and outdoor vehicle testing, NVH (Noise, Vibration, Harshness) testing, durability testing and other performance related developments.

The state-of-the-art Engine Factory manufactures the Tata 697/497 naturally aspirated and turbo charged engines, with a capacity of supplying upto 200 engines per day.

The Vehicle Factory's main assembly line rolls out one truck every 5 minutes. Two other lines are dedicated to the Prima range, Multi-axle, special purpose vehicles and for meeting the requirements of the defence sector.

The chassis frames are supplied by the Frame Factory, which is equipped with a 5000 Ton Siempelkamp press to manufacture frames upto 6.2 metre wheel base.

The fully equipped Foundry supplies high-grade SG Iron Castings and is rated as one of the highly automated foundries in the world. It manufactures all critical automobile castings, viz. Cylinder Block, Cylinder Head etc. Its sophisticated Kunkel Wagner High Pressure Moulding line has a rated production capacity of 90 moulds/ hour. The melting shop has Medium Frequency Induction Furnaces for melting and Channel Furnaces for holding while 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, followed by QS 9000 and  TS: 16949.

The Cab & Cowl Factory is equipped with an automated Centralized Paint Shop with a provision for metallic painting and Centralized Trim Lines, which help improve logistics flow.

The facility also houses a Shower testing facility in vehicle dispatch area, an NABL-accredited Metrology lab, a Clean room for CRDI engines to ensure a dust-free environment for fitment of critical parts and a world-class Technical Training Centre and Driver Training centre. The Plant incorporates a flexible approach to manufacturing, such that it is ready to respond rapidly to changing customer needs.

TML Drivelines Limited was established on March 13, 2000 as a subsidiary of Tata Motors by taking over operations of Tata Motors' erstwhile Axle and Gearbox Divisions. It 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 the leading supplier of M&HCV axles to the Jamshedpur and Lucknow plants of Tata Motors.

It has state-of-the-art manufacturing facilities for making all major axle 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. The Quality System of TML Drivelines Limited is certified under ISO/ TS-16949. On the environmental and safety front, it received OHSAAS-18001 in 1999 and ISO 14001 certification in 2004.

TML Drivelines Limited has proven skills in manufacturing axles from component level to assembly & testing. As one of the most modern forging set-ups in the country, the Forge is equipped with the 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 rear axle shafts. The Forge has been certified as ISO 9002 and QS 9000 by the BVQI.

While making technological, product and service advancements, Jamshedpur Plant has been deeply committed to the communities among which it operates. Working closely with various NGOs, it has pioneered initiatives in Health, Education, Livelihood and Environment. These initiatives have resulted in 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.

Pune

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 Vehicles (Indica and Indigo).

The Passenger Vehicle 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 29334 Tons of high precision castings in 2012-13 while the Iron Foundry at Maval produced 10646 Tons of spheroidal Iron castings in 2012-13. These include Cylinder Blocks, Cylinder Heads, Gear Box Housing, etc. The Aluminium Foundry at Chinchwad produced 4292 Tons of casting mainly Cylinder heads required for PVBU and FIAT.

Lucknow

Tata Motors Lucknow (TML-Lucknow) is an important production facility of Tata Motors Limited, which was established in 1992 to meet the growing demand for Commercial Vehicles in the Indian market. The state of art plant is strongly backed up by an Engineering Research Centre (ERC) & Service set-up to support with latest technology & cater to the complexities of automobile manufacturing. Fully Built Vehicle business (FBV), which is one of the fast growing areas of business, is also head quartered here. This plant rolls out commercial vehicles & is specialized in the designing & manufacturing of a range of modern buses which includes Low-floor, Semi Low-floor, and High Deck & CNG Buses. Lucknow plant also specializes in integral bus manufacturing & has recently commissioned JV Company, Tata Marcopolo Motors Ltd. in the premises.

The major facilities at the plant comprise of:

  • Vehicle Factory - Assembly Plant for Trucks and Bus Chassis
  • Integral Bus Factory - Assembly Plant for Module Buses catering to the needs of Tata Marcopolo Motors Limited and FBV operations
  • Transmission Factory - Gear Parts, Crown wheel & Pinion and Heat Treatment facility
  • Production Engineering Shop catering to the tool design and manufacturing needs
  • A well established Training Centre through which around 500 apprentices are trained in various trades.
  • Engineering Research Centre with specific focus on buses, including a Digital prototyping lab, use of PLM software etc.
  • Service Training Centre providing training to drivers and technicians of the STU's.
  • RECON Factory (for Reconditioning Business)
  • The satellite plant of TMML which caters to the Hi-end buses for the Northern Market.
  • State of the art facilities like the Paint Shop, BIW Shop and the TCF factory with automated lines have been benchmarked with the best in the world.
Pantnagar

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.

Sanand

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.

Dharwad

Tata Motors' Dharwad Plant, Located on the Pune- Bangalore highway around 425 km northwest from Bengaluru, became operational on "Founders Day" 3rd March 2012. This is the latest green field project by Tata Motors being commissioned for production of Ace Zip. Dharwad plant in a record time rolled out 15,000 Ace Zip's in first year of operations.

In line with world-class manufacturing practices Dharwad Plant has installed most advanced technology which includes robotics, automated line with Automated Guided Vehicles and ultramodern manufacturing systems and practices. The Plant has a high capacity paint shop which brings perfect harmony between plant and conveyor equipment with RoDip technology.

Dharwad is a quiet and pleasant city is continuously growing and a promising beehive for commercial activities. Plant is spread over an area of 400 Acres. It has an installed capacity of 90,000 vehicles annually. Dharwad Plant is the one of the first plant in automobile industry to obtain Platinum Rating by Indian Green Building Council and it also holds the ISO 14001 and ISO 50001 Certification for Environment Management System and Energy Management System respectively. Dharwad Plant was awarded with ‘State Level Safety Award' for development, implementation and practicing of sustainable safety culture in its location.

The plant within a short period of time, has indulged itself in number of initiatives like Green-Drives (with sapling plantation/donation campaign, Rain Water Harvesting, Eco-friendly processes, use of wind energy) Blood Donation Drive, Health & Education Camps in surrounding communities, innovative employee engagement and communication activities.