Industrial Visit Report on Mahindra and Mahindra

INDUSTRIAL VISIT REPORT MAHINDRA & MAHINDRA LTD. – NASHIK PLANT (25TH NOVEMBER, 2013)

Acknowledgement I would like to thank a few people who have helped made this industrial visit a knowledgeable experience. Firstly, I would like to thank our course co-ordinator Mr. V Naik as well as the college management who provided us with the opportunity of visiting the plant to help us better understand the working of the production functions. Also, I would like to thank Ms. Asha Sabarwal, the Admin and employee development department of Mahindra & Mahindra Ltd. Who helped us and guided us all throughout our visit. She also briefed us about the company as well as the nashik plant before we actually visited the plant. Also, Mr. Vithal, the plant Head, Mr. Prasad Bhatt, the Plant Supervisor, as well as the entire staff of Mahindra & Mahindra Ltd. Who were extremely supporting all throughout our visit.

ABOUT THE COMPANY The company Mahindra And Mahindra Ltd. Was founded in the year 1945. However, the company entered into the automotive manufacturing sector in the year 1947 by bringing the iconic jeep onto the Indian roads. However, over the years the company also diversified into various other sectors to meet the different needs of their customers like farm equipment, Shipping, telecom, IT etc. The company has its operations spread across almost 100 countries employing nearly 1,44,000 employees all throughout the world. Today, the company has a net turnover of 16.2 billion $. The company today is India’s number 1 utility vehicle Player. Also it is India’s number 1 tractor manufacturing company. The company is also into Rural NBFCs and rural Housing Finance. The Company was the first to set up an SEZ in India. The Founders of the company were J. C. Mahindra , K. C. Mahindra and Ghulam Mohammed. The company was established on 2nd October, 1945. The company is also involved in various CSR activities. The company gives back 1% of its PAT (Profit After Tax) to the society. The 8 Core Values of the company were as follows:       

In Built Safety Pleasure Of driving Enhancing Status Sustaining Longevity and Resale Value Appealing Style and design Proactive Sales and service Low cost Earning Potential The company’s operations revolve around these basic core values and beliefs.

Mahindra & Mahindra Ltd. Nashik Plant:The plant is located at Satpur in the Nashik District of Maharashtra. The plant is spread across 170 acres. The vehicles being produced in this plant are: XYLO  SCORPIO  VERITO  BOLERO  QUANTO Out of the above five, Xylo, Verito and Scorpio are manufactured in Plant 1 and Quanto and Bolero are manufactured in the Plant 2. We had visited Plant 1 where we saw the manufacturing of Verito , Xylo and scorpio. The company manufactures Xylo and Scorpio on the same line. However, there is a separate

assembly line for the manufacture of Verito. The Verito Plant had the manufacturing of Verito Vibe which is a new model of Verito being launched my Mahindra & Mahindra in the year 2013. The company also has another plant in Pune where they produce Rexton, XUV and all other new vehicles. The Pune plant is 750 acres however, the plant’s capacity is underutilised. When during the session after the visit we asked Mr. Vitthal as to how much time does it take to manufacture one car and also every 2 minutes a car leaves the plant for the show room We visited the verito plant first. The first thing we found there was the PURPOSE 2016. The Purpose 2016 had an objective of:“To be the top 10 Global Automobile.” This objective or the purpose acted as a guideline for the company to meet its short term goals and objectives. Each and every employee of the company were given different goals and targets daily and these targets were in accordance with the company goals. There were meetings held every morning where these daily targets were set and also the problems and issues of the employees were addressed to. This process of meeting every morning and deciding the targets etc, was termed as Daily Working Management by the company. The Plant Layout:The manufacturing process is divided into various phases and it passes through different stages. They are:Body shop, paint shop, Dye Shop, Work shop, Press Shop. The vehicle passes through different processes:1. 2. 3. 4.

Trims Engine Paint Testing

In the trims process, the company goes through various processes like Wiper Mechanism, Door Latch fitting, passenger compartment wiring, etc. The Company had TCF i.e. Trims, Chasis, and Final phases. Under the chasis phase, the engine is assembled and finally the car is assembled in the final stage. The outer body of the vehicle is fitted on the engine mechanically. On the final assembly line, the car also goes through final testings. The readymade engines for the automobiles are procured from France and they are attached to the automobile through Under Body fitting process. The car passes through various workstations step by step and stops at each workstation for 12.9 minutes. When asked to the plant head, these 12.9 minutes was the industry standard and was derived after various tests. At this stage, the automobile was fitted with the air conditioners, coolants, spare wheels, roller and brake testings, break oil, etc.

In the next step, the car is passed on to the paint shop where the final touch ups were made. This stage focuses on the looks and appearances of the automobile. It ensured that the car was up to mark. Finally the car passes through two different tests:Shower test Dynamic Test The company adopts Japanese Quality Model In their manufacturing Process. Also, it was being told to us that the die shop used the latest technologies i.e CAD/ CAM technology. Also, when asked we were being told that the car takes maximum time at the paint shop. The Various Japanese techniques used by the company were:1. POKAYOKE:This method ensured that all the processes were carried out with minimum human error. The plant had various charts and indicators displayed along the assembly line to instruct the workers how they should go about their tasks. 2. KANBAN:Under this method, the employees were constantly reminded of their targets. In case of any defects, there was a board at the centre of the plant where the fault would be displayed and an alarm started ringing. Also if there were any materials or parts which were out of stock it was displayed on the board with an alarm ringing. 3. Abc analysis:Verito had 288 spare parts which were classified under these following categories :A - 21 B - 47 C- 160 According to the above analysis, it was found that the parts in Category A were the most important and B little less and finally C category least important. These were the basic learnings about the production and manufacture of the automobiles. The company had a policy of keeping trees at almost all departments wherein there are cards being put up regarding the problems faced by the department. They are being put up month wise. There are two different colours. One indicated that the problem could be resolved within the company and the other indicated that there was a need for a third party to resolve that particular issue.

CSR ACTIVITIES OF THE COMPANY As mentioned earlier, The company believed in giving back 1% of its PAT to the society. The company has organised a campaign named Nanhi Kali through which they provide education to the girls in the rural areas. Also, the company is engaged in creating awareness about AIDS and also helping the people suufering from AIDS. The company engages marriages between the AIDS affected people. Also, the company is engaged into tree plantations and playgrounds for school children. FOR THE EMPLOYEES The company provides Gymnasium Facilities, free annual health checkups, education and career counselling facilities to the children of these employees. Also, the company provides canteen facilities to the employees. They also reward the employee of the month. Also, at the end of the year, Out of these Employees of the month, an employee is awarded as the Employee of the year award. Hence, these were the data we got through from the plant as well as the briefing sessions with the company employees.