[blackwasp]

Many of us here have been to a car production line or at least seen reports of the same like Ford's plant in Chennai, Jaguar's Castle Bromwich (UK) facility or even component factories like Apollo tyres and SF Sonic batteries. But have you ever wondered how the logistical side of these plants is handled? How are individual components brought from different vendors or even from different parts of the same factory? And finally, what happens to the finished goods once they get off the assembly line? Mahindra Logistics invited us to explain the same, as well as showcase the improvements they could incorporate in a car assembly line from a logistics point of view.



This report will focus only on the auto logistics side of an automobile manufacturing process. Mahindra Logistics Limited (MLL) is the sole logistical supplier of Mahindra Vehicle Manufacturers Limited (MVML) in Chakan. They handle shipping of the various components to the manufacturing plant, their storage, getting them to the assembly line and finally taking the end product to the market.

The event took place on March 14th, 2019. The agenda for the day was as follows:
11.15 am – 11.30 am – Arrival and refreshments
11.30 am – 11.45 am – Corporate presentation
11.45 am – 12.15 pm – A presentation on MLL’s operations and what the tour will include
12.15 pm – 1.30 pm – Plant tour
1:30 pm – 2:30 pm – Lunch
2:30 pm – 3:00 pm – Interaction with Sushil Rathi, COO of MLL
3:30 pm onwards – Departure to Mumbai

Before we begin, here are some points to give you a rough idea of the scale at which these guys operate. And mind you, MVML is just one of the customers of Mahindra Logistics. They have other clients from Aerospace, Automotive, E-Marketplace, Information Technology, Financial Services, Energy, Hospitality, Real Estate, Retail and Defence sectors.

• Mahindra Logistics is one of the largest 3rd Party Logistics (3PL) suppliers in India. Their FY18 annual revenue was Rs. 3400 crore across 475+ client locations in India. The total workforce count is over 15,800.

• They operate across two divisions - Supply Chain Management and People Transport Services.

• The Supply Chain division handles national transportation with 340+ operating locations, 25 offices, and 34 network hub locations. They also handle warehousing with over 13 million sq. ft. of storage space across 50+ stockyards and in-factory stores and line feed at 35+ manufacturing locations across India.

• The People Transport division operates in 12+ cities with 120+ clients and 500+ business partners. They primarily serve corporates in the IT, ITeS, Business Process Outsourcing, Financial services, Consulting and Manufacturing industries.

• A broad segregation of Mahindra Logistics' services at Chakan. The plant is spread over 750 acres and MLL has over 600 fixed employees and a variable manpower of 800+. Monthly production volume across all lines is ~14,000 units:


• The various places MLL works and their tasks:


• Stages of a Stores and Line feed:


• Supply chain planning and control:


• Inbound process:

[blackwasp]

The first stop was the press shop. Here, sheets of steel are stamped using high pressure from both sides and formed into the required shape. Before we started, Mahindra provided us with safety shoes and protective headgear:


We were greeted with a giant German-made Schuler machine:


These conveyors take the final part under the watchful eyes of the examiners. Any defects are identified here:


Boards like these are all over the factory. Places with overhead equipment like cranes have the compulsory helmet rule. Others could have mandatory eye protection or gloves usage:


Green walkway identifies the path we have to follow. Everyone, including the factory floor workers, were walking only on this path:


These giant dies are kept ready for the next batch. The average weight of one of these is 50 tons:


Generally, a set of 4 dies is needed for one part. Some parts require only 3, in which case the fourth one is a blank. Changing of dies for a new part takes about 15 minutes:


These sheets are transformed into the required shape by the dies. Sheet thickness varies from 0.65 mm - 1.2 mm based on the model as well as the location of the part in the car’s structure. Interestingly, the Alturas G4's front floor is made here while the other parts are imported from Korea:


Before going forward, the sheet metal is cleaned and undergoes an oil bath here:


The oil filtration reveals impurities, which are carefully monitored from this chart:


The stamping not only takes place from the top, but also from the bottom. Equal pressure is applied from both the top and bottom sides to get the desired result:


From the window, you can see one of the robots in action. The process is automated:


And here it is coming down hard on the die to transform the piece of metal:


Stamped parts come out like this - here is a KUV100's side body panel:


Once produced, the panels are neatly arranged as per vehicle as well as part number:


Here are a bunch of TUV300 panels, waiting to be taken to the assembly line:


