Metalman Auto to set up new plants in South India
Sheet metal and tubular component major Metalman Auto Private Limited (MAPL) is setting up new plants in Hosur, Mysore and Chennai to cater to the growing demand from its various OEM customers. Hosur and Mysore plants will commence production from January 2018, and the Chennai plant from June 2018. The company plans to produce frames, silencer, and components like handle bar, side stand, and centre stand in the new plants. It is adding petrol tank and mud guard to the Mysore facility. Metalman is investing around Rs 250 crore for the 3 new plants. The company is also setting up plating plant, paint shop, and ED shop. It has plants in various locations like Ludhiana, Pantnagar, Pithampur, Nashik, Aurangabad, and Dharuhera. The capacity of the Hosur plant in terms of quantity is 6000 units per day and at Mysore 4000 units per day. For the Chennai plant, the components to manufacture are yet to be finalised.
“As the customers want plants near to them to reduce the cost of logistics, we are setting up plants in the South India. From these plants, we will supply to Royal Enfield and TVS Motor Company. We will cover only the domestic market from these new plants and after 2-3 years we might look at exports. There are some more orders in the pipeline from Harley Davidson, BMW and Ducati also. We will supply air filter cover to Harley Davidson, and stands and handle bar to BMW. From our Aurangabad facility we export centre stand, handle bar, side stand and foot rest to BMW Berlin, Camso in Canada,
Anvis in Romania,” Shrikant Gulabchandji Mundada, Group President, Metalman Auto, said.
Currently, Metalman supplies handle bar to Royal Enfield from its Northern plants. Once the Chennai plant is ready, Royal Enfield orders will be executed from there. Supply to TVS will be primarily from Mysore. The company supplies 1300 three-wheeler windshield frames to Bajaj Auto daily. To enhance production and quality, Metalman has set up a new fully robotic plant in Aurangabad and the capacity utilisation is 100%.
Metalman’s R&D division is operating on light weighting the components. The change in material and value engineering will help it to accomplish light weighting. The company meets all designing and prototyping demands of its customers on time with the assistance of its in-house tool room, which has state-of-the-art machinery.
“We mainly manufacture frames in Aurangabad for twowheelers to Bajaj Auto, which will be around 4000-5000 products per day and we have started supplying about 1000 products daily to Hero MotoCorp from Dharuhera. We are planning to manufacture frames for TVS Motor from January 2018. Its demand is for 3500 products a day. Currently, we are manufacturing frames both manually and with the help of robots. But now we plan to go fully robotic. All the welding will be performed only by the robots. So we have ordered for more than 100 robots to perform these operations. There are 3 things to go for robotic operation- Cost is one of the aspects but we want to give the consistency in quality. The second is the problem in getting skilled manpower and the third is, we would like to give a different outlook both in quality and production from the other suppliers,” Mundada explained.
From 1 plant in 1986, MAPL has grown to 7 plants in Ludhiana, Waluj and Pithampur in addition to 2 sister concerns. The company has over 2,000 employees, including about 200 engineers, across all plants.
As a group, it caters to several OEMs including Case New Holland, Force Motors, Mahindra Two-Wheelers, Maruti, Renault India, Nissan India, Volkswagen, GM India, Ford India and Volvo. Besides, it exports to Aurelia and Meiller Kipper. Metalman reported a turnover of Rs 850 crore in 2016-17 and it hopes to end the next fiscal with Rs 1500 crore.
The company’s projected growth is mainly from new orders, new plants, and capacity expansion in Aurangabad at a cost of Rs 20 crore to manufacture frames and wind shields. MAPL has plans to adopt laser welding technology for operational speed and cost-efficiency.
Two-wheeler frames are manufactured at Metalman’s Aurangabad plant
Two-wheeler frame welding line