www.autocomponentsindia.com Vol 7 Issue 04
` 100
June 2020
COMPONENTS
INDIA
VOICE OF THE AUTOMOTIVE SUPPLIERS
Toyota Global Unification Strategy
Vehicular Platform Consolidation One-to-Many
Special Read Improving Manufacturing Efficiencies l #Trending Scouting Opportunities for Recovery
Just in Time
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utocomponentsindia.com
ue 01
Vol 7 Issue 01
March 2020
` 100
March 2020
Shape of COMPONENTS Recovery OMPONENTS INDIA
OF THE AUTOMOTIVE SUPPLIERS
VERSARY
For the components industry to stage a recovery, a focused stimulus will ensure its not left alone to fight the demon.
T
INDIA
AUTO COMPONENTS INDIA
VOICE OF THEheAUTOMOTIVE SUPPLIERS world has moved on from predicting
the Covid-19EXPO recession 2020 to predicting the AUTO recovery shape. Will the shape of the recovery curve be ‘L’, ‘U’, ‘V’, ‘W’, ‘Z’ or as th some say the ‘Nike Swoosh’? In the early ANNIVERSARY stages of predictions, you must have come across the ‘V’ shape. Touted as the best-case scenario, it signals a quick bounceback from the slump. On the other end of the spectrum is the ‘Nike swoosh’ where all hands point in the direction of quick surge at the end of the lockdown only to be blunted from thereon. For a ‘Z’ shaped recovery, the assumption is that people at the end of the lockdown would be in a celebratory mode and end up spending all the money held on to during the lockdown. This is expected to result in a brief boom. Post it, the GDP could settle down at the pre-pandemic levels. The ‘U’ shape recovery resembles a sharp dip before a slow and gradual recovery expected to last over many quarters. It is based on the assumption that the vaccine will be found only in 2021. The ‘L’ shaped recovery signals permanent damage to the GDP taking it down to levels lower than estimated. The ‘W’ or double-dip recession hints at a difficult journey till the time the vaccine is found. With the latter, one can’t rule out new waves of infections bringing with it more uncertainty and the need to impose more lockdowns. It’s a rare occurrence though. For the components industry to stage a recovery, a focused stimulus will ensure its not left alone to fight the demon.
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AUTO EXPO 2020
105-106, Trade World, B-Wing, 1st Floor, Kamala Mills Compound, Senapati Bapat Marg, Lower Parel (W), Mumbai - 400013, India. Tel +91 22 43525252, Email us at a.bhatia@nextgenpublishing.net Executive Editor Ashish Bhatia Editorial Advisory Board H. S. Billimoria, Aspi Bhathena Head - Design & Production Ravi Parmar Asst Art Director Ajit Manjrekar Production Supervisor Dinesh Bhajnik Publisher Marzban Jasoomani General Manager – North & East Ellora Dasgupta General Manager – South Girish Shet Deputy General Manager – North & East Chanchal Arora (Delhi) Regional Marketing Manager Salma Jabbar (Chennai) Marketing Manager Minocher Parakh (Mumbai) Manager Circulation - North and East Kapil Kaushik (Delhi) Subscription Supervisor Sachin Kelkar Tel +91 22 43525220 Apple Newsstand & Magzter Queries: help@magzter.com Territory Sales Incharge (Circulation) Srinivas Gangula (Hyderabad) Cell +91 09000555756
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AN INTEGRATED APPROACH
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Brose India: Relying on Speed l ZF WABCO Shareholding Acquisition
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All readers are recommended to make their own independent enquiries before sending money, incurring expenses or entering into commitments in relation to any advertisement appearing in the publication. Auto Components India does not vouch for any claims made by advertisers for their products and services. The editor, publisher, printer and employees of the publication shall not be held liable for any consequence in the events of such claims not being honoured by the advertisers. All disputes are subject to the exclusive jurisdiction of competent courts and forums in Mumbai only. Editor Ashish Bhatia
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Content June 2020
COMPONENTS
INDIA
Cover Story
16 Vehicular Platform Consolidation The strategy to use one platform to underpin many models is expected to enable manufacturers to sustain business in the long run.
06 Newscast
n n n n n n n n n
Valeo wins 2020 PACE Award Moody’s FY2021 India growth forecast Blockchain for supply chain failures Maharashtra hits a roadblock Skoda comes online Record low manufacturing PMI Automechanika Frankfurt rescheduled TVS Eurogrip Bandhan Hyundai EMI Assurance
AUTO COMPONENTS INDIA n JUNE 2020
12 Upfront
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n Shiv Kumar, Managing Director, Bollhoff Fastenings Pvt. Ltd.
Toyota Global Unification Strategy
Toyota Motor Corporation has secured investment in future technologies by globally unifying vehicular platforms and processes.
14 Mobilised
n
Triumph BSVI Street Triple RS 2020
23 Special Reads
n
Improving Manufacturing Efficiencies
27 Trending
n Scouting Opportunities for Recovery n Future of Factory Automation in Automotive Manufacturing n ACMA Restart Manual
38 #Trendsmap
To Subscribe turn to page www.autocomponentsindia.com
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VLC 200 GT
HIGH PERFORMANCE HARD MACHINING FOR GEARBOX PARTS PRECISE
DYNAMIC
PRODUCTIVE
COMPACT
Gearbox production with 12 tool position tool turret and internal/ external aluminum oxide/CBN grinding spindle.
HIGHLIGHTS + Reduced machining time: The combination of hard
pre-turning and finish grinding reduces machining time.
+ Maximum workpiece quality: A combination of the best technology and a single clamping operation is used to ensure the best workpiece quality.
+ Shorter process chain: By combining the different processes, the process chain can be shortened.
+ Maximum technological diversity: Internal and external grinding spindles, tool block holders or the time-tested EMAG turret equipped with 12 tool positions are available.
Technical data for the VLC 200 GT: Chuck diameter, max. 210 mm I Swing diameter, max. 270 mm I Workpiece diameter, max. 160 mm I Workpiece length, max. 100 mm I Travel distances X (total stroke from pick-up to turret) / Z 1,700 / 250 mm I Loading time (depending on clamping device) 6 – 10 sec. I Main spindle capacity: 40% duty cycle / 100% duty cycle, 22 / 18 kW I Main spindle torque: 250 / 202 Nm I Main spindle max. speed: 3,000 rpm I Spindle bearing dia., front: 110 mm
EMAG India Private Limited “Technology Centre” I No. 17/G/46-3 · Industrial Suburb I 2nd Stage · Yeshwanthpur I Bangalore · 560022 I Karnataka · India Phone Sales: + 91 80500 50163 (Sales) I Phone Service: + 91 80500 50165 I E-mail: sales.India@emag.com I www.emag.com
www.emag.com
Newscast
Valeo wins 2020 PACE Award Valeo XtraVueTM Trailer won the ‘2020 PACE Award’ for developing the world’s first drive assist technology. Claimed to help drivers to ‘see-through’ the trailer or caravan while towing, it is said to make the operations simpler and safer. The technology software-controlled cameras are known to have been developed inhouse. Aiding in visualising the environment at the rear of the towed vehicle, the system collates the data recorded through the fitted cameras, rendering it as a single, homogenous image. This image is displayed on the screen visible from the cockpit. Drivers can look forward to changing lanes, reversing and parking with complete control over their surroundings. Commenting on receiving the award Marc Vrecko, President of the Comfort and Driving Assistance Systems Business Group said, “This award attests to the creativity, expertise and agility of our
AUTO COMPONENTS INDIA n JUNE 2020
Moody’s FY2021 India growth forecast
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Moody’s Investors Service has cut the FY21 growth projection to zero per cent for India. Warning of a possible rating downgrade for the country subject to fiscal metrics “weakening materially”, the forecast rides on a prolonged or deep slowdown in growth. According to the global rating agency’s latest credit opinion, there are only limited prospects that the government would be able to restore stronger output through economic and institutional reforms. Moody’s, however, expects GDP growth to recover to 6.6 per cent in FY22. The global rating agency, in November 2019, revised its outlook for India from stable to negative. www.autocomponentsindia.com
teams who developed this unprecedented technology, which makes driving simpler and safer.”
