{"id":22716,"date":"2022-10-19T10:12:02","date_gmt":"2022-10-19T10:12:02","guid":{"rendered":"https:\/\/webttldev.tatatechnologies.com\/?p=22716"},"modified":"2024-07-29T09:49:48","modified_gmt":"2024-07-29T09:49:48","slug":"a-fully-operational-automotive-manufacturing-plant-in-12-months-thats-better","status":"publish","type":"post","link":"https:\/\/webttldev.tatatechnologies.com\/en\/success-stories\/a-fully-operational-automotive-manufacturing-plant-in-12-months-thats-better\/","title":{"rendered":"A fully operational manufacturing plant in 12 months. That\u2019s better\u00a0"},"content":{"rendered":"\n<div class=\"wp-block-create-block-copy-block-two py-5\"><div class=\"container px-6\"><svg class=\"w-full mb-7\" version=\"1.2\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"1536\" height=\"10\"><defs><clipPath clipPathUnits=\"userSpaceOnUse\" id=\"cp1\"><path d=\"M0-1h1919.71v12.66H0z\"><\/path><\/clipPath><\/defs><g id=\"Clip-Path\" clip-path=\"url(#cp1)\"><g id=\"Layer\"><path class=\"text-purple s0\" d=\"M.5 11.5 5.2-.8M7.5 11.5 12.2-.8M14.5 11.5 19.2-.8M21.5 11.5 26.2-.8M28.5 11.5 33.2-.8M35.5 11.5 40.2-.8M42.5 11.5 47.2-.8M49.5 11.5 54.2-.8M56.6 11.5 61.2-.8M63.6 11.5 68.3-.8M70.6 11.5 75.3-.8M77.6 11.5 82.3-.8M84.6 11.5 89.3-.8M91.6 11.5 96.3-.8M98.6 11.5l4.7-12.3M105.6 11.5l4.7-12.3M112.6 11.5l4.7-12.3M119.7 11.5l4.6-12.3M126.7 11.5l4.7-12.3M133.7 11.5l4.7-12.3M140.7 11.5l4.7-12.3M147.7 11.5l4.7-12.3M154.7 11.5l4.7-12.3M161.7 11.5l4.7-12.3M168.7 11.5l4.7-12.3M175.8 11.5l4.6-12.3M182.8 11.5l4.6-12.3M189.8 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md:grid-cols-2 mb-7\"><h3 class=\"font-header text-4xl md:text-5xl pb-5 -mt-1 text-primary pr-5\">Challenge<\/h3><div><div class=\"copy-block-two-blurb text-lg\"><p>Upon acquisition, the OEM inherited the plant with minimal machinery and disparate systems that lacked essential software, intellectual properties, and IT\/OT integration utilities. The OEM was committed to establishing connectivity while fully integrating these assets to initiate production and scale the plant&#8217;s annual capacity, across four primary shops\u2014stamping, body construction, paint, and final assembly\u2014each infused with high levels of automation and the latest digital technologies. Moreover, building the capability to manufacture both ICE vehicles and EVs in the same plant posed another significant challenge. They set a clear and ambitious directive for our engineers: Transform the plant into a lighthouse of cutting-edge technology and digital innovation.\u00a0<\/p><\/div><\/div><\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-create-block-copy-block-two py-5\"><div class=\"container px-6\"><svg class=\"w-full mb-7\" version=\"1.2\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"1536\" height=\"10\"><defs><clipPath clipPathUnits=\"userSpaceOnUse\" id=\"cp1\"><path d=\"M0-1h1919.71v12.66H0z\"><\/path><\/clipPath><\/defs><g id=\"Clip-Path\" clip-path=\"url(#cp1)\"><g id=\"Layer\"><path class=\"text-purple s0\" d=\"M.5 11.5 5.2-.8M7.5 11.5 12.2-.8M14.5 11.5 19.2-.8M21.5 11.5 26.2-.8M28.5 11.5 33.2-.8M35.5 11.5 40.2-.8M42.5 11.5 47.2-.8M49.5 11.5 54.2-.8M56.6 11.5 61.2-.8M63.6 11.5 68.3-.8M70.6 11.5 75.3-.8M77.6 11.5 82.3-.8M84.6 11.5 89.3-.8M91.6 11.5 96.3-.8M98.6 11.5l4.7-12.3M105.6 11.5l4.7-12.3M112.6 11.5l4.7-12.3M119.7 11.5l4.6-12.3M126.7 11.5l4.7-12.3M133.7 11.5l4.7-12.3M140.7 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11.5l4.7-12.3M1528.5 11.5l4.7-12.3M1535.5 11.5l4.7-12.3\" style=\"stroke:#8468F6\"><\/path><\/g><\/g><\/svg><div class=\"copy-block-two