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Automotive
Mahindra Vehicles
Mahindra rises with digitally planned new vehicle manufacturing facility
Products Mahindra Vehicle Manufacturers succeed and to create a better future for
Teamcenter, Tecnomatix Limited (Mahindra Vehicles) themselves, their families and their com-
munities. In the spirit of “Rise,” a new
uses Tecnomatix to establish a
Mahindra manufacturing facility recently
Business challenges state-of-the-art automotive rose in the Chakan corridor near Pune,
manufacturing plant India.
Manage global markets and
competition
A world leader in vehicle manufacturing Mahindra Group’s Automotive Sector man-
Shorten the vehicle develop- rises in South Asia ufactures and markets light commercial
ment lead time to reduce Mahindra Group (Mahindra) is among the and utility vehicles, including auto rick-
time-to-market biggest and most powerful publicly listed shaws (three-wheelers). The sector has
Minimize manufacturing companies in the world. It operates in the been the leader in India’s utility vehicles
launch issues to accelerate key industries that drive economic growth, market since its inception, and currently
production ramp-up enjoying a leadership position in tractors, accounts for about half of India’s utility
utility vehicles, information technology vehicle market. The company exports its
Meet increasing demand for
(IT) and vacation ownership. Mahindra products to Europe, Africa, South America,
highly customized vehicles
focuses on enabling people to “Rise,” a call South Asia and the Middle East.
to action to unite the many companies
Keys to success within the Mahindra Group to a common Mahindra decided to expand its lineup to
Get the new Chakan plant up purpose. More specifically, Mahindra include a new range of medium and heavy
and running quickly employees are encouraged to rise, to commercial vehicles, including SUVs,
Improve quality and consis-
tency in manufacturing, sup-
porting “first time right”
approach
Analyze the impact of product
mixes on production through-
put and optimize facilities
layouts
Virtually analyze complex
assembly scenarios of the new
product lines
Share best practice process
data between multiple sites
and with suppliers
The new Maxximo light commercial vehicle, manufactured at the Final Assembly of the Mahindra Navistar
Mahindra Chakan plant. truck in the Mahindra Chakan plant.
www.siemens.com/plm
A Mahindra manufacturing
engineer uses Manufacturing
Process Planner.
Results trucks and buses. This expansion required assembly suppliers use Teamcenter® soft-
Reduced lead time and the a new plant, so Mahindra decided to estab- ware for product lifecycle management
overall duration of a vehicle lish a new manufacturing facility in (PLM). The company also uses NX™ soft-
project Chakan. Mahindra’s challenge was how to ware for some of the powertrain product
assess, design and build the facility, plus design, and a few years ago Mahindra
Decreased capital investment get it running and producing vehicles started using Tecnomatix® software for
in machines and conveyors according to the aggressive schedule that digital manufacturing.
Substantially shortened lead management had defined.
time for concept design of “In 2007, we selected and introduced the
production facilities As of 2012, 1,500,000 cars are produced Tecnomatix solution, because it offers a
Reduced bottlenecks in annually in the Chakan corridor by full range of digital manufacturing tools
production Mahindra, Volkswagen, General Motors, that serve our needs, integrates smoothly
Mercedes Benz and other automotive man- with our existing product data manage-
Increased re-use of manufac-
ufacturers. Mahindra is one of the largest ment systems and clearly stands out in
turing tools
manufacturers in this area, producing light meeting the criteria we had defined,“ says
Maximized production commercial vehicles (LCV), pick-up trucks, Nagesh Nidamaluri, senior general man-
resource utilization SUVs and the Mahindra Navistar heavy ager, Assembly Systems, MES and Digital
duty trucks. Manufacturing, Chakan plant, Mahindra
Vehicles.
Revisiting engineering processes to
establish “state-of-the-art” plant Mahindra uses the Manufacturing Process
Mahindra is a long-time customer of Planner solution in the Teamcenter
Siemens PLM Software. Designers, data portfolio for the planning of various pro-
administrators and some of its product duction processes; as well as Plant
“ The Tecnomatix solution...offers a full range
of digital manufacturing tools that serve
our needs.”