Blockchain for supply chain failures Geneva-based World Economic Forum (WEF) study advocates the use of Blockchain to tackle supply chain failures exposed by COVID-19. Recently, WEF is known to have released ‘Redesigning Trust: Blockchain Deployment Toolkit’ for organisations to accelerate an economic rebound to recover from the pandemic. Enabling leaders to maximise the benefits and minimise the risks of the technology, the toolkit will help maintain a resilient supply chain through trust, transparency and integrity. Drawing on the global expertise of more than 100 organisations, piloted in a variety of different contexts, the kit helps companies manage the complexities of deploying a new technology while helping to accelerate the positive impacts.
Newscast
Maharashtra hits a roadblock The Maharashtra state government recently announced a 67 per cent cut in its spending for developmental works this fiscal. With a budget size second to the state of Uttar Pradesh, Maharashtra has incurred an estimated revenue loss in excess of Rs. 50,000 crore over the months of March and April 2020. As per the expert panel set up, it is estimated that the revenue for FY2021 could decline by an estimated 40 per cent or Rs. 1.40 lakh crore short of the state’s revenue projections. With no new development schemes and existing schemes likely to be put on hold or scrapped, 33 per cent of the total outlay is expected to be released. This will be applicable even to those schemes decided by the state cabinet before March 31, 2020.
Skoda comes online
AUTO COMPONENTS INDIA n JUNE 2020
Skoda Auto India has introduced a centralised online booking platform. Offering customers the convenience to choose a Skoda vehicle round the clock from the comfort of their home, the company platform is aimed at leveraging the new normal of transparent and contactless experience. Pioneering the online sales experience with the launch of the Octavia RS 245,
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Skoda is claimed to have sold 200 units then. The company has commenced the online booking of the new Superb FL. The Karoq can be had against a refundable booking amount of Rs. 50,000. The new Rapid 1.0 TSI can be booked against a token amount of Rs. 25,000. A seamless and secure booking platform, it is claimed to be supported by a robust consultation programme and integrates over 80 dealership touchpoints pan India.
Record low manufacturing PMI The April manufacturing Purchasing Managers’ Index (PMI) dropped to a record low of 27.4 amidst the lockdown as per an IHS Markit study. With the PMI known to have contracted for the first time in three years, it is by far the lowest since the www.autocomponentsindia.com
survey first recorded data in March 2005. Blaming the lockdown of factories and the stringent restrictions on consumers for the decline, record contractions in output, new orders and employment point to a severe deterioration in demand conditions
according to the study. For instance, new export orders saw the steepest decline. New orders fell for the first time in two-and-a-half years and at the sharpest rate in the survey’s history, far outpacing the drop during the global financial crisis.
Newscast
Automechanika Frankfurt rescheduled Postponed in response to the local and global measures to curb the spread of Covid-19, Messe Frankfurt has rescheduled Automechanika Frankfurt to September 1418, 2021, post which the event is expected to resume its biennial itenary. Originally scheduled to take place from September 8-12, 2020, the Automechanika Frankfurt show was postponed in consultation with stakeholders including exhibitors, industry representatives, workshops and retail among its associations and partners expected to participate from over 180 countries. Giving priority to ensuring the health and safety of everyone, holding the event in 2021 was the right choice, said the members of the Executive Board of Messe Frankfurt.
TVS Eurogrip Bandhan
AUTO COMPONENTS INDIA n JUNE 2020
TVS Srichakra Limited announced a new feature of online purchase in its retailer app ‘TVS Eurogrip Bandhan’. Claiming to offer a comprehensive e-commerce experience to its customers, the app. helps to both place and track orders. P Madhavan, EVP – Sales & Marketing, TVS Srichakra Limited said, “Digitalisation has been at the core of our sales strategy. We launched the TVS Eurogrip Bandhan app. last year to enable loyalty programmes and the majority of our retail partners are already well versed with it.” Facilitating contactless ordering, it facilitates easy
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browsing of the entire product portfolio for its retail partners. It, in turn, allows them to place an order with respective distributors. The company also plans to introduce exclusive offers and promotions along with loyalty schemes. Besides the app. is said to have added new features to ease the process. www.autocomponentsindia.com
Hyundai EMI Assurance To enhance the convenience and raise positive customer sentiments, Hyundai Motor India announced an EMI assurance program. Keeping the fear of employment uncertainty at bay, the program is claimed to ease the buying process. Offered on select Hyundai car models purchased during the month of May 2020, the program covers a customer for a period of one year from date of sale of the car (excluding first 3 months). Uncertainties such as employment loss in view of poor financial health or acquisition or merger of the company or due to any applicable laws are also factored by Hyundai.
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for more information email us on info@stepperindia.com
Upfront AUTO COMPONENTS INDIA n JUNE 2020
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Bollhoff Fastenings is Future Ready
In an upfront interaction Shiv Kumar, Managing Director at Bollhoff Fastenings Pvt. Ltd. spoke of the company being invested for sustainable growth in the long term. Interview by: Ashish Bhatia
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Upfront Q. How is Bollhoff Fastenings Pvt. Ltd. negotiating the headwinds and the tailwinds faced by the automotive sector? A. Yes, the market is volatile. However, it is also true that companies invested in India are in the game for the long term and are confident of growth. Even though we have seen a correction take place in markets like Germany, we are confident of sustaining growth in India. The future of mobility holds a lot of promise for us. Be it compliance of vehicles with the Euro6 or the BSVI emission standards or pertaining to the lightweight applications. Q. Which are the latest innovations in line with these trends? A. We are especially buoyant on the
fastening solutions which help in weight reduction measures. We are also closely watching the developments in electrification where this could be a boon. We are also testing fastening solutions with a wide range of materials. For instance, aluminium, steel and plastic are some of the materials where we have options in basic customer needs. Q. Are these innovations an outcome of regulatory changes? A. In our case, at the group level, we are ready to meet these demands talking about our current readiness levels. Especially to meet the demands of electrification. There have been major developments in processes and innovations in markets like Germany and China. This backup is readily available to us for the India operations
and will be put to use once the market opens up. It will, however, take time for the market to mature. Q. Any new technical or financial JVs in this era of collaboration? A. We strongly endorse the business model of being financed with 100 per cent equity across the board. Q. Going forward, your challenge and growth areas for the foreseeable future? A. The change in technology is a challenge. Driven by trends like Euro6 and electrification are big growth areas that the company is focussed on. With it, we expect the requirement of the fastening solutions to grow. In the next four to five years we should be able to double or even triple our sales volumes. ACI
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AUTO COMPONENTS INDIA n JUNE 2020
“The future of mobility holds a lot of promise for us. Be it compliance of vehicles with the Euro6 or the BSVI emission standards or pertaining to the lightweight applications.�
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Mobilised
Triumph BSVI Street Triple RS 2020
AUTO COMPONENTS INDIA n JUNE 2020
Triumph Motorcycles India launched the BSVI compliant Street Triple RS 2020. The new Street Triple is claimed to offer a more robust mid-range with changes to suit real-world rideability. Story by: Deven Lad
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T www.autocomponentsindia.com
riumph Motorcycles India Pvt. Ltd. launched the BSVI compliant Street Triple RS 2020 on April 22, 2020. The Street Triple, regarded by many as a revolutionary, category-defining, game-changing ride is banking on the updated 765 cc triple engine. Interestingly, the engine was developed by Triumph’s Moto2™ engine team, to deliver track-ready levels of power and torque. In the new model, Triumph has further fine-tuned the model to meet real-world rideability. On the anvil is a noteworthy combination of categoryleading equipment and handling. The Street Triple is claimed to top the outgoing BSIV model with nine per cent more power and torque in the mid-range coupled with a notable improvement in throttle responsiveness.