md:grid grid-cols-1 md:grid-cols-2 mb-7\"><h3 class=\"font-header text-4xl md:text-5xl pb-5 -mt-1 text-primary pr-5\">Solution<\/h3><div><div class=\"copy-block-two-blurb text-lg\"><p>Our team took on the challenge of implementing a top-notch digital manufacturing solution that ensured both capacity and precision. We led the charge in designing and deploying a smart manufacturing system, including an IT\/OT layer, paperless quality system, handheld-based in-plant logistics, and digital factory monitoring. This system seamlessly integrated Enterprise Resource Planning (ERP) and Product Lifecycle Management (PLM).<\/p><p>The implementation represented the Holy Trinity of Digital Manufacturing (PLM-ERP-MES), creating a solid foundation for Digital Thread. This allowed the company to leverage data for AI\/ML use cases and introduce innovations like GenAI to boost quality and productivity. The solution was deployed across all production lines\u2014Paint, BIW (Body in White), and TCF (Trim Chassis &amp; Frame)\u2014playing a crucial role in starting production on time and scaling the plant&#8217;s capacity to around 300,000 units annually.\u00a0<\/p><p>The real-time digital factory monitoring system provided transparent information to all stakeholders, from operators to senior management, detailing targets, actuals, and troubleshooting needs at all times.\u00a0<\/p><p>Ready-to-implement accelerators and our engineers working on-site at the manufacturing plant were key to making the plant operational within nine months, much before the anticipated timeline. This project showcased the power of collaboration within the Tata ecosystem as ONE TATA.\u00a0<\/p><\/div><\/div><\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-create-block-infographics pb-11 pt-5 mb-20 md:pt-8 md:pb-11\" style=\"background-color:#8468F6\"><div class=\"container\"><svg class=\"w-full mb-7\" version=\"1.2\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"1536\" height=\"10\"><defs><clipPath clipPathUnits=\"userSpaceOnUse\" id=\"cp1\"><path d=\"M0-1h1919.71v12.66H0z\"><\/path><\/clipPath><\/defs><g id=\"Clip-Path\" clip-path=\"url(#cp1)\"><g id=\"Layer\"><path class=\"\" d=\"M.5 11.5 5.2-.8M7.5 11.5 12.2-.8M14.5 11.5 19.2-.8M21.5 11.5 26.2-.8M28.5 11.5 33.2-.8M35.5 11.5 40.2-.8M42.5 11.5 47.2-.8M49.5 11.5 54.2-.8M56.6 11.5 61.2-.8M63.6 11.5 68.3-.8M70.6 11.5 75.3-.8M77.6 11.5 82.3-.8M84.6 11.5 89.3-.8M91.6 11.5 96.3-.8M98.6 11.5l4.7-12.3M105.6 11.5l4.7-12.3M112.6 11.5l4.7-12.3M119.7 11.5l4.6-12.3M126.7 11.5l4.7-12.3M133.7 11.5l4.7-12.3M140.7 11.5l4.7-12.3M147.7 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11.5l4.7-12.3M1535.5 11.5l4.7-12.3\" style=\"stroke:#ffffff\"><\/path><\/g><\/g><\/svg><div class=\"infographics md:grid grid-cols-1 md:grid-cols-2 md:px-0 mb-7\"><h3 class=\"font-header text-white text-4xl md:text-5xl pb-5 -mt-1\">Highlights<\/h3><\/div><div class=\"md:grid  md:gap-x-6 md:gap-y-6 md:px-0 md:grid-cols-3\"><div class=\"mb-10 md:mb-5\"><div class=\"border-white border-t border-solid mt-3 pt-6 text-white\"><div class=\"mb-5 font-body text-5xl\">300,000 vehicles <\/div><div class=\"text-white font-body text-lg\">Plant\u2019s annual production capacity  <\/div><\/div><\/div><div class=\"mb-10 md:mb-5\"><div class=\"border-white border-t border-solid mt-3 pt-6 text-white\"><div class=\"mb-5 font-body text-5xl\">460-acre plant  <\/div><div class=\"text-white font-body text-lg\">Operational in record time of 9 months<\/div><\/div><\/div><div class=\"mb-10 md:mb-5\"><div class=\"border-white border-t border-solid mt-3 pt-6 