A parting shot of the press shop:


SPM stands for strokes per minute. We were told they are usually in the range of 12-15. But the day we visited, they were doing some tooling changes for a new product. Hence, the speed was less:

[blackwasp]

We then headed to the TUV300 body shop. Here, the panels from the previous stage are welded together to form a car shell:


A map along with some of the unique features of the shop:


As usual, safety first - an evacuation map at the start. We were also handed safety glasses as there was welding going on and could result in sparks flying around:


Such boards are present in most areas of the plant. They act as a motivation tool for the employees as well as showcase some of the initiatives by Mahindra to visitors like us:


Panels are brought in from the previous stage on trolleys:


Multiple panels are stacked together for processing:


A mock-up of the part is displayed at the respective station:


For most parts, they are mounted securely on a dolly and a technician spot-welds at certain spots:


The left and right side panel assemblies are separately done before being attached to the main body:


Another one of the safety boards. This one tracks if any incidences took place that day:


This technician is working on the right-hand side parts, which are parallel to the left side assembly line:


324 days since the last breakdown, accident or a defect!


One of the most interesting parts of the assembly line - the fully automatic welding station that has 8 robots:


Panels to be fed to the station are kept in a particular arrangement just outside:


The floor, front and rear compartments and the side panels are attached by robots to get the perfect welds. Humans are not used as precision of the robots is very high:


Map of the complete robot station:


This overhead conveyor brings the individual panels to the robot station:


You can see a right-hand side body panel coming up now:


One of the fully robotic stations - the roof is attached to the body here:


The finished body minus the doors and fenders. The doors are attached later on:


At the end, we were shown one of the innovations of the plant. The sealer used in the welding process is bought in these cans. However, at the bottom, some part of it is leftover (as the machine can't reach so low). Mahindra now brings these leftover sealant cans here and the sealant is removed, repacked and used again thereby reducing wastage:


These loading docks are used for material input as well as sending out finished goods from one plant to another:


The yellow portion can move up and down to align with a truck's load bay:


While removing material, the plastic wrap, cartons, etc. are put into these bins for taking out later in one go after the bins are full:

[blackwasp]

Now it was time to move to the final assembly line. We were taken to the S Block for the XUV500 and KUV100 assembly line:


At the entrance, an XUV500 and a KUV100 were kept. Look closely and you will notice that the KUV is for Left-hand-drive (LHD) markets:


A transformer from waste / leftover bits was made by the line staff while the 'Make in India' lion sits towards the left:


Towards the right is this storage space where parts required for the line are kept ready on their trolleys:


Now, this is one of the innovations by the Mahindra Logistics at this plant. Before the trolley system, technicians used to go fetch individual parts, thereby taking a long time and wasting some time in coming and going:


Multiple parts are kept in a single trolley ready for fitment. Here are the exhaust pipes and the end cans:


The cars come from another parallel line already fitted with some parts like the engine, hood, etc.:


One more interesting innovation - the kitting trolley. This contains all the parts needed for one car at a particular station. The trolley is loaded with parts as per the production schedule by Mahindra Logistics and brought to the required station. The trolley then moves along with the assembly line till all the contents are installed on the car:


Here are a bunch of such kitting trolleys beside the assembly line:


At each station, the car moves to a particular height to provide the best ergonomics for the staff:


Next up are the windshields and side windows:


All of them are attached using a robot to get the best fitting:


The robot is applying the 3rd-row windows here:


Simultaneously, the doors are fitted with glasses, speakers, switches, etc. on a separate line:


The car once again comes down for seat fitment:


Next up are the wheels and tyres. The tyres come fitted onto the rims as per the plan. Sets of tyres come together:


Different technicians independently attach the left and right wheels. You can see that the left side wheels are already attached:


The right side wheels are now added:


Cars now go on an overhead conveyor to the next station:


The cars are fuelled up at the fuel station:


Meanwhile, the doors get an assembly line of their own:


The cars are almost done, undergoing the last few steps here:


We also spotted a KUV100 on the line:


And here it is at the end of the line:


Last step before the rolling road tests is the alignment. This KUV is LHD and made for the Italian market:


Here is an XUV500 rolling out:


The bumps are positioned at an offset to check the suspension:


The headlights are aligned here and then the car is sent to a rolling road test before packing off to a dealer near you:

[blackwasp]

