16TH NOVEMBER SAW THE PUNE ENGINE PLANT INAUGURATION. THE OFFICIAL OPENING WAS LED BY NICK SPENCER AND PETER DOMENEY FROM UK EMC, MR DESAI (PCBU TML PLANT DIRECTOR) AND MR KHATRI (TATA MOTORS MANUFACTURING OPERATIONS DIRECTOR). ANDY GALLON AND TREVOR JONES REPRESENTED GLOBAL MP&L AND GIVE US AN INSIGHT INTO THE EVENT
The new Engine Manufacturing Centre in Pune India will
manufacture engines for the six vehicles that we currently
assemble in the region. The first official Job1 AJ200D engines
were delivered to the L Block car manufacturing facility on
Tuesday 12th September 2017.
The Material Planning & Logistics (MP&L) team have spent
many hundreds of hours working with cross functional teams
from within JLR & TML to ensure robust processes, IT systems,
packing & packaging solutions are in place.
The Plant, on the Tata Motors Pimpri site, is a specialised low
volume manufacturing centre measuring approx. 2200m2 and comprising
a 26 station assembly line which will produce six engine
variants. The assembly line and associated MP&L area is
designed based on a ‘room in a room’ concept in order to
protect the product from any particulate ingress.
The project required the design and implementation of an
innovative supply chain solution. This uses SAP to order from
circa 70 suppliers and supports part by parts shipments from
Europe to India.
In order to ensure that the components are protected during
the Journey to India, a new solution for packing of cranks,
blocks and cylinder heads at the Engine Export Facility in
Wolverhampton was designed by the International Manufacturing Development Pack team. This design was rigorously tested over a six month
period in environmental labs in Hamburg. A unique packing
operation was also developed to protect the parts at the Global Packshop at Midpoint, Minworth, using environmentally controlled pods as packing
stations prior to onward shipment to India.
A Puja (Hindu prayer ritual) was held in the EMC to
celebrate the first shipment of engines to the vehicle plant.
FACTS & FIGURES
The EMC started as a TMI PDI shed - the complex conversion to
a dust free, temperature and humidity controlled environment
commenced August 2016
There are 3 logistics routes for delivering 453 part numbers
to this plant (EMC, Global Packshop, Direct Source)
The plant has the capacity to produce 20000 engines per year
on a 2 shift basis
The EMC assembles engines which go into the Jaguar XE, XF,
F-PACE, Range Rover Evoque and Discovery Sport
JLR & TML teams have worked closely overcoming several major
challenges to deliver this project in a short span of 1 year from
construction of plant to delivering engines to vehicle plant.
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