text-white\"><div class=\"mb-5 font-body text-5xl\">In-house expertise<\/div><div class=\"text-white font-body text-lg\">Future AI\/ML and GenAI innovations<\/div><\/div><\/div><\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-create-block-image-split\"><div class=\"py-16\"><div class=\"container-size grid grid-cols-2 h-[var(--cqh)] [--cqh:375px]\"><div class=\"angled-br h-full relative -mr-16 md:-mr-32\"><img decoding=\"async\" width=\"1969\" height=\"750\" alt=\"\" loading=\"lazy\" src=\"https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_L-1.jpg\" sizes=\"auto, 50vw\" class=\"wp-image-22761 absolute object-cover w-full h-full\" srcset=\"https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_L-1.jpg 1969w, https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_L-1-300x114.jpg 300w, https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_L-1-1024x390.jpg 1024w, https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_L-1-768x293.jpg 768w, https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_L-1-1536x585.jpg 1536w, https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_L-1-1792x683.jpg 1792w, https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_L-1-24x9.jpg 24w, https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_L-1-36x14.jpg 36w, https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_L-1-48x18.jpg 48w\" \/><\/div><div class=\"angled-tl h-full relative bg-black pl-2 -ml-16 md:ml-0\" style=\"background-color:#8468F6\"><div class=\"angled-tl h-full bg-white\"><img decoding=\"async\" width=\"1458\" height=\"750\" alt=\"\" loading=\"lazy\" src=\"https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_R.jpg\" sizes=\"auto, 50vw\" class=\"wp-image-22755 absolute object-cover w-full h-full\" srcset=\"https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_R.jpg 1458w, https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_R-300x154.jpg 300w, https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_R-1024x527.jpg 1024w, https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_R-768x395.jpg 768w, https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_R-24x12.jpg 24w, https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_R-36x19.jpg 36w, https:\/\/webttldev.tatatechnologies.com\/app\/uploads\/2024\/07\/Bottom_images_R-48x25.jpg 48w\" \/><\/div><\/div><\/div><\/div><\/div>\n","protected":false},"excerpt":{"rendered":"<p>To tackle a critical demand-supply challenge in the SUV segment, a leading Indian automaker boldly acquired a 460-acre plant from a competitor. Could this strategic acquisition be the game-changer the OEM needed? Absolutely. With an ambitious plan, they aimed to start manufacturing best-in-class cars within just 12 months, achieving remarkable efficiency and market impact.<\/p>\n","protected":false},"author":32,"featured_media":22744,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"inline_featured_image":false,"footnotes":""},"categories":[47,64,53,59,58,61,18],"tags":[],"class_list":["post-22716","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-automotive","category-digital-enterprise-solutions","category-enable-the-electrification-of-your-product-portfolio","category-meet-demanding-quality-targets","category-integrate-disparate-legacy-systems","category-reduce-time-to-market","category-success-stories"],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v24.1 (Yoast SEO v24.1) - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>A fully operational manufacturing plant in 12 months. 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