Engine and Transmission
The updated 765 cc triple engine is now BSVI compliant. The liquid-cooled, 12-valve, Dual Overhead Cam (DOHC), the in-line threecylinder engine boasts of a peak rated power of 123 hp at 11,750 rpm and a peak torque of 79 Nm at 9,350 rpm. It is mated to a six-speed gearbox with Triumph shift assist. Fitted as standard to the Street Triple RS, Triumph’s very own Shift Assist is an up and down quick shifter for smooth comfortable gear changes while maintaining the accelerator position. The higher precision machining is claimed to have enabled the removal of the anti-backlash gears, in turn reducing overall mass and adding a higher level of riding refinement. A higher precision
Mobilised
Street Triple RS 2020 Engine Engine Type
12 valve, DOHC, in-line three-cylinder
Displacement
765 cc
Fuel System
Multipoint sequential electronic fuel injection with SAI. Electronic throttle control
Cooling
Liquid
Transmission Transmission
Six Speed
Final Drive
X ring chain
Chassis Front Suspension
Showa 41 mm upside down big piston forks (BPF), 115 mm front wheel travel. Adjustable compression damping, rebound damping and adjustable preload
Rear Suspension
Ohlins STX40 fully-adjustable piggyback reservoir RSU, 131mm rear wheel travel.
Front Brakes
Twin 310 mm floating discs, Brembo M50 four-piston radial monobloc calipers, switchable ABS
Rear Brakes
Single 220 mm fixed disc, Brembo single piston sliding caliper, switchable ABS
Twin LED headlights
765 cc triple engine
Nose-down poise adds to the style quotient
machining on the crankshaft, clutch and balancer is said to lower rotational inertia by seven per cent to give a more responsive and refined ride. The rideability is enhanced by five riding modes: rain, road, sport, track and rider, and is said to suit the higher performance of the updated engine. In addition, ride-by-wire for precise throttle response, adjustable ABS, switchable traction control and selfcancelling indicators are included. A multipoint sequential electronic fuel injection with secondary air injection offers electronic throttle control. As
Wheelbase
1410 mm
Fuel Capacity
17.4 L
Rake
23.9°
Trail
100 mm
per the EU Type Approval Certificate, the engine offers fuel consumption of 5.2-litres per 100 kilometres as derived from specific test conditions and for comparative purposes only.
Chassis
The Street Triple’s frame is built up of a front aluminium beam twin spar and a two-piece high pressure die-cast. It features a twin-sided cast aluminium alloy swingarm. The frame sits on a cast aluminium alloy five-spoke 17x3.5 inch wheel at the front and a 17x5.5 inch wheel at the rear. The front wheel is fitted with 120/70 ZR 17 and the
rear wheel is fitted with 180/55 ZR 17 tyre (Pirelli Supercorsa SP tyres). The front suspension is made up of fully-adjustable 41 mm Showa Big Piston Forks (BPF) with adjustable compression damping, rebound damping and preload adjustment. The rear suspension is made up of Ohlins STX40 piggyback reservoir RSU. Front brakes on the Street Triple are made up of the Brembo M50 4-piston radial monobloc callipers and twin 310 mm floating discs. The rear brake consists of a Brembo singlepiston calliper, single 220 mm disc and switchable ABS. ACI www.autocomponentsindia.com
AUTO COMPONENTS INDIA n JUNE 2020
Dimensions
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Cover story
Vehicular Platform Consolidation The strategy to use one platform to underpin many models is expected to enable manufacturers to sustain business in the long run. Story by: Ashish Bhatia
AUTO COMPONENTS INDIA n JUNE MAY 2020 2020
V 16
ehicular platform consolidation is an exercise undertaken by manufacturers the world over to prune their number of platforms. For some, the objective is to reduce manufacturing and platform upgradation complexity while for others it’s a strategy to eliminate any redundancies that there may be in the ecosystem. Those focused on business economics would want to continue with the existing range of products however look at attaining a higher degree of localisation to meet the demographic demands and stay price competitive. Undertaking platform consolidation for meeting the taste of their customers is a given. Heavyweights like Toyota Motor Corporation, Suzuki Motor Corporation, Mahindra & Mahindra, Tata Motors, Ford Motor Company have at some point or the other given it a thought and pursued it with conviction. The strategy to
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use one platform to underpin many models, after all, is expected to enable manufacturers to sustain business in the long run. According to a Granth Thornton in India, technological advancements are reshaping the automotive manufacturing. Add to it, disruptions, new product development and globalisation are driving the change. With the time to market in the automotive industry known to have dramatically reduced to under two years according to a majority of manufacturers, it is being said that the product development cycles of the automotive industry could well be moving in the direction of consumer electronics. The growing trend of faster time to the market according to the study is an outcome of manufacturers looking to address market
Acquisitions and investments
Among emerging trends said to have played a hand in driving the change are also the aggressive proliferation of electrification among others like connected car, vehicle-to-vehicle communication, and the shared mobility ecosystem that OEMs are working to keep up with. It has also resulted in acquisitions and investments gathering speed. For instance, in February 2018, Bharat Forge is known to have acquired a 45 per cent stake in Tork Motors in a deal known to be valued at USD five million. The former looking to leverage the latter’s knowledge in EV powertrains besides access to knowledge in the emobility space. Later in June the same year, the company also acquired a 35 per cent stake in Tevva, at a valuation of USD 14 million. Again, the focus was on EV powertrains both for India and worldwide and scalable to commercial vehicles.
Challenges in reducing automotive cycles
Testing, supply chain and manufacturing is keeping companies on their toes as they strive to meet the demand of short product development cycles. From trends gauged between March 2015-19, the projection is that the already short product development cycles could turn shorter over the next half a decade. This has impacted tier 1 suppliers especially. 50 per cent of them are expected to drive New Product Development (NPD) after all. According to Alok Verma, Partner, Grant Thornton, “We have captured the views of both the OEMs as well as tier 1 suppliers and the shifts companies are making or expected to make in the light of the rapid changes in the automotive landscape such as
Cover story
chem for developing a unique cell aimed at an India application explicitly. It was also to supply Li-ion cells based on Nickel Manganese Cobalt (NMC) chemistry with high energy density. Nissan and Renault have extended their alliance to become a leader in electrification. In the case of commercial vehicles, for instance, JBM Auto and Solaris Bus & Coach inked a JV for engineering, designing and developing fully electric and hybrid vehicles in India.
Alok Verma, Partner & Consulting Leader - West & South, Grant Thornton LLP
multiple breakthrough technologies and changing consumer preferences as well as the regulatory environment.”
New product development There are several factors that impact NPD cycles. New technology adaption, new entrants in the ecosystem, change in OEM expectations, alliances to generate economies of scale, IoT led product development, bundling software and product development and changing customer preferences to name a few. Resources including R&D spend are especially being spent to understand and align with the latter’s preferences pertaining to both product development and experiential. It has also formed the basis for outsourcing of R&D activities a domain where startups are said to be pioneering developments. ACI
Toyota Motor Corporation and Suzuki Motor inked a JV in November 2017 to produce EVs for the Indian market with the former also providing technical support. In March 2018, Mahindra&Mahindra and Ford Motor Company inked a JV for mutual benefits in the realm of manufacturing connected vehicles, electric battery vehicles, development of compact sports utility vehicles, B-segment electric SUVs and powertrains. Ford from 27 platforms in 2007 aimed to retain eight platforms for instance as per Ford’s corporate data. The company in the same year also acquired LG www.autocomponentsindia.com
AUTO COMPONENTS INDIA n JUNE MAY 2020 2020
demand, supply chain efficiencies and technological advancement. It is here that platform consolidation is being looked at as a key attribute to short development product life cycles. OEMs are said to be on the hunt for generic platforms in order to build agile systems to score on metrics like efficiency, scalability and sustainability.
