The Company
Tata Cummins Limited (TCL) is a 50:50 Joint
Venture between Tata Motors Limited, India's largest Automobile manufacturer and
Cummins Engine Company Inc. of USA, world leaders in design and manufacture of
diesel engines. The Rs 300 Crore project with an authorized share capital of
Rs 250 Crore has been set up at Jamshedpur for the manufacture of Diesel engines
to power Tata Motors Limited's commercial vehicles. The decision to locate at Jamshedpur was
based on the desire to be near the customer.Commercial production of engines
from kits commenced in January 1996 and the machining lines for in-house
manufacture of components started in March 1997.
Tata Cummins currently
employs about 850 people and has a capacity of 72,000 engines per annum & has
plans to increase its capacity up to 1,20,000 in recent period. Our Product The low emission Diesel
Engines manufactured by Tata Cummins are for use in a new generation of Tata Motors Ltd's
Medium and Heavy Commercial Vehicles. The engines conform to EURO - I ,
EURO - II & EURO - III standards for emissions. The 78 to 235 Horsepower engines
have a high power to weight ratio and will enable Tata Motors Ltd. access new markets
worldwide with its advantage of emissions, power, oil consumption and
durability.
Our Plant
Tata Cummins has a modern manufacturing facility located adjacent to Tata Motors Ltd.,
designed by Kevin Roche, John Dinkeloo Associates of USA and C P Kukreja
Associates of Delhi. The unique plant comprises a fully air-conditioned
182 x 186 m building with pre-cast concrete coffer roofing and 15 x 15 m bays.
The North and South walls are of glazed curtain glass. Features such as a PLC
controlled Fire Detection/Suppression System, Skylights and Building Management
System ensure high levels of Safety and Energy efficiency.
Manufacturing System
The world class manufacturing systems of Tata Cummins are benchmarked against
the best internationally and comprise facilities for machining 5 major engine
components, and facilities for Assembly, Test and Paint of engines.
Assembly of engines is performed on a state-of-the-art Automated Electrified
Monorail System, which is roof, mounted for clean floor assembly. The system is
fully PLC controlled and linked to a computerized Assembly Management System.
It incorporates Failsafing at each station and In-Process-Verification Systems
at critical points for defect free assembly. Laser Pulse Tools, Pneumatic
Manipulators and Ergonomically designed workstations and facilities are provided
to reduce operator fatigue.
Dedicated Machining lines are commissioned for each of the 5 components which
are manufactured in-house viz. cylinder block, cylinder head, crankshaft,
camshaft and connecting rods. Equipment has been sourced from leading suppliers
in India and overseas to ensure very high levels of capability and reliability.
This includes latest gauges, three Coordinate Measuring Machines and
sophisticated equipments such as Topometer, Incometer for cylinder bore
measurement.
Management System
The company's efforts in
achieving manufacturing excellence are guided by the principles and practices of
the Cummins Operating System (COS), and the Customer Led Quality objectives. The
Company has a flat organization structure. The level of first line Supervisors
has been eliminated with the operatives (known as Associates) being organized in
Teams. The formally structured Team Based Work System constitutes an integral
part of the COS and is a key initiative to involve / empower shop level employees
to work towards continuous improvement and customer delight. Total Quality
systems or TQS has been adopted from the early stages in the company, in line
with Cummins Quality Systems. The latest communications and computing systems
have been installed for connectivity internally and with Cummins systems in USA
to provide real-time on-line information integrating the manufacturing and
management information / control systems.
Milestones