Regardless of a sluggish get started, automobile production in India has shifted into the global speedy lane. The country’s car business – nonetheless in its infancy as past due because the 1960s – has since sped up. As of late the arena’s biggest democracy is the sixth-largest manufacturer of passenger automobiles and industrial cars.
Tata Motors has performed a pivotal function in remodeling transportation in India. Throughout many of the 20th century, a automobile used to be a luxurious reserved most commonly for the wealthy. Moreover, nearly all of the ones cars both have been imported or manufactured in India via multinational car firms. Tata Motors got down to develop into the primary indigenous automobile producer.
In 1998, Tata Motors introduced the primary absolutely indigenous Indian passenger automobile, the Indica. In 2008, Tata Motors introduced the Nano – the arena’s maximum inexpensive automobile.
Tata Motors is dedicated to reaching world-class high quality in each car it produces. So when the corporate made up our minds to switch the growing older production execution machine (MES) in one in every of its present factories, it selected the FactoryTalk® ProductionCentre® machine from Rockwell Automation, as a step against standardizing its MES panorama.
The Tata Motors passenger car plant in Pune, India, manufactures the Zest, Bolt, Indica and plenty of different fashions in a couple of variants. In 2011, plant managers and engineers identified that their 6-year-old Production Execution Machine wanted an improve.
The present machine used to be starting to display early signs of growing old.
“We have been dealing with machine availability problems stemming from sporadic server disasters.” stated Satarupa Roy Sarkar of Tata Motors, IT “If those endured or turned into worse, it might end up tricky to satisfy prime availability expectancies of customers.”
Constant high quality used to be every other initiative the Tata Motors crew sought after to help. They wanted an MES system with computerized, real-time, information-sharing capabilities thru high quality gates.
“If a defect is detected, corrective movements wish to be taken briefly,” stated Satarupa. “We would have liked this to occur extra briefly with computerized indicators and traceable communications.”
To support the velocity of interlinked high quality similar conversation, machine primarily based comments and feed ahead mechanisms have been carried out. This could assist quicker movements to help achievements of high quality benchmarks.
“We learned we had to have a revamp of all of the MES,” stated Jagdish Belwal, Leader Knowledge Officer for Tata Motors. “After we went for this improve, we additionally handled it as a chance to do industry procedure re-engineering. But even so making improvements to manufacturing efficiency, we would have liked to standardize programs, processes and generation with two sister crops, either one of which have been greenfields.”
Tata Motors already used FactoryTalk ProductionCentre (FTPC) device in its two more recent crops. In keeping with their successes with the cutting-edge MES, the Tata Motors crew made up our minds to changeover to FTPC within the Pune plant as neatly.
Via transitioning to the FactoryTalk machine, the crew knew they may improve operational consistencies and supply visibility for determination help throughout the Pune plant. Plus, they may additionally assist permit a Hooked up Endeavor via integrating all 3 crops and standardizing communications, programs, processes and generation.
Underneath commonplace cases, a transition of the magnitude required at Pune – together with server installations, community redundancies and alertness switch-overs for 6 assembly-line retail outlets and 93 purposes – would have led to a big shutdown.
On the other hand, the Tata Motors crew and its generation companions made up our minds to conquer this problem and pass reside whilst the plant used to be working – with very little downtime and minimum impact on manufacturing.
The 20-plus-member transition crew incorporated utility companions from Tata Applied sciences Restricted, IT infrastructure-support suppliers from Tata Consultancy Services and products, programs integrators from MESTECH Services and products, and generation mavens from Rockwell Automation and the industry IT crew of Tata Motors.
Step one within the making plans procedure used to be to listen to what functions have been wanted within the new MES. To take action, consultations have been held with all inner stakeholders within the Pune plant – together with most sensible managers from engineering, the meeting line retail outlets, high quality regulate and general plant operations.
With that want record in hand, the crew went to paintings at the MES migration, however they briefly found out the brownfield conversion could be extra sophisticated than anticipated.
“We began with the straightforward assumption that after a machine is operating and is visual to all, we didn’t wish to outline the essential tests and balances in-depth,” Belwal stated. “We quickly discovered that we had underestimated the volume of customization that the prevailing MES had passed through in closing 6 years.”
So the crew excited by figuring out the necessities, together with those who were constructed into the older MES through the years.
After growing and broadly checking out of the producing state of affairs, the crew used to be able to take on the problem of a reside transition to the brand new MES.
This required an leading edge way. The crew constructed information bridges between the previous and the brand new machine that might run parallel throughout the migration procedure. The knowledge captured via one machine used to be transferred by way of an information bridge to the opposite machine. The modern migration way supposed that if any failure came about throughout transition, the advance crew may change from side to side between the 2 programs with out affecting manufacturing.
“The transition took one and a part months,” Satarupa stated. “We went store via store, serve as via serve as. We proceeded very moderately, as a result of our number one objective used to be to steer clear of downtime.”
The Tata Motors crew met that objective. In truth, the migration used to be completed with a downtime of simply zero.1 p.c – and that too and not using a loss in manufacturing.
“We had a complete of 2 hours and 45 mins of downtime out of about 1,600 hours, that the department stores have been working,” Satarupa stated. “And that downtime used to be deliberate into the method with the producing crew, so lets stay commonplace manufacturing ranges.”
Because the of completion of the challenge in fall 2013, the brand new machine is being monitored and measured.
Moderately than depending on every store to maintain its personal working documentation, the MES device systematically collects and types thousands and thousands of information issues, and turns them into actionable data.
Satarupa defined the alarm escalation procedure the use of the FactoryTalk machine. “Once a defect is detected at a high quality gate, an alarm is issued in the course of the gate and relying at the defect class, messages are despatched to the supervisors and bosses in the course of the machine. Advised corrective and preventive movements are taken
Tata Motors IT crew additionally wish to spend much less time growing and deploying new programs with the FactoryTalk machine. “With the brand new machine, they don’t have to visit every station to deploy the similar utility or write the similar code over and over again,” Satarupa stated.
But even so decreasing handbook processing, the brand new MES connects the plant to the undertaking, opening the door to a mess of manufacturing and potency beneficial properties. For instance, information codecs, modeling and design way are all unified a number of the 3 websites.
“Adopting the Rockwell Automation answer has helped to standardize our MES panorama,” Belwal stated.
Now that Tata Motors have harmonized its applied sciences throughout 3 production crops, they’re comparing the possible to put into effect Rockwell answers in different crops as neatly.
“From a strategic viewpoint, we noticed transparent benefits in replicating the generation from our different websites into Pune,” Belwal stated. “What we’ve completed right here has the possible to be replicated in different crops.”
The effects discussed above are explicit to Tata Motors’ use of Rockwell Automation services at the side of different merchandise. Particular effects would possibly range for different shoppers.