TATA NANO

Introduction to Tata motors – Tata nano

Singur plant issue & shift to sanand

Product Design –

Challenges

Gandhiyan Engineering

Plant location –

Plant layout

Flow chart of Processes

Manufacturing processes

Complete Details

Supply & demand of

Nano

Why it is failure

Conclusion

TATA MOTORS

An Indian multinational automotive manufacturing company

Headquarter in Mumbai

Founded in 1945 as manufacturer of locomotives

Manufactured it’s first commercial vehicle in 1954

Entered in passenger vehicle market in 1991

Among world’s largest vehicle producers

Acquired Daewoo & Jaguar Land Rover

Ranked 314th in Fortune Global 500 ranking

Manufacturing plants in India as well as in Argentina, South Africa, Thailand & United Kingdom.

Research & development centers in India, South Korea, Spain & United Kingdom.

Tata Nano Singur Controversy- Singur in Hoogly district, West Bengal, India.

construction of the plant on 21 January 2007.

The small car was scheduled to roll out of the factory by 2008.

The Tata Group announced on October 3, 2008 that they are pulling out of Singur

On 7 October 2008,the Tata announced that they would be setting up the Tata Nanoplant in Sanand, Gujarat.

Why Tata nano pulled out from singur to

sanand –

POLITICAL BATTLEFIE

LAND CONTROVERSY

CHALLENGES

Product DesignProject X3

Challenge of maintaining security , beauty , less fuel consumption & Better handling.

Concept of less number of parts & cost reduction.

Door , Tyres , fuel pump unit, engine

Engine :

2 cylinders

Crank shaft & Weight shaft

Air scope for cooling

One windscreen wiper instead of the usual pair. No power steering, unnecessary due to its light weight.

Three lug nuts on the wheels instead of the usual four . Only one wing mirror on base models. No airbags on any model 624cc rear engine has only 2 cylinders No air conditioning in base model Front passenger seat same as the driver seat, and the headrests are integrated. Thinner 135/70-R12 space saver spare tyre. No external fuel filler cap. Fuel inlet is accessed by opening the front hood.

State of art equipment manufacturing process

70 % Automation

130 robots for automation of ‘processes’

Body assemble in body shop just in 53 sec

Body painted in paint shop in just 58 sec

Total maximum production capacity is 350000 units per year.

Spread Over 1100 acres at Sanand , Gujrat.

Working plant 725 acres

adjacent 375 acres for future expansion

Press Shop

Weld Shop

Paint Shop

Powertrain Shop

TCF (Trim-Chassis –Finish) Shop

TATA MOTORS NANO PLANT.SANAND, GUJARAT

Source : Google Earth

PRESS SHOP

WELD SHOP

PAINT SHOP

POWERTRAINSHOP

TCF SHOP TESTING

Uses 5 Cast Iron Dies High Speed Hydraulic Tandem Press Forklift Feeds the steel sheets Press Capacity: 1200 to

2000 tones Process Carried: 1.Pressing2.Trimming3.Flanging4.Piercing

11 Body panels welded together

State-of-the-art Welding facility

Capacity: 1900 bodies on 3 Shift basisCycle Time : 54 to 90 Seconds

Fully Automated welding facility

Body in white (BIW) brought to Paint shop

Programmed robots painting on outer side.

Process Carried:

Prewashing

Phosphate Coating

Electro Coating

Baking

Cycle Time: 58 sec ( 1 body /min)

Assembly of Engine and Gearbox

Most process carried manually

Uses automated material handling systems

Assembly of Powertrainand all the remaining parts.

Uses automated moving assembly line.

Cycle time : 58 seconds

Separate assembly line for door assembly.

Headlamp Adjustments

Suspension Testing

Wheel Balancing

Roll & Brake Testing

Paint Quality Checking

Shower Testing

Nominal factory output is 250,000 with some balancing is expandable up to 350,000 cars per year.

FY 2009-2010 30,000 approx

FY 2010-2011 70,432

FY 2011-2012 74,527 [42]

FY 2012-2013 53,848 [43]

FY 2013-2014 first half (April to Sept.) 10,202

SUPPLIERS TO TATA NANOBosch Freudenburg

Caparo GKN

Continental Itw Deltar

Delphi INA

Denso Johnson Controls

Fag Mahle

Ficosa Saint gobain

TRW

Ceekay

Vibracoustic

Visteon

Z.f (friedrichshafen) A.G

Behr

Positioning

Pricing

Promotion

a) A different positioning strategy for rural, urban and smaller cities as a totally different sub brands and with minor customization.

b) Promotion based on the attributes like performance, efficiency instead of affordability.

c) Create special segments for college, women and first time drivers.

d) Position NANO as a regular car rather than as an upgrade for and from two-wheelers.

e) Evolve in every two years based on the market feedback.

Tata Nano is world’s cheapest car.

It is design without compromising on any aspects of safety or comfort of car.

Huge efforts are made in designing this product & implementation of processes in factory.

They should work on Marketing strategy of the Nano to make it big success.