MAN Trucks India manufacturing facility, Pithampur
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.
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.