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Cover story
Toyota Global Unification Strategy Toyota Motor Corporation has secured investment in future technologies by globally unifying vehicular platforms and processes.
AUTO COMPONENTS INDIA n JUNE MAY 2020 2020
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Story by: Ashish Bhatia and Deepti Thore oyota Motor Corporation is not new to building vehicles on common platforms with common parts. Pursuing a global unification strategy to consolidate vehicular platforms and processes, it largely revolves on the principle of securing investment for future technologies with the help of cost-savings from the present. After all, the erstwhile business practice of appointing an independent chief engineer to each new model project and meet local demands had led to the company accumulating 100 platforms and subplatforms in the original equipment manufacturer’s lineup. On the components front, the number of powertrains to cater to these platforms was pegged at 800 making it hard for Toyota to improve the universe of models during its production lifespan.
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Speaking at the FY2020 results announced on May 12, 2020, averred Akio Toyoda, President, Toyota Motor Corporation,“Just before the global financial crisis, while operating income increased due to favourable exchange rates and increased vehicle sales, our earnings structure excluding the effect of foreign exchange rates was not good by any means due to a large increase in fixed costs.” In the four years up to March 2013, the company according to Toyoda drastically reduced R&D expenses and capital expenditures. The amount allocated for R&D in the current running term appears to be roughly the same level of investment as the prior fiscal year, of about JPY 1.1 trillion. For the fiscal year ending in March 2021, the company
is expected to invest JPY500 billion. In the seven years up to March 2020, while the fixed costs increased due to investments in response to CASE, the company strengthened its composition and absorbed costs of these investments through the reduction in expenses. The change in strategy, known to have been inspired by the financial crisis of 2008, most would agree has fructified. In late 2015, the Toyota New Global Architecture built on the ethos of the Toyota Production System bolstered the use of standardised parts and components in a bid to simplify the development cycle on the whole. The company opined Toyoda, has freed itself from a hitherto theory constructing a new Toyota in a
new era. Toyota today produces an estimated three million units in the domestic market, in Japan and an additional six million units overseas.
Platform unification
Redefining lay-out rules for the position of different state-of-the-art components, the TNGA platform simplifies vehicle design in key areas without compromising the styling qualities which in turn give each vehicle its individual character and appeal. Making it possible to produce multiple models from the same line, the TNGA platform is claimed to help accommodate changes in design and specifications in a much simpler and quicker way. In this manner, spending too much time on millimetre-adjustment to define the
Bringing in a new approach to the design of the engine compartment, the platform enables placing of components lower down in a more rationally organised space. This further improves safety by giving the driver a clearer forward view and lowering the car’s centre of gravity for better handling and stability. The common components shared among different vehicles in different segments significantly reduces the number of different parts that have to be designed, manufactured and supplied. Claiming that the platform reduces the amount of manpower required for vehicle development by 20 per cent, the manufacturer has been able to reduce the level of investment required for bringing new products to market. It has also increased the competitiveness and flexibility of Toyota’s existing manufacturing plants.
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AUTO COMPONENTS INDIA n JUNE MAY 2020 2020
Toyota Motor Corporation (TMC) announced its financial results for the fiscal year ended March 31, 2020 in a press conference on May 12, 2020
Cover story
most suitable design and arrangement of the components to achieve the optimum driving position in every new model is no longer a major concern area at Toyota. For instance, providing an ergonomically ideal combination to suit the vehicle, in line with the floor height provided by the platform, the company is now able to refine each layout with detailed adjustment to the pedal and pedal operation angles. It is also able to refine the position and angle of the steering column.
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Cover story
The new modular platform GA-B joined the GA-C and GA-K platforms in 2019. Aimed at small cars, the new chassis is known to use rigid underbody and shave off significant weight. Highly modular with a variable wheelbase, track width and height, it is speculated to underpin the nextgeneration Yaris. Another iteration of the modular GA-B platform makes use of McPherson strut front suspension and is said to support either a torsion beam or a multi-link rear suspension basis the application. Vehicles with a low height and wide stance are expected to be derived from the latter.
e-TNGA platform
A pure electric platform, the e-TNGA is said to be key to Toyota’s future range of BEVs. As per reports, Toyota could use the platform to derive 10 models worldwide spanning across compact segment (in collaboration with Suzuki and Daihatsu), mid-size crossover SUV, mid-size sedan, minivan, and a mid-size SUV (in collaboration with Subaru). A large SUV is also in the fray. Designed as a mixed platform specialising in electric drives, the platform supports a range of battery packs in combination with the rear, front and four-wheel drives. Partitioned into five modules including front module, centre module, rear module, battery and motor, e-TNGA platform uses conventional lithium-ion cells.
AUTO COMPONENTS INDIA n JUNE 2020
DNGA platform
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All new Toyota Yaris built on TNGA platform for compact cars
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Toyota Motor Corporation (TMC)’s fully owned subsidiary Daihatsu Motor Co. Ltd. (Daihatsu) is responsible for the unified development, procurement and production preparation for compact vehicles in case of emerging markets. Based on the Daihatsu vehicle architecture, known as DNGA, it is aimed at improving fuel efficiency and driveability besides driving lower costs. To ensure weight shavings, the architecture combines intensive high-tensile steel with resin outer panels. Said to score higher over previous platform generations, it offers
Cover story
roomier interiors and compact exterior dimensions.
Badge engineering
Process unification
In a makeover to the process of building cars, Toyota took to new generation factories, re-inventing production line, new production equipment, redesigning paint booths, techniques like laser screw welding to replace traditional spot welding, slush-moulded dashboards, one at a time bumper production to name a few. A structural innovation program,
L to R: Akio Toyoda, President, Toyota Motor Corporation and Osamu Suzuki, Chairman, Suzuki Motor Corporation
it entailed globally unifying process and assembly standards besides the unifying process and equipment specifications to enhance agility with a global architecture. Operating on the improvement tools and methods developed by Toyota under the Toyota Production System (TPS), the company has been achieving mass-production efficiency with a small production volume of a few thousand vehicles per
year. TPS has become the basis for highly efficient ‘lean’ manufacturing in industries worldwide. It combines a balanced mix of human resources and robot technology for increased productivity. Operating on two principles: Jidoka and Just In Time manufacturing, the company has been able to successfully freeze on the size and position of key components within the standard new vehicle platforms. ACI
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AUTO COMPONENTS INDIA n JUNE 2020
Platform rebadging or badge engineering is a means to share the platform between two OEMs without incurring the cost to build a vehicle ground up. For instance, TMC and Suzuki Motor Corporation under their pact to rebadge models in India are expected to spring a derivative of the Maruti Suzuki Vitara Brezza - Urban Cruiser with a few cosmetic changes. Signed in 2019, it has already led to the launch of rebadged Maruti Suzuki Baleno as the Toyota Glanza.
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Special Reads
Improving Manufacturing Efficiencies Sustainable manufacturing practices gather steam as manufacturers strive to increase plant efficiencies. Story by: Deven Lad
AUTO COMPONENTS INDIA n JUNE 2020
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fficiencies in manufacturing have taken centre stage. The idea of being able to produce something without wasting materials, time or energy has long appealed to manufacturers. While most would like to target 100 per cent efficiency levels reports suggest that many are still operating at 60 to 80 per cent levels in reality. Initiatives like the Climate Group’s global EP100 are known to be at the forefront of climate action. The initiative to save energy, in partnership with the Alliance, for instance, brought together 77 energy-smart companies. These companies committed to using energy more productively, to lower greenhouse gas emissions and accelerate a clean economy.
On the EP100 list are Indian companies like Mahindra & Mahindra Limited, Mahindra Heavy Engines Limited, Mahindra Vehicles Manufacturers Limited, Swaraj Engines Limited. Companies like BMW and Tata Motors were among companies to join initiatives like RE100 a global collaborative initiative of the world’s most influential companies committed to 100 per cent renewable power, led by The Climate Group in partnership with CDP. One of the key focus areas of the RE100 program, for instance, is to help manage fluctuating energy costs and improve competitiveness through the use of renewable power. RE100 comprises a total of 235 companies committing to go 100 per cent renewal.