Nagesh Nidamaluri
Senior General Manager Assembly Systems, MES and Digital Manufacturing
Mahindra Vehicle Manufacturers Limited
Simulation, FactoryCAD™ software and Laying out the new Chakan plant in 3D “In 2007, we selected and
FactoryFlow™ software, all in the While constructing the new plant in introduced the Tecnomatix
Tecnomatix portfolio, for plant design and Chakan, Mahindra decided to significantly solution, because it offers a
optimization; Process Designer and Process upgrade the way it creates and manages full range of digital manufac-
Simulate and Jack™ software, also all in plant layout data. There were a number of turing tools that serve our
the Tecnomatix portfolio, for assembly issues to deal with, including the fact that needs, integrates smoothly
planning and validation. there was no uniform plant layout method with our existing product
across the enterprise. Each site was man- data management systems
The establishment of a new plant was a aging plant layout separately. Plant layout and clearly stands out in
good opportunity to revisit Mahindra’s cur- drawings were not maintained in a central meeting the criteria we had
rent engineering processes. “We have real- repository, which made it very time-con- defined.“
ized that in order to shorten a vehicle suming to locate them when they were
Nagesh Nidamaluri
manufacturing project, we need to deploy needed. There was no revision manage-
Senior General Manager
concurrent engineering methods,” ment system and only one engineer at a
Assembly Systems, MES and
Nidamaluri says. “This means that manu- time could work on any given layout.
Digital Manufacturing
facturing engineering needs to work con- Drawings provided by suppliers were
Mahindra Vehicle
currently with product design. Digital maintained in different layers in the same
Manufacturers Limited
manufacturing tools provided by Siemens file, resulting in duplication of data and
PLM Software facilitate this approach. This unnecessarily large files, which degrade
is a dramatic change to our current engi- visualization performance.
“Providing the essentials
neering processes.
needed to create detailed
To resolve these issues, FactoryCAD was
and intelligent factory mod-
“We have a gate system, and one of the used to create 3D plant layouts for all of
els, FactoryCAD allowed our
gates is the virtual validation gate. In the the Chakan plant production lines, includ-
planners to use ‘smart
past, mostly the product design group was ing body and trim, chassis and final (TCF).
objects’ to represent their
actually doing validations for this gate; but “Providing the essentials needed to create
factory resources.”
now, with the help of Tecnomatix digital detailed and intelligent factory models,
manufacturing tools, the manufacturing FactoryCAD allowed our planners to use Anupam Patil
engineering group is very active in prepa- ‘smart objects’ to represent their factory Senior Manager
rations for this gate.” resources,” says Anupam Patil, senior man- IT and PLM
ager, IT and PLM, Chakan plant, Mahindra Mahindra Vehicle
Mahindra decided to execute the digital Vehicles. Manufacturers Limited
manufacturing journey at the Chakan plant
in a series of steps, deploying point solu- “This was especially advantageous because
tions to address specific needs, followed the objects provided the ability to snap a
by the manufacturing bill of materials layout model together, instead of wasting
(MBOM) and fi`nally the bill of process time drawing the individual equipment.
(BOP). Mahindra plans to clone proven Using FactoryCAD, we were able to
methodologies developed in the Chakan resolve many issues before erecting and
plant at other plants. commissioning of the factory, such as
interferences of process and utility
Left: Truck cargo mounting analysis created
with Jack human simulation.
Middle: Engine docking station simulation
created with Jack human simulation.
Right: Interference of a robot and a column
found using FactoryCAD.
Left: Plant Simulation
model – routing with no
cross-over.
Right: Plant Simulation
model – routing with a
cross-over for empty skids.
equipment with the civil structure, for into three separate TCF assembly lines.
example, as well as a monorail system that Tecnomatix Plant Simulation was used to
caused interference with the supporting conduct a what-if simulation to determine
beams at a specific area and a robot that the best scenarios for the plant’s inter-
caused interference with the building col- shop conveyor system. Several scenarios
umn in another area.” of mixed-model production volumes were
simulated and the optimal size of central
A planned production line, virtually painted body buffer storage and individual
simulated BIW shop storage was determined. This
Before building the production line, simulation project substantially reduces
Mahindra completed a number of simula- the lead time in designing the storage.
