Tata Motors Adopts
Smarter Assembly
BUILDING ENGINES BETTER
IMPACT
Kicked off digitalisation of plant
Ensured complete data traceability
Achieved a quality product
The Customer Journey
About The Customer
Part of the Tata Group, Tata Motors is a leading global automobile manufacturer of cars, utility vehicles, pick-ups, trucks and buses. Tata Motors is India’s market leader in commercial vehicles and among the top three in the passenger vehicles market. Tata prioritises human centricity with technological prowess and engineering excellence to make cargo and passenger mobility safer, smarter and greener.
Customer Goals
Tata Motors wanted to:
- Start their digitalisation journey
- Make the Pune plant smarter
- Achieve a quality product
- Ensure complete data traceability for the whole plant
The Problem
At its manufacturing facility in Pune, vehicles and engines were still being manually assembled the traditional way. Therefore, process security and data traceability were two of the major challenges the customer was facing. Standard operating procedures weren’t always followed, especially by operators performing manual operations.
Because machine-related mechanical poka-yokes (safeguards) were not in place, some station operations were skipped before passing the part on to subsequent stations, leading to incorrect assembly down the line. At the quality gate, when a defect was identified, it led to line stoppages and high recovery time, reducing overall equipment effectiveness (OEE) and first time through rates (FTTR).
Smarter Assembly
Implementing the ODIN Workstation solution has made Tata Motors’ engine assembly line smarter, with all the required mechanical poka-yokes and safety systems provided.
This digital solution provides step-by-step, visual guidance to ensure that operators follow the correct assembly sequence.
Because it does not allow the part to move on to subsequent stations if steps have been skipped or incorrectly performed, it ensures complete process security and compliance in building a safety critical product.
Full data traceability for every product that comes off the line also means that if there is a problem, it can be rapidly traced and solved with minimal downtime.
A real-time analysis of the overall line also allows the production management team to see where any problem areas may lie and take corrective action.
Measuring Success
- 100% traceability achieved
- 20% reduction in defects
Conclusion
Jendamark’s flagship Industry 4.0 solution, ODIN Workstation, has helped Tata Motors in Pune to start their digitalisation journey.
As both a worker guidance and process security solution, with deep hardware integration capabilities, it ensures that Tata Motors delivers a well-built, quality end-product with full data traceability for added peace of mind.
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