Special Reads In March 2020 Mahindra Heavy Engines Limited attained the feat of doubling energy productivity in a span of four years. Averred Vijay Kalra, Chief Executive Officer at Mahindra Vehicle Manufacturers Ltd. & Chief Manufacturing Operations at Automotive Sector, Mahindra & Mahindra Ltd., “ It was looking difficult. We were targeting for the next 15 years but it happened in four years. “Cost and energy efficiency are two major factors when we talk about energy productivity. Energy productivity improvement is known to have tangible and intangible benefits to up the sustainability of manufacturing plants,” he explained. Doubling over the 2016 baseline, MHEL Chakan unit, according to Kalra is claimed to have become India’s first and the world’s third manufacturing unit to achieve the feat. EP Mike Peirce, Corporate Partnerships Director, The Climate Group said, “By integrating smarter energy use into their business strategy, they are driving down greenhouse gas
emissions while boosting the bottom line. MHEL is the first EP100 member from India to achieve this ambitious goal and is leading by example”.
MHEL has prepared a sustainability framework. Under the framework, sustainability efforts were focussed on fostering inclusive development.
MHEL Chakan unit
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AUTO COMPONENTS INDIA n JUNE 2020
MHEL doubles energy productivity
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Special Reads L to R: Anirban Ghosh, Chief Sustainability Officer, Mahindra Group; Vijay Kalra, Chief Executive Officer, Mahindra Vehicle Manufacturers Ltd. and Chief Manufacturing Operations at Automotive Sector, Mahindra & Mahindra Ltd., and Atul Mudaliar, Senior Manager - Energy Transitions (India)
The company aimed at rejuvenating the environment by achieving carbon neutrality, ensuring no wastage in the landfill and by promoting biodiversity. MHEL is known to have achieved this through energyefficient lighting, energy-efficient airconditioning, energy-efficient motors and appliances, usage of alternative
l EP100
fuels, smart metering for real-time monitoring of energy consumption along with other natural resources. The company also ensured manufacturing efficiency improvement through cycle time reduction, production shift optimisation, resource optimisation and built-in flexibility in the process to avoid ad-hoc addition of equipment.
co2
Under an efficient motor program, the company is known to have replaced 800 motors with an investment of 3.4 crores. It is claimed to have resulted in savings of 1281-tonnes of CO2 per year. Mentioned Nasir Deshmukh, Head of Manufacturing Operations at MHEL (Chakan and Igatpuri Engine plant) that at the Chakan unit of MHEL, daily operations of 816 units of light and heavy machines (CNC and special pumps) translated to a high operational cost which the company is said to have reduced by a margin of approx 30 per cent. Other focus areas include growing green revenue, making supply chains sustainable, embracing technology and innovation. MHEL according to Anirban Ghosh, Chief Sustainability Officer at Mahindra Group is also focussing on Energy Management System (ISO50001) certification, smart metering, energy data analysis, review and actions, facilitation for project implementation, resource optimisation, flexibility in manufacturing, green procurement guideline and energy audits to its advantage. Drawing attention to 70 per cent of the plant operations cost being a direct outcome of energy utilisation, claimed Ghosh, returns on energy productivity investments were up to 24 per cent.
S ENERGY COSTS
AUTO COMPONENTS INDIA n JUNE 2020
EP
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The Climate Group in collaboration with ‘Alliance to Save Energy’ started a global EP100 initiative involving a group of energy-smart companies. Committed to improving their energy productivity and doing more with less, these companies on the back on this initiative have been integrating ambitious energy targets into their business strategy. While driving www.autocomponentsindia.com
innovation in energy efficiency and increasing competitiveness, these companies are claimed to have delivered on emissions reduction goals set up by the United Nations. Energy productivity means getting more economic output out of every unit of energy consumed. Increasing energy productivity enables the companies to closely monitor their energy use and helps them align their business growth
with sustainability targets. According to the International Energy Agency (IEA), improvements in energy efficiency could deliver over 40 per cent of the greenhouse gas emissions reductions. To qualify as a member of EP100, companies choose among three commitments which include doubling energy productivity, implementing an energy management system or building net-zero carbon buildings.
Special Reads
l RE100
Renewable energy sourcing
Minimising the use of energy in its functions and processes, Tata Motors’ Lucknow plant is leveraging innovation, optimising operations, implementing energy-efficient technologies and adopting energy conservation measures. It is also banking on renewable sources of energy and low-cost automation. Pramod Choudhary, Plant Head - Tata Motors Lucknow said, “Our Lucknow plant has always been cognisant of the need for energy conservation and has been steadily making progress towards attaining 100 per cent renewable energy
Tata Motors is setting up solar and wind energy farms at manufacturing plants.
Tata Motors Jamshedpur plant
sourcing for all its operations by 2030.” The plant is known to have increased the share of renewable energy to over 16 per cent in the last two years by installing 4MWp capacity rooftop Solar power panels within the plant premises. Attributing the increased share to the implementation of processes like energy monitoring and analysis by means of data captured through hourly energy report, daily energy report, daily energy audits and monthly energy reports, with these, the company has been able to track, analyse and reduce variations in energy consumption across the board including by a
dedicated energy management cell. This is claimed to have helped in reducing the plant’s non-working day energy consumption by over 57 per cent from 33,000 kWh to 14,300 kWh between April 2018 and January 2020. The company aims to further enhance the in-house solar capacity through solar walkways, solar street lights, solar heating, electric vehicle charging station etc. Besides, it is also banking on green energy generated through a Biogas plant. Gradually, the target is to adopt new RE technologies taking renewable energy contribution towards 100 per cent. ACI www.autocomponentsindia.com
AUTO COMPONENTS INDIA n JUNE 2020
The Government of India increased its renewable energy target to 227 GW by 2022 thus providing an opportunity to Indian investors and the corporate sector to play an important role in the growth of renewables in India. Led by the Climate Group in partnership with CDP, RE100 is a global corporate leadership initiative introduced to increase corporate demand and supply of renewable energy. It brings together companies which are committed to sourcing 100 per cent renewable electricity globally in the shortest possible timeline ( by 2050 at the latest ). To achieve this goal, the companies need to match 100 per cent of the electricity used across their global operations with electricity produced from renewable sources, either sourced from the market or selfproduced. Switching this demand to renewables is transforming the global energy market and accelerating the transition to a clean economy.
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Brose India: Re
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nities for Re outing Opportu #Trending Sc ding Acquisition ciencies lCO AB Sharehol nufacturing Effi
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Trending
Scouting Opportunities for Recovery In a Frost & Sullivan growth opportunity briefing, stakeholders of the auto industry discussed growth segments, resource optimisation and cost rationalisation across verticals for recovery. Story by: Deepti Thore
Dr Julia Saini, Associate Partner - Mobility, Frost & Sullivan
Sarwant Singh, Managing Partner - Middle East, Africa and South Asia, Frost & Sullivan
29, 2020, associate partners from the firm got together to weigh the impact of the Covid-19 pandemic on the global automotive fraternity including the Middle East, Europe and AsiaPacific regions. The stakeholders built on the firms’ comprehensive scenario-based analysis prepared on the basis of challenges faced
Vivek Vaidya, Associate Partner - Mobility, Frost & Sullivan
Franck Leveque, Partner & Business Unit Leader - Mobility, Frost & Sullivan
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F
rost & Sullivan got key, global associate partners to discuss growth segments, resource optimisation and cost rationalisation across verticals for industry recovery from the pandemic. In the webinar titled, ‘Identify Growth Opportunities Across Automotive Verticals for Industry Recovery’ held on April
27
Trending thrown at multiple automotive segments. Among topics touched upon were critical insights and directions to help organisations rebound and recover. The webinar focused on global economic analysis, the shift in powertrain preferences besides talking about emerging trends like in automotive
retail. Automotive annual vehicle production projections, OEMs mitigations plans and decisive actionable roadmaps made for insightful takeaways from the session. With demand recovery posing a substantial challenge, the automobile sector is projected to experience a degrowth 24 per cent during 2020.