tion projects that helped to make impor-
tant decisions in configuring the Another project was to determine the
production line. One of the projects optimal routing method of painted vehicle
addressed the inter-connections of the bodies from the single paint line to the
body-in-white (BIW) welding shop, paint three TCF assembly lines. “The simulation
line and the TCF assembly line, where all helped to identify bottlenecks, and
the parts are assembled to form a com- verify the robustness of the selected
pleted vehicle. option,” says Amit Jahagirdar, digital man-
ufacturing manager, Chakan plant,
The goal of the simulation project was to Mahindra Vehicles. “One simulated option
find out the optimal buffer storage capac- was a clockwise flow of bodies with no
ity in between these production lines. The cross-over. The simulation showed that in
challenge arose because there were three the event that one of the three TCF lines is
BIW planned production lines (for the shut-down, the respective bodies in the
Maxximo, Genio and XUV vehicles) going main line would create blockage in moving
into a single paint line, which then goes bodies to the other TCF lines. The second
option was a counter-clockwise flow, with
a cross-over for the empty skids to flow
back to the paint shop. This is a more
“The simulation helped to robust option because each TCF feeder line
is practically independent of others. So,
identify bottlenecks, and there is little or no impact on the overall
performance of the line shutdowns.”
verify the robustness of the Using Plant Simulation, Mahindra gained
critical insight regarding its factory layout
selected option.” and installation processes across vehicle
lines. Accurate and fast validation of pro-
cesses enabled the company to achieve its
Amit Jahagirdar
goal of getting the implementation right
Digital Manufacturing Manager,
the first time. Detailed throughput exami-
Chakan plant
nation notably reduced bottlenecks, and
Mahindra Vehicle Manufacturers Limited
“So, we decided to use dedicated tools for
this task, and developed a robust MBOM
creation and update methodology using
Manufacturing Process Planner.”
Anupam Patil
Senior Manager
IT and PLM
Mahindra Vehicle Manufacturers Limited
what-if analysis capabilities substantially process. For example, in the paint line, the
decreased unnecessary capital investment chassis will be represented by a bare chas-
in machines and conveyors. sis, cathodic electrocoat deposition body
and painted body. These forms, which we
MBOM creation means no part is call ‘semi-finished parts,’ appear as a single
forgotten in the production assembly in the EBOM, but as different
The engineering bill of materials (EBOM) is assemblies in the MBOM. Another exam-
created and managed using Teamcenter. ple of MBOM-specific information is the
Then manufacturing engineers create the addition of scrap weight to the stamped
MBOM using Manufacturing Process parts, as this information is used down-
Planner by consuming parts from the stream in the recycling process.
EBOM. The MBOM is then sent from
Manufacturing Process Planner to SAP® “Handling the MBOM changes throughout
software, the enterprise resource planning the development lifecycle is crucial for us.
(ERP) system Mahindra uses. Therefore, the engineering notifications
are transferred along with the EBOM from
“In the previous method, planners used Teamcenter. The notifications are put into
Microsoft Excel to define and maintain the a common pull, and from there they are
MBOM,” Patil says. “While the tool is intui- assigned to the relevant MBOM planner. In
tive, it was clear to us that this is not sus- addition, once an initial MBOM is created,
tainable for handling large BOMs and all subsequent changes in the MBOM are
sharing engineering data. So, we decided done in a controlled configuration, using
to use dedicated tools for this task, and the incremental change mechanism,
developed a robust MBOM creation and which enables us to analyze very clearly
update methodology using Manufacturing the impact of any EBOM change on the
Process Planner. Using this methodology, MBOM. Within the incremental change,
we use the workflow mechanism of MBOM in Manufacturing Process
planners adjust the EBOM and add relevant
Planner with “make or buy” definitions.
production information such as a ‘make or Teamcenter which helps ensure that every
buy’ definition for each item and the point change goes through a predefined
of consumption along the production line, sequence of events and an authorized
which is later used by the shop floor logis- approval. These capabilities are unique,
tics management system.” and provide us the ability to put a lot of
structure into the MBOM creation
“The MBOM will include the car parts in process.”