All this while, there is a large part of the operation taking place in the backend, not visible on the assembly line. This is the role of Mahindra Logistics. Here is Mr. Mukesh Kapoor, DGM - Operations, explaining the functioning of the kitting trolley:


Depending on the model and the part of the assembly line, each kitting trolley can contain over 100 different parts. The MLL technicians prepare these trolleys based on the production plan. They take out individual parts from the store and get it ready for the assembly line:


This is just one part of the giant storeroom:


Parts are also stored in high bays (right side) with easy access to the loading bays (for quickly getting the parts):


A pathway separates the high bays with the bins on the right:


One of the Dos and Don'ts of the high bays:


These are massive. It was impossible to get the base and the tallest part of the high bays in one frame:


Another interesting part of the supply chain management is something called as the strong room. Just like a bank, all high-value parts are kept here under security:


Access to these is only for the people whose photo is put on the board:


All buildings in the entire campus have a cafe for lunch / dinner / tea breaks. This one is called as the 'Refuel Cafe':


More parts ready to be sent to the line:


The logistical side of the plant is entirely handled by Mahindra Logistics. They are a company within a company:


More trolleys with parts...


... and new ones coming fresh off the trucks:


Prebuilt engines from the engine plant brought in on specific trolleys:


In the background, you can see the main assembly line. This way, all the incoming parts come via the side - loading bay > stores / sorting > kitting trolley > assembly line:


They also use forklifts and pullers to haul cargo. These are all battery operated = no diesel fumes inside:

[blackwasp]

The Mahindra plant at Chakan not only makes cars, but also trucks amongst others. We were taken to the M&HCV assembly line, where the Blazo and the Furio trucks are made. Even here, a transformer with truck parts was on display:


Compared to a car line, the truck line is scaled up - the sizes are huge + trucks come in more configurations than a car - multi-axle, drive away chassis, etc.:


This plant makes the Blazo and Furio trucks. At the entrance, there is a truck cab along with the drivetrain:


A truck line starts unconventionally. As the truck consists of nothing but a ladder-frame for chassis, assembling things on it is easy. At the beginning all parts related to the wheels are assembled first:


The chassis is brought in upside down to aid ergonomics. Also, the wheels and tyres go on at an early stage compared to a car as rolling a truck is much easier than carrying it around:


A clear view of the upside down chassis:


The plant map including the engine line:


One of the truck stations:


Trolleys similar to the car plant are used. Each of them carries multiple copies of the same part:


Notice the pulleys above this station? Here, the chassis is flipped and sent for wheel fitment:


Meanwhile, the engine is also fitted along with the brake lights:


Tyres as per the configuration are fitted, but they still don't touch the ground:


The truck chassis along with the engine is now moved to the final line:


Other components like the batteries, etc. being added:




From the side, cabs of the trucks start coming in:


They have an assembly line of their own:


Kitting trolleys trail the cabs while technicians add more parts at each station:


Like the XUV500 line, only robots install the cabin glass:


Stacks of side windows awaiting installation:


The cab is finally lifted and put on the chassis:


Once the cab is in place, other stuff like the tanks, cables, etc. is added:




These are the fuel tanks for the trucks:


Different design tanks for another model:


Radiators and fans for the truck engines:


The cab is tilted forward to install under-cab components:


Before going into the rolling road test, a quick alignment of the truck tyres is done:


The rolling road booth has a window to check the process going on. These include testing the brakes, ABS, top speed, acceleration in all gears and parking brake amongst others:


Ok-ed trucks come out and head to the water test:

[blackwasp]

Water test booth before the truck is finally cleared for shipping:


A Furio truck awaiting its driver. These trucks are driven out in a convoy by a team of drivers to various dealers:


In case of any fault or imperfections during the assembly process, the truck is brought to the side, rectified and thoroughly inspected again:


Some more trucks awaiting shipping:


The line also makes drive-away chassis:


Mahindra Logistics manages the supply chain of the trucks as well. Here they have the entire parts stocked ready to be sent to the line:


High bays store parts in a space-efficient manner:


Notice these channels?


They are to ensure kitting trolleys and dollies don't stray off the track:


Post tour, we had a discussion session with Mr. Sushil Rathi, COO, Mahindra Logistics. We discussed topics like GST, e-way bill system, axle load limits and how its improved freight, further scope of role of logistics in India, electrification and clean fuel usage in logistics. Some of the key takeaways:

• Despite players like Mahindra Logistics, the overall sector is largely unorganised.