Global macroeconomics trends
Providing a quick overview of the global macroeconomic scenario, Sarwant Singh, Managing Partner - Middle East, Africa and South Asia, Frost & Sullivan started by highlighting three key factors regarded as important and pertaining to the recession. Depth of disruption, the length of recession and the speed of recovery. According to the analysis, the depth of disruption is expected to be anywhere between one to five per cent. The length of disruption is expected to span two to three quarters. In terms of global emergency scenarios, it could last until four to five quarters, opined Sarwant. Citing measures to restore normalcy, he cited various governments known to offer stimulus packages. For instance, the United States offered 1.5-2 trillion worth packages, the European government might consider offering stimulus of similar levels. Taking an optimistic view on recovery in the automotive sector from Q42020, Sarwant expressed it as a crucial time for recovery. As per a statistical graph, the industry is expected to make a V
recovery. “It means once the market starts recovering we can come back to the original numbers very quickly,” he stated. Adding that most of the western region was expected to be weighed down by a recessionary period, Sarwant mentioned that there could be exceptions. “The Asian region including China might escape it,” he said. Citing China’s 60 per cent dip in car sales relative to 2019, initial numbers that trickled in for April-January 2020, according to
Sarwant, were 80-90 per cent lower in comparison to the last year. The panel also discussed how the auto industry staged a return from the global recession of 2008-09. Back then, the industry was resilient enough to bounce back within two years. In the current scenario, Sarwant predicted the market to decline to 10-15 million units. It was concluded that the target to reach 100 million car sales wasn’t realistic until 2025-26. Sarwant cautioned the industry of a recovery period of two to three years to get back to pre-recession levels.
that most of the model variants are being deferred. It is also learnt that most OEMs are cutting down on complexity levels to sustain. With customers expected to resume buying in a quarter’s time, OEMs could work out a flurry of promotions and incentives to lure the customer post the lockdown ends. Among other
initiatives, relief programs, new payments terms, Flexi EMIs and heavy discounting could be on the anvil. In finance, credit line extension measures are expected to be taken. Second generation stimulus packages will include a lot of benefits for capital spending and electric vehicles will also benefit from these stimulus packages.
AUTO COMPONENTS INDIA n JUNE 2020
Financial support and revamp measures
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Most of the OEMs and components manufacturers have successfully revamped or are in the process of revamping their production lines to manufacture medical equipment, PPE kits etc. With learnings from the Great Recession (2008-09), the auto industry has been very quick to adapt. In terms of liquidity, suppliers it was said were at a greater risk compared to OEMs. Gathering insights from case studies across manufacturing plants across North America and Europe, it is learnt www.autocomponentsindia.com
Trending
Mortality matrix
As per the F&S mortality matrix developed on the basis of impact on and growth opportunities in different verticals, industries have been divided into four different quadrants namely ‘Endangered Verticals’, ‘Immortal Verticals’, ‘Moribund Verticals’ and ‘Nirvana Verticals’. While carpooling, bike pooling, ride-hailing and ICEpowered vehicles were classified as Endangered, Mobility as a Service(MaaS) and Carpooling were appended to Moribund. Immortal Verticals included electric vehicles, connectivity, LCV leasing, used car sales and short-term lease subscription. Nirvana vertical included digital retailing, on-demand service models, Feature on Demand
(FOD), contactless delivery, Health Wellness and Wellbeing (HWW) and aftermarket hygiene-related accessories. Companies working
on the development of ionisers and ozonisers as standard for the cars were spoken off extensively in the panel discussion.
and drop of vehicles, service options, sanitisation programs and good warranty options to show brand loyalty has been witnessed. OEMs and retailers are focusing on investment strategy with digitisation as plan A.
generation revenue pegged at USD four billion driven largely by retailers and the aggregators. In terms of unit sales, online would account for six million units by 2025. While Europe tops the list of online vehicle sales as per recent data, China could catch up through a locally built platform with retailers like Alibaba leading the path. It is noteworthy, in 2016, Alibaba is claimed to have sold a whopping 100,000 cars online within 24 hours. Since utilisation rates have nosedived, garages were advised to operate at 80-90 per cent utilisation levels to turnaround business.
Talking about digitisation and retail becoming a reality, Dr Julia Saini, Associate Partner Mobility, Frost & Sullivan mentioned that physical visits to the showroom had declined by 80-100 per cent depending upon the region. “Digitisation will be a ticket to survival as it is already seen that around 50 per cent dealers are able to acquire complete online vehicle sales over the phone or by doing home delivery,” she said. Urging the industry to look at out of the box solutions to recover from the slump, Saini gave the example of Skoda. In the UK, Skoda engaged in imparting online guidance, experiential virtual tours and demonstrations to customers. In the first month of the lockdown itself, the manufacturer is said to have delivered 2000 hours of product demonstration online enabling it to generate an estimated 200 crores in just one working week. Renault, on the other hand, launched a new platform providing special showroom tours and remote signature processes. Dealers can now participate in it and receive a full margin and final commission on each sale without the customer having to visit the showroom. From an aftersales perspective, the proliferation of pick up
Revenue generated by online vehicle sales and aftermarket sales is expected to grow from USD 120 billion to 605 billion by 2025 as per a projection. Online used vehicle market alone is also expected to grow by a margin of 3x by 2025. Parts and accessories business globally is expected to reach a valuation of USD 78 billion with online service
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AUTO COMPONENTS INDIA n JUNE 2020
Digital Retailing
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Trending
Connectivity platforms
Connectivity is about building more communication with customers to deliver relevant digital features, prioritising development and rolling out more relevant features. Taking the example of General Motors leveraging their ‘OnStar’ platform with telematics powered, free emergency services known as ‘Crisis Assist’, a case was made for advanced connectivity platforms, open-sourced and scalable in nature. “To be able to monetise some digital features around the topic of health and well being which is in demand is also a good opportunity”, advocated Franck Leveque, Partner & Business Unit Leader Mobility, Frost & Sullivan. Leveque batted for pay-as-you-go features gaining more prominence in the near to medium term.
Health Wellness and Wellbeing
Topics such as Health Wellness and Wellbeing (HWW) have already been identified as a megatrend for the automotive industry and the current COVID situation, it was said, would only help further accelerate the proliferation. Automobiles will have more built-in solutions which are active and embedded in vehicles, brought-in types of solutions that leverage devices and wearables. Beamed-in solutions which are cloud-enabled, including
location-based service, on-demand features and so on. Companies like Tesla are offering filters with biodefense mode as an attractive value proposition. Location-based tracking for hotspot or emergency services will gain prominence. Monitoring of vital parameters using sensors and cameras for the vehicles to respond and analyse is also crucial. Cabin sterilisation is one of the many features considered by MG motors in India with ‘MetLife’. Surface shield protection is another emerging domain.