their form through the entire production
“We use the workflow mecha- Due to the importance of maintaining an could support sufficient door opening. The
nism of Teamcenter which accurate MBOM, starting from the engi- limit to which the doors can be opened
ensures that every change neering team and down to the shop floor, was calculated based on the virtual 3D
goes through a predefined Mahindra uses Teamcenter to execute a simulation, instead of waiting for actual
sequence of events and an daily update to synchronize any incremen- parts to arrive at plant. This resulted in
authorized approval. These tal changes to the EBOM. In a similar man- cost and time savings and reduced the
capabilities are unique, and ner, Teamcenter integration for SAP number of iterations of the hanger
provide us the ability to put synchronizes the MBOM daily with SAP design,” says Jahagirdar.
a lot of structure into the based on make or buy attributes. For
MBOM creation process.” example, any assembly node with children,
which was identified in the MBOM as a
Anupam Patil
purchased assembly, will be automatically
Senior Manager
exported and will appear in SAP as a
IT and PLM
single node.
Mahindra Vehicle
Manufacturers Limited
Dynamic 3D simulation supports
analysis of complex assembly scenarios
“Manufacturing engineers for the new Maxximo
used Process Simulate to val- The painted body of the Maxximo mini-
idate hanger design that truck is transported inside the new assem-
could support sufficient door bly shop for operations. The car body is Process Simulate is used to simulate the doors
opening while the truck is on a hanger.
opening. The limit to which moved along using a hanger system in the
the doors can be opened was underbody areas and on transfer lines. The
calculated based on the vir- system was initially designed to carry the The assembly process for the Maxximo was
tual 3D simulation, instead car body with the doors closed. After ana- planned so that the engine assembly from
of waiting for actual parts to lyzing the conceptual flow of assembly, the engine production unit is transferred
arrive at plant. This resulted other possible assembly operations were to the final assembly shop from a logistic
in cost and saving of time analyzed. It was found that in order to area. It moves on a predefined track and
and iterations of the hanger reduce production time, some assembly gets synchronized with the conveyor carry-
design.” operations could be executed when the car ing the Maxximo car bodies on hangers.
body is on the hanger, as long as the doors Because this is a complex scenario, which
Amit Jahagirdar
could be opened to a certain extent, which involves many parameters, manufacturing
Digital Manufacturing
will enable operators to work inside the engineers also performed a dynamic 3D
Manager
cabin area. simulation of this scenario. “The main
Mahindra Vehicle
objective of this simulation was to validate
Manufacturers Limited
“Manufacturing engineers used Process the planned process and its duration esti-
Simulate to validate hanger design that mation. The ergonomics of operators was
“ Manufacturing engineers used Process
Simulate to validate hanger design....This
resulted in cost and saving of time and
iterations of the hanger design.”
Amit Jahagirdar
Digital Manufacturing Manager
Mahindra Vehicle Manufacturers Limited
Implementing Tecnomatix portfolio
enabled a 25 percent reduction in the green
field plant setup time, a 28 percent
improvement in effective working time.
also evaluated based on Mahindra stan- “The digital manufacturing tools play a key “We have defined a workflow
dards,” Jahagirdar says. role in the first steps of a car project,” says using Teamcenter to classify
Nidamaluri. “These tools are already used our existing and new tools
Tools management lowers cost by in the requirements definition phase of a by part number, so that
enabling re-use new or modified production line. This eventually we will have a
Mahindra plans to use the resource classifi- enables us to provide more mature engi- structured library of tools
cation capability of Teamcenter to manage neering information upfront to our system across the Mahindra auto-
its many production tools. According to suppliers, and will therefore reduce lead motive sector.”
Jahagirdar, “The objective of this initiative time and the overall duration of a car proj-
Amit Jahagirdar
is to lower costs, reduce lead time and ect. I also expect that our production facili-
Digital Manufacturing
improve quality by helping the manufac- ties and tools suppliers will interact with
Manager
turing engineer/planner select the proper the system, and introduce their inputs.”
