MAN Trucks In­dia man­u­fac­tur­ing fa­cil­ity, Pitham­pur

Auto components India - - OEM - Bhushan Mhapralkar

Built on a land par­cel of 343082 sq. m., the Pitham­pur plant of MAN Trucks In­dia was estab­lished in 2005. Com­mis­sioned in 2006, the plant has a ca­pac­ity to man­u­fac­ture 9000 units per year. Man­u­fac­tur­ing com­mer­cial ve­hi­cles in the 16- to 49-tonne seg­ments in the form of trucks and front-en­gine bus chas­sis, the plant fol­lows the global man­u­fac­tur­ing con­duct of MAN Truck & Bus.


With a good amount of pro­cesses done man­u­ally, the plant con­sists of 3 main sec­tions. Of these, the ‘Truck-In­Box’ sec­tion caters to the ex­port needs. Ag­gre­gates like en­gines, axles, trans­mis­sions, cab­ins, etc., are packed in boxes to ex­port trucks in the form of CKD kits. Ag­gre­gates and com­po­nents are also packed in boxes and shipped to ex­port mar­kets as parts. The boxes are pre­pared in such a way that they can be trans­ported in a 40 ft con­tainer.

Ag­gre­gate Shop

There are 3 main sec­tions in the ag­gre­gate shop. The rough cast parts re­ceived from the ven­dors are ma­chined in the first sec­tion. The sec­ond sec­tion is an air-con­di­tioned fa­cil­ity that as­sem­bles axles and en­gine pe­riph­er­als. Since many ex­port mar­kets are still at the Euro 2 and Euro 3 level, the en­gines made at the plant vary in terms of the pe­riph­er­als. The Euro 2 and Euro 3 level en­gines are fit­ted with in-line me­chan­i­cal fuel in­jec­tion pump whereas the BS IV en­gines for the In­dian mar­ket are fit­ted with a Bosch common-rail fuel in­jec­tion sys­tem. The use of turbo, ECU and soft­ware also dif­fers as per the re­quire­ment of each truck that rolls out of the plant. This line will be suit­ably tweaked when the man­u­fac­ture of BS-VI en­gines starts. The third sec­tion of the ag­gre­gate shop in­volves the fill­ing of oils and check­ing of var­i­ous com­po­nents for seal­ing or proper func­tion­ing. The ve­hi­cle shop in­cludes a ve­hi­cle fi­nal as­sem­bly line, a trim line and a fi­nal in­spec­tion line that car­ries out wheel align­ment and shower test.


The first sta­tion on the ve­hi­cle fi­nal as­sem­bly line in­volves the fit­ting of bell crank lever on the C-sec­tion lad­der chas­sis. At the sta­tions that fol­low, leaf springs, front axle, rear axle, and the pro­pel­ler shaft are fit­ted. The chas­sis is in­verted at the next sta­tion to fa­cil­i­tate the fit­ting of en­gine, fuel lines, cabin and ECU flash­ing. The trim line in­volves the fit­ting of var­i­ous trim parts. The bare cabin in painted form is sourced from China.

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