Me­tal­man Auto to set up new plants in South In­dia

Auto components India - - COVER STORY - Story by: Ramya Srini­vasan

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

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