Draft Detailed Project Report

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Technology Centre Systems Program – <strong>Draft</strong> DPR for New TC at Rohtak Key discussion during primary survey Name Nagata India, Manesar (Japanese tool room) Motherson (tier 1 supplier of plastic parts to OEMs, has a captive tool room) JBM auto tool room and training centre Hero Motors Corp, (Plant Dharuhera) Key points of discussion ► Suggested, to start with new auto TC can be sheet metal focussed as within auto sector, sheet metal accounts for major chunk out of 4 key sub segments - Sheet metal, Plastic, Forging tools, Pressure die casting. There is about INR 600 cr of sheet metal business for tool rooms in each car model. ► There is a huge demand for operators, die fitters/ makers for sheet metal operations. ► Need for manpower trained in CNC, CAD/CAM/CAE. ► Rapid prototyping/ 3d printing will not be of much use in short term (at least 5-10 yrs away from now) for sheet-metal parts. ► Suggested that auto TC should be sheet metal and plastic focused as these account for majority of auto components. ► Trained manpower in tool design, machine operators are in short supply. Key industry trends and requirements– ► Overall there is a shortage of trained manpower at machine operator level in auto sector ► Requirement of skilled manpower in upcoming areas like mechatronics and automation ► One of the key current industry trends in automotive manufacturing is light weighting. Auto manufacturers have moved from use of low tensile strength steel sheet (~290-300) to high tensile strength steel sheet (600-700). Hence need for products made of high tensile steel strength of 590 ► Also emphasized that going forward, Technology centres should focus equally on both production and training. Training in high end simulation (die design) should be provided to engineering graduates ► Tool room should focus on Technologies that are futuristic and currently not available in India ► Trainees from existing tool rooms lack practical knowledge especially in areas like mechanical maintenance, electrical Page 235 of 251
Technology Centre Systems Program – <strong>Draft</strong> DPR for New TC at Rohtak maintenance, automated paint shops, assembly jobs, supply and quality assurance (SPC & SQC, PFMEA, Six sigma) ► Key capabilities sought in skilled workers and areas of development Training in Automated paint shops Injection and spot welding Assembly line training Mechanical & electrical maintenance Mr. Kahli, Manager, Tool Room, Tata Motors Jamshedpur ► Mr. Santosh Raout, Tool Procurement Manager (Nano), TATA motors. ► Mr. Nitin Solanki and Mr. Prasana, Tool procurement managers, Renault Nissan, Chennai. ► Mr. Venkatesh M, Development manager (tooling), General Motors, Bengaluru. Discussion on the tooling requirements in the commercial vehicle. Major outcome of the discussion were: ► The tooling requirement in sheet metal for a commercial truck is in the range of 50-60 crore. ► The usage of plastics is increasing in the newer models. ► There is a need of mid-size sheet metal TC to cater to a large market. Major outcomes of these discussion were mainly the following: ► The tooling requirement for 4 wheeler is estimated to be around 600-700 crore. ► There is a need for mid-size to large size sheet metal TC for 4 wheeler segment. ► Mostly, major plastic moulds required for the 4 wheeler are imported mainly because of cost effectiveness and quality as compared to Indian moulds. ► There is a need of mid-size capacity in the plastic mould at least in comparison with the Korean manufacturers. Page 236 of 251
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