Inside Tata Motor’s car assembly line

Tata Motors' Pune plant is spread over two geographical regions- Pimpri (800 acres) and Chinchwad (130 acres).

It was established in 1966 and has a Production Engineering Division, which has one of the most versatile tool making facilities in the Indian sub-continent.

It houses a Vehicle manufacturing complex which is one of the most integrated automotive manufacturing centres in the Country producing a large variety of individual items and aggregates.

It is engaged in the design and manufacture of sophisticated press tools, jigs, fixtures, gauges, metal pattern and special tools, as well as models for the development of new ranges of automobile products.

Its capabilities have enabled Tata Motors to introduce new products and improve existing ones without resorting to imports of dies or fixtures.

Over the years, this division has developed expertise in design and manufacture of automated dies, fixtures and welding equipment.

Its large design group is fully conversant with state-of-the-art CAD facilities and manufacturing facilities.

Manufacturing facilities comprising of light and heavy CNC machine shops, jigs boring room, plastic template shop, wood pattern and model pattern shop, five axis precision machine tools and laser control machines.

To cope with such a diverse range, four assembly lines have been established, one each for MCVs and HCVs, LCVs, Utility vehicles and one for Passenger Vehicles (Indica and Indigo).

The Passenger Vehicle Division in 'K' block executes the entire process of car manufacture over five shops - the engine shop, the transmission shop, press and body shops, paint shop and the trim and final assembly shop.

The shops are fully automated ensuring that there is minimal chance for error in the manufacturing processes.

After the car is completely assembled, it goes through several checks like wheel alignment, sideslip test, brake test, shower test, and a short test run before it is ready for dispatch.

All systems such as materials management, maintenance and other activities are computerized, enabling smooth operations and minimum inventory needs.

The Electronics Division is engaged in the production of a wide variety of Machine Tool Controllers, PLCs, Test rig instrumentation, Servomotors, Proximity Switches.

In addition, it has developed a number of components such as flashers, horns, timers that are used in Tata Motors' vehicles.

Industry experts rate the fully automated Foundries at Chinchwad and Maval among the best, worldwide.

The Iron Foundry at Chinchwad produced 29334 Tons of high precision castings in 2012-13 while the Iron Foundry at Maval produced 10646 Tons of spheroidal Iron castings in 2012-13.

These include Cylinder Blocks, Cylinder Heads, Gear Box Housing, etc. The Aluminium Foundry at Chinchwad produced 4292 Tons of casting mainly Cylinder heads required for PVBU and FIAT.