Mahindra Vehicle
resource, increasing the re-use of manu-
Manufacturers Limited
facturing tools, reducing tool inventory, Mahindra Vehicles receives top award
maximizing resource utilization and deliv- Mahindra Vehicles received the top honor
ering digital models for verification and in Siemens PLM Software’s Asia Pacific “The benefits of the
simulation.” Innovation Awards 2012, which places a Tecnomatix digital manufac-
spotlight on how PLM technology enables turing tools for Mahindra are
“We have defined simple categories for any companies to make smarter decisions that already invaluable. This tool-
tool we have in our production plants, lead to the creation of better products. set deployment strengthens
including a tool suitable to a specific part, The top award is presented to the com- the ‘first time right’ mindset
such as fixtures or specific gauges. There pany that uses PLM technology in a way we have in Mahindra, as it
are also more generic tools, such as robots that enables it to be a hallmark of success enables us to conduct differ-
and torque wrenches. Based on this, we in the manufacturing industry, maximizing ent ‘what-if’ analyses of pro-
are defining a workflow using Teamcenter the value derived from its products duction scenarios.”
to classify our existing and new tools by throughout the entire lifecycle to stream-
Nagesh Nidamaluri
part number, so that eventually we will line its productivity and performance.
Senior General Manager
have a structured library of tools across the
Assembly Systems, MES and
Mahindra automotive sector.” Implementing Tecnomatix portfolio
Digital Manufacturing
enabled Mahindra Vehicles to come closer
Mahindra Vehicle
The next step is the development of the than ever before to real-time digital manu-
Manufacturers Limited
BOP using Manufacturing Process Planner. facturing. Other benefits included a 25
Assembly operations and their duration are percent reduction in the green field plant
defined, and then linked to the parts that setup time, a 28 percent improvement in
should be handled and to the specific tools effective working time by validating and
required to carry out the work. This meth- reducing nonvalue-added activities and an
odology enables Mahindra manufacturing overall increase in flexibility, which pro-
engineers to re-use best practices and cap- duced more product model mixes and
tured knowledge in planning or modifying reduced time-to-market.
a production line.
Solutions/Services
Teamcenter
Manufacturing Process Planner
www.siemens.com/teamcenter
Tecnomatix
Process Designer
Process Simulate
Plant Simulation
FactoryCAD
FactoryFlow
Jack
www.siemens.com/tecnomatix
Robotic simulation created with Tecnomatix to reduce cycle time of welding operations.
Customer’s primary business
Mahindra Vehicle
Manufacturers Limited manu-
“First time right” will lead to a brighter robots in our Chakan plant. Currently, even
factures and markets utility future the slightest change in a robot program
and light commercial vehicles,
“The benefits of the Tecnomatix digital requires us to contact the line builder and
including auto rickshaws
manufacturing tools for Mahindra are ask for modifications. I believe we can
(three-wheelers). It is the
already invaluable,” Nidamaluri says. “This develop skills by using the Tecnomatix
leader in utility vehicles in
toolset deployment strengthens the ‘first robotics offline programming tools to con-
India and currently accounts
time right’ mindset we have in Mahindra, duct some of this work ourselves. This will
for about half of the country’s
as it enables us to conduct different ‘what- bring multiple benefits, including higher
utility vehicle market. The
if’ analyses of production scenarios. Still, flexibility due to greater engineering capa-
Mahindra Group’s Automotive
we are looking forward to make more bility, shortening the modifications lead
Sector is part of the globally
progress in the digital manufacturing jour- time and reducing cost.”
recognized Mahindra Group,
ney. For example, we have more than 100
which is among the top 10
industrial companies in India.
www.mahindra.com
Customer location
“ The benefits of the Tecnomatix
Chakan, Pune,
Maharashtra District
digital manufacturing tools for
India
Mahindra are already invaluable.”
Partner Nagesh Nidamaluri
Tesis PLMware GmbH Senior General Manager Assembly Systems
www.tesis.de/plmware MES and Digital Manufacturing
Mahindra Vehicle Manufacturers Limited
Siemens Industry Software
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Europe +44 (0) 1276 413200 Siemens AG. D-Cubed, Femap, Fibersim, Geolus, GO PLM, I-deas, JT, NX, Parasolid, Quality Planning Environment, Solid
Edge, Syncrofit, Teamcenter and Tecnomatix are trademarks or registered trademarks of Siemens Product Lifecycle
Asia-Pacific +852 2230 3308
Management Software Inc. or its subsidiaries in the United States and in other countries. Jack is a trademark or registered
trademark of The Trustees of The University of Pennsylvania. AutoCAD a registered trademark of Autodesk, Inc. SAP is a
trademark or registered trademark of SAP Aktiengesellschaft. Excel is a registered trademark of Microsoft Corporation. All
other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders.
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