AUTO COMPONENTS INDIA n JUNE 2020
EV ecosystem
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In markets like Italy and Europe, the demand for electric vehicles has been higher than the demand for ICE-powered vehicles. “We have recession combined with possible relaxation of regulations and low oil price which under any circumstances will be a recipe for a disaster situation,” said Franck Leveque, Partner & Business Unit Leader Mobility, Frost & Sullivan. Adding that demand for EVs stands to be hit hard, the production model applied to EVs, supply chain solutions and consumer confidence associated with EVs will eventually become its biggest allies to rebound. Skateboard manufacturing platform characterised by a low flat battery that is the structural belly of the car according to the panel emerged as the ideal choice for joint manufacturing and licensing. Such collaborations are expected to drive the volume back once the market corrects itself. “Consumer demand changes constantly and for selfsufficiency, it is necessary to open doors not just for EVs but for the entire ecosystem that comes with it,” he opined. Since most vehicle manufacturers planned EV launches for 2021 and 2023, Leveque was of the firm belief that there would be a limited impact. He, however, cautioned startups on the road ahead. With support from the government, auto companies can rethink the fundamentals of the business www.autocomponentsindia.com
model in terms of value creation, vehicle sales or throughout the lifecycle of a vehicle. ACI
Trending
Future of Factory Automation in Automotive Manufacturing Story by: Deepti Thore
M
esse Frankfurt India recently concluded a webinar titled ‘Future of Factory Automation in Automotive Manufacturing’. The stakeholders of the automotive industry got together to lay the roadmap of future factory automation. Capitalising automation in the context of automotive manufacturing, the session drew attention to the industry beginning to look at it as an asset in the
balance sheet rather than an expense in the income statement. The role of Industry 4.0, the introduction of next-generation digital technologies, roles and contributions of different stakeholders took centre stage. Drawing attention to the strengths, weaknesses, opportunities and threats, machinery safety, services and solutions were cited as crucial to developing best www.autocomponentsindia.com
AUTO COMPONENTS INDIA n JUNE 2020
In a Messe Frankfurt hosted webinar, stakeholders of the automotive industry shared the roadmap to capitalise automation in manufacturing.
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Trending manufacturing processes. With the backdrop of social distancing and limited manpower deployment in the aftermath of the pandemic, mentioned Sudhanshu Kantoor, GM - Product Management, Pepperl+Fuchs that automation solutions would cater to these limitations. “They would aid the human workforce to make their life easier. These solutions also help reduce the inventory and enable remote monitoring and remote diagnostics.” Kantoor further stressed on focus areas including component detection, collision avoidance, positioning, identification, material handling and IO link interface deployed point-to-point serial communication protocol used to communicate with sensors and or actuators pertaining to factory applications.
AUTO COMPONENTS INDIA n JUNE 2020
Business Threats
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According to Ninad Deshpande, Head-Marketing & Corporate Communications, B&R Industrial Automation, for Ninad Deshpande, Head-Marketing & Corporate maintaining the Communications, B&R Industrial health of any Automation manufacturing plant, defining KPIs and monitoring them is crucial. Deshpande stressed on how quality was by far one of the most important aspects in terms of service or product. “For any factory or factory manager to derive the required output they eventually need to look at the productivity,” he said. Higher Overall Equipment Effectiveness (OEE), better availability of the machine or lines and high-quality levels are some of the factors the company should look at to overcome the new set of business challenges. The downtimes, however, need to be lowered for any factory operation, he beamed. Added Deshpande that in order to restrict the investment or keep maintenance levels low, the need of the hour was for factories to focus on asset maintenance,
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monitoring, remote diagnostics to name a few. “Future factories will enable industries to increase their competitive advantage or become more competitive or efficient, productive and eventually more profitable. This is what a future factory holds for everyone,” he opined.
Predictive Maintenance Scalability+ Mass Customisation
Predictive Maintenance
Digital Twin
Future Factory
Edge Architecture
entities. Here digital transformation is expected to play a crucial role. Predictive maintenance solutions were said to be gaining prominence. For example, if a bearing in a machine is about to fail in a couple of weeks, the factory can get the spare parts dispatched in advance and the maintenance team can then replace it by doing a planned shut down rather than having an unplanned shutdown with the bearings failing and the production coming to standstill.
Component Detection
Web-based HMI & diagnostics
Open connectivity IIOT for brownfield and greenfield
Future factories can be built on the back of a combination of various technologies or solutions applied on the shop floor, IT and the cloud. Some of these include scalability, digital twin, web-based HMI and diagnostics, open connectivity, IIOT, edge architecture, predictive maintenance and mass customisation. Speaking about how factories can leverage these turn more collaborative, Deshpande stressed on the need to ensure collaboration between multiple vendors on the shop floor on the operational front as well as on the IT front if factories were to evolve. Given that any automotive factory has around 1001000 machines, automation vendors, it was recommended be kept the same to avoid a seamless flow of information. Especially to avoid maintenance side issues. To operate future factories from remote locations, deliverables and raw materials have to come in time. Similarly, the lines and the machines need to work round the clock with minimum interference from different
Briefing on the importance of precise component detection, the importance of the presence and absence of Sudhanshu Kantoor, a target, proper GM-Product Management, Pepperl+Fuchs orientation, quality checks and quality inspections were discussed. Drawing attention to the harsh working environment making sensors susceptible to damage over a period of time, the panellists focused on the different available technologies for aiding reliable and precise monitoring. “There are stainless steel housing sensors with stainless steel sensing faces made from a single metal housing. These sensors are capable of withstanding high mechanical impacts thereby giving a longer life to the operation of normal sensors,” explained Kantoor. With the availability of coated sensors claimed to offer insulation from high magnetic fields, added Kantoor that the robust sensors could be deployed in many lines sans problems thereby helping in curbing the instances of failures.
Trending Quality control
the inspection works such that a laser beam falls on the component to capture a 2D profile image inturn. The mother part and the child part are welded but since they are of the same colour and contour it is difficult for the conventional system to check the quality of welding for instance. It is here that automated inspections were agreed upon as an efficient mechanism to reduce the downtime.
Anti-collision mechanism
Sensing solutions were talked off as a robust way to ensure both personal and machine safety, especially in automated areas. Of the opinion that it guarantees smooth processes on conveyors, presses and lifter, it was talked off as a crucial inclusion in future factories. Take, for instance, the automotive shop floor, where automotive parts or structures can be found moving on an Electrified Monorail Systems (EMS) conveyor. In the case of the latter, it is a possibility that collisions occur on certain bends. Here the role of Pulse Ranging Technology (PRT) scanners were highlighted. With a scanning range of eight metres and coverage span of 88 degrees and a set of Ultra infrared 11 LEDs, the scanner found a mention.
enabled access control system to aid in attendance, social distancing and reduced work deployment, the diverse range of such systems with a reading range of up to six metres was spoken of in the session. Direct Part Making (DPM), one-dimensional and two-dimensional barcode reader incorporated in a single system, with Optional Character Recognition (OCR) numbers were also mentioned. Identification scope was expanded from being limited to components to finding application in other feeder lines.
Industry 4.0
Optical-based identification systems Manual inspections are more prevalent. Here the introduction of the automated inspection was said to have an upper hand. Using a unique combination of light section sensors with the inbuilt 2D vision,
Identification is especially important to engine assemblies, monorail conveyors and overhead conveyors. The optical-based identification systems or RFID based systems were spoken of in the context of engine assemblies, body shops and high-temperature areas like paint shops. With the capability of RFID
Industry 4.0 enhances interconnectivity of devices thus making the devices connect with www.autocomponentsindia.com
AUTO COMPONENTS INDIA n JUNE 2020
In terms of different sensing solutions, multiple targets available in the automotive manufacturing industry were touched upon. Classified broadly as ferrous or non-ferrous materials, the latter need to be sensed in an equidistant manner. “There is a need to reduce the switching distance on the field every time there is a change in the target. There are special sensors which can detect all types of ferrous material from the same sensing distance,� stated Kantoor. For instance, sensors are known to work precisely on sensing an old metal target. However, a change in target from mild steel to copper or brass, as per the ferrous content inside the sensors calls for recalibration. It is here that the special sensors are said to eliminate the need for any recalibration including mounting.