• Government has recently created a Logistics division in the Ministry of Commerce & Industry and appointed a Special Secretary for the integrated development of the logistics sector in the country. This is heading in the right direction, but will take some time for smooth operations pan-India.

• Non-standardisation across the industry - there is no fixed palette size, various companies use different forms for material procurement, bills, sorting, etc. This was one of the points being discussed in the plan by the Special Secretary.

• Axle loads - MLL helped clients in the Steel sector by adjusting the size of the steel rods to maximise the capacity of the truck, thereby reducing costs.

• E-way bill - One of the most important steps to reduce the travel time of goods across the country, eliminating the border tax / checks. Trucks today travel much faster across India compared to pre-GST days.

• Electrification - While at a nascent stage, this is primarily being focused on the people transport division than the movement of goods. On the trucking side, CNG is being used recently for local deliveries where possible.

• Just-in-Time (JIT) and Just-in-Sequence (JIS) methodology - Thanks to an asset light model, MLL offers customised solutions to clients at the same time investing time and effort in their partners to grow them as well. This is scalable as well. JIT and JIS are mostly used towards assembly lines, and the same was demonstrated at the plant for use in the auto sector.

As a parting note, I would like BHPians to add to the points and discuss the overall condition of the auto logistics sector, scope for improvements, personal experience (if any) and ideas for betterment in this field.

[Aditya]

Thread moved out from the Assembly Line. Thanks for sharing!

[speedguy]

Thanks for the detailed review & some fantastic pics.
Only one thing you need to modify. The image under which you have described as Make in India Lion, it seems a Cheetah actually! Make in India's Lion is slowly walking whereas the animal in the image (I am presuming it a Cheetah) is running.
Moreover, Mahindra always advertised XUV 500 using Cheetah as their role model.

[superbad]

Fascinating insight into the behind-the-scenes of vehicle production. It's mind boggling to appreciate the thousands of small things which come together to form a vehicle, & that thousands of these vehicles are being made everyday with very few errors. Testament to progress made by mankind.

[ashikthomson]

Fantastic writeup. It's really exciting to see the efforts of a large number of people, to deliver us the car at a perfection. Once in a while thinking about all these backstage efforts and the thought process and implementation which goes into the execution of such assembly lines really makes us wonder the advancements in engineering.
Just remember that how important is, even a small screw that fixes the smallest parts are, to the safety of machines that we drive at real roads.

[gauravanekar]

Thanks for the report. Highly informative thread.

1. I think shower test is carried out not only for trucks but for cars also, maybe that process was not shown.
2. Following JIT is challenging in a truck / commercial plant compared to PV plant.
3. Was there any information given out regarding plant capacity and current operating volume?
4. Was any information given as to how information flows within various division of manufacturing plant? like order number, spec sheet etc for the particular vehicle. How well do they leverage IT for information management? Ultimately JIT is as good as their information management is.
5. Are cars & trucks made to order in their plants or is it based on sales forecast?
6. In car manufacturing do they follow batch production process or do they not?
7. I could see TPM board in one of the picture, TPM is Total productive Maintenance, wherein each employee engages in continuous improvement processes which shall improve quality, productivity and safety performance of the plant. TPM when implemented in the right spirit shall give out great results.
8. Overall the 5S of the plant looks good. Hope it stays like that always even when there are no visitors expected.

[batterylow]

A very informative thread.



Thank you for showing the unglamorous side of the automotive industry.

[N33raj]

I learnt something new today. Thank you very much for sharing this rather exhaustive look into the other side of the Auto industry. Going through the photographs gives a good idea of the size of ops that large carmakers have to have to keep vehicles rolling into showrooms and eventually into homes.

[Thermodynamics]

Big thanks, very informative and insightful. Initially I thought I would learn logistics but you have a covered a full scale plant. Kudos to the grasping power of you guys, so much in just a day ?

Truly wish M&M for their vision to become a top 10 global player. In one of the pictures, they claim to be on track with regard to vision milestones of the past. I was curious to know 2019 promise, tried to zoom in but couldn’t manage to read.

Usually, no industry would allow photography inside premises due to proprietary reasons. That makes this a special thread as it provides great information and details for enthusiasts to munch on.

One last question, how long does it take from start to end to build a typical car i.e. from sheet metal to completion before it enters logistics.

Thanks again for sharing.