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Trending| each other and to higher levels of ERP systems or SAP. IO link was spoken off highly with its capabilities of facilitating bidirectional communication. For instance, it was said, on the field, the health of field devices could be monitored with the help of sensors and the actuators to check the status. IO technology, it was agreed upon, facilitates a higher degree of control on field devices. The generated parameters further allow a feedback mechanism to route it to the ERP system and or the cloud with the capabilities of remote access made possible through the OPC Unified Architecture (OPC UA). A machine to a machine communication protocol for industrial automation is developed by the OPC Foundation. Remote automatic parameter setting was deemed as an added advantage. OPC UA TSN is a low cost open international standard independent software with plug-and-produce features and integrated security system. It has got inbuilt security and certificate exchange. The factory today can leverage the user authentication inbuilt into its protocol and build a future factory by reducing the cost for horizontal and vertical communication.
AUTO COMPONENTS INDIA n JUNE 2020
Industrial Internet of Things
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In an automotive sector, when the engine or the entire chassis is being transmitted on a railing or car trains, a lot of vibration is recorded. If these vibrations are not taken care of, the bearing, the chains or the entire shafts stand to collapse leading to a high downtime. Today data points can help monitor the vibrations, in turn providing a high degree of a predictive maintenance solution in such operations. Lines cab have become more efficient thus. The session called for stakeholders of the industry to map relevant techniques, conduct feasibility studies, prioritise technologies and ultimately create a clear actionable road map. www.autocomponentsindia.com
Machinery safety services and solutions
Talking about automotive machinery safety and solutions, Girish Alawe, Head-tec.Nicum, Machine Safety Consulting, Schmersal India Pvt. Ltd., focused on topics such as smart safety devices, Industry 4.0, light curtains with Bluetooth, serial diagnostic interface, safety controller and safety field box in the session. Alawe drew attention to the adaptable ISO standards in Bureau of Indian Standards (BIS) which can happen in the near future. Citing an ongoing discussion between the BIS and the ISO for the adoption of International Organization for Standardization (ISO) machinery standard in India, Alawe informed of 32 standards being identified and taken into consideration by BIS. “These standards have already been finalised in 2018 and have been sent to Indian ministry for final approval. In future, the machines will need to have the qualification of these BIS standards,� he claimed. As per the analysis carried out by Schmersal India, procedures like emergency stop as per the full specific machinery safety standards, two-hand control, and safety devices like safety mats, door interlocking guards could drive the change. Robots have gained popularity among manufacturers. The door interlock is one such form of robot application with fencing around it creating a boundary for intervention. Safety light curtains, safety sensors, emergency stop beside other safety controllers are gaining prominence too, it was said.
Safety components and controllers
Safety Light Curtains ( SLC ) is a type of safety application which protects personnel from injury and machines from damage by creating a sensing screen that guards machine access
points and perimeters. If the curtains are connected via Bluetooth, they provide all the data through an app. such as SLC assist’ to check whether the curtain is aligned or not and whether any of the beams are disturbed. The app. basically helps to monitor the curtains and also provides details about the operating modes, the status of the output, the status of the protective field, which of the beams are disturbed etc. With preventive maintenance, the curtains stand to be replaced in the near to medium term. At the supplier and end-user side, in case of multiple complicated wiring on a field from long distances to control panel, SD-adapter was spoken of as a good option. If one has to reduce the wiring from the machine or reduce the number of cabling parts and y connectors, the serial diagnostic technology was cited as an apt option to connect multiple devices to a central controller. It can connect up to 120 devices. The field boxes which are connected to controllers and a master controller ensure data availability on the gateway. Controllers are another important aspect of any logic or machine safety. These safety controllers connect to the master controller and transmit the data to the Programmable Logic Controller (PLC). When they transmit the data to the master PLC, it is of utmost importance that they keep to safety standards in accordance with ISO 13849-1 safety standard. ACI
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ACMA Restart Manual In line with the government’s lockdown exit plan, the ACMA manual prescribes a general guideline, preparing for a safe and sustainable restart of the automotive industry. Story by: Deepti Thore
Maintain Social Distancing
Contactless attendance
Use face shield in congested areas
Thermal Scanning
Maintain social distancing
Team briefs with social distancing
Collating best practices, pooled from ACMA members and other industries, the manual with a foreword from the President includes guidelines from other countries known to have sustained manufacturing operations in spite of practising stringent safety measures. With an aim to explain the precautions needed at each step, the manual pictorially explains necessary preventive steps outlined in an end to end manner. From commuting to the workplace, functioning at the assigned place of work to commuting back home. Recommending download of the Aarogya Setu app. to support the government in this collective fight, the manual stresses the role of the management and the precautions to be taken for employee safety. For instance, the role of the management is highlighted to
Courtesy : Mahindra & Mahindra Ltd. Nashik Plant
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AUTO COMPONENTS INDIA n JUNE 2020
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Disinfection of Transport Buses
t is no secret that the automotive industry is process-driven. Safety and Quality practices have always been a top priority. It, therefore, doesn’t surprise that in line with the government’s Covid-19 lockdown exit plan, the Auto Components Manufacturers Association (ACMA) has prepared a manual. The 58-page manual prescribes general guideline to ACMA associates and employees, preparing for a safe and sustainable restart of the industry. Confident of the sector being able to adhere to all prescribed norms of social distancing among other government guidelines, ACMA wants to assure associates and employees of a safe and secure operating environment. According to Vinnie Mehta, Director General at ACMA, the components industry is in preparatory mode, depending upon whether their factories are in green, orange or red zones and if their customer is resuming or not. Stressed Mehta that prior to resuming operations, a host of checks including manufacturing locations undergoing sanitisation procedures need to be done keeping in mind the safety of returning employees.
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Social distancing should be maintained Fumigation to be carried out in plants, offices and canteen before starting operations
PPEs for security guards mandatory
Avoid shaking hands
Thermal temperature checking should be mandatory
Provide good quality sanitisers
Use gloves to avoid any physical contact
Avoid Biometric attendance
Create big displays to communicate precautionary measures
Meeting to be done via Virtual/Conference calls only Use of masks should be mandatory
Make audio announcements for sanitisation regularly
AUTO COMPONENTS INDIA n JUNE 2020
Do not allow visitors or restrict as much as possible
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Diagonal seating at workplace
Fumigation of private vehicles should be done
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Alternative bus seating
Ensure all employees download and install Aarogya Setu app.
Trending Precautionary measures for safety
Fumigation tunnel for disinfecting clothes of employees
Display banners for avoid talking
Training on restarting day to all employees to explain safety measures
Maintaining gaps between two cars
Social distancing should be maintained in canteen
create an emergency response group. HR teams are asked to regularly communicate and monitor all employees as a standard operating procedure including with associates, contractual employees and their supervisors. Training employees for fumigation and sanitisation methods before starting are strongly advocated too in addition to the emphasis on fumigation of all incoming and outgoing vehicles and materials. In turn, each company is advised to modify the suggested guidelines as deemed appropriate.
Precautionary measures The guidelines strongly recommend that companies use PPE equipment, chemicals, disinfection tunnels as
Social distancing in elevator
per the Central and State guidelines. Ensuring availability and use of cloth face masks by all employees features right at the top. The use of PPEs by support staff including security guards, canteen staff and the driver community. Only essential employees are allowed with the rest to be permitted to work from home. The manual further recommends the formulation of strategies to work on a rotational basis by developing multiskills. Thermal temperature checking to be a must for employees ahead of boarding company transport and entering the premise. Hand sanitisation to be made mandatory at all prime locations along with recommendations to ensure social distancing at vulnerable areas
including on the shop floor. The manual further recommends regular audit in case of outsourced canteen besides prescribing basic etiquette. In the new normal, the manual further promotes virtual meetings with strict curbs on visitor inflow. The manual recommends creating war rooms with all information and accessibility to be continuously manned with trained personal. It is recommended that lines in the engineering department be redesigned to ensure multi-machine operations using the minimum workforce. Maintenance of industrial wastewater treatment and sewage treatment plants are highly recommended too. It is advised to keep adequate levels of preventive material inventory too. ACI www.autocomponentsindia.com
AUTO COMPONENTS INDIA n JUNE 2020
Use of RFID cards for attendance
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