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Industrial Heavy Machinery Engineering Solutions
Industrial Heavy Machinery Engineering Solutions
Contents
04 Engineering a Better World
06 Why Tata Technologies?
07 Our Core Domains
09 Off-shore Engineering
10 Industrial Heavy Machinery Market
12 Better Solutions
14 Case Studies
19 Our Operations
IHM Engineering Solutions 3
Designing and engineering products that change the world, improving efficiency and safety, environmental impact and time-to-market. We work with our customers to realize their vision, providing resources and services to get them from where they are today to where they want to be tomorrow.
Our customers are making more products, faster and better than ever
before and it’s the millions of people who benefit from those products
we help to make that inspires us to constantly innovate, to develop
better solutions and deliver a better experience for everyone.
IHM Engineering Solutions4
We believe it’s our people that make the difference
Engineering a better world
We work with our customers to realize their vision, providing
solutions and resources to get them from where they are today to
where they want to be tomorrow.
IHM Engineering Solutions 5
Provide outsourced engineering services for
our manufacturing customers globally to help
them conceive, design, develop and realize
better products.
Help manufacturing customers identify and
deploy emerging technologies, tools and
solutions to manufacture, service and realize
better products.
Engineering, Research & Development Digital Enterprise Solutions
Help our customers
realize better products
Better Faster Safer
Greener Experiential
Product Development is at the core of everything we do
Why Tata Technologies?
Global presence and diverse resource pool to deliver complex product development programmes cost effectively helping customers realize better products
Our Globally Distributed Execution Model (GDEM) with a balanced approach between onshore
customer intimacy, and offshore capacity and cost-effectiveness in delivering complex projects has been
recognized by our Customers and Analysts.
Deep industry knowledge in developing various construction, mining, material handling, rail and agricultural/forestry equipment helping deliver better and reliable products at lower production cost
Full product development, deep knowledge of design technologies and experience of working on various
IHM products and customers has been recognized by Customers and Analysts like Zinnov as part of the
Zinnov Zones top quadrant.
Proven experience in developing products for both western and emerging markets
Deep knowledge of frugal engineering based on our experience in emerging markets as well as 20 years’
experience developing products for western OEMs, help us provide route to market to companies
planning to launch products in different regions.
End-to-end Product management offering leveraging our product engineering expertise to deliver IT solutions to the manufacturing Industry which help realize better products
Deep industry knowledge of product development combined with an intelligently different approach to
technology and IT solutions that help us enable our clients realize products that are better, faster, safer,
greener, and experiential.
IHM Engineering Solutions6
Provide outsourced engineering services for
our manufacturing customers globally to help
them conceive, design, develop and realize
better products.
Help manufacturing customers identify and
deploy emerging technologies, tools and
solutions to manufacture, service and realize
better products.
Engineering, Research & Development Digital Enterprise Solutions
Help our customers
realize better products
Better Faster Safer
Greener Experiential
Engineering services for the manufacturing sector
Our Core Services
Tata Technologies - a leader in product engineering services - caters to the global manufacturing industry; enabling ambitious manufacturing companies to design and build better products
IHM Engineering Solutions 7
Core Domains in the Industrial Heavy Machinery Industry
MARKET DEFINITION &PRODUCT STRATEGY
CONCEPT, STYLING &VEHICLE ARCHITECTURE
DETAILED ENGINEERING & DESIGN
PRODUCT & PROCESS VALIDATION
PRODUCTION READINESS
MANUFACTURING PROCESS & RESOURCE PLANNING
PRODUCTION LAUNCH & CONTINUOUS IMPROVEMENT
IHM Engineering Solutions8
ON-SITE
NEAR-SHORE
OFF-SHORE
Senior Engineers • Lead Design E ngineers • Lead Process & Methods Lead • Data Management • Delivery Quality
OFF-SHORE• Off-shore PMO • Design & Development • Simulation Activities
• Manufacturing Execution • Resource Management
NEAR-SHORE• Senior Engineers • Lead Design Engineers • Lead Process & Methods Lead
• Data Management • Delivery Quality
ON-SITE• On-site PMO • EM & Liaison Lead • Project Reviews • KPI Reporting
• Supply Chain Management
We are a pioneer of global engineering outsourcing
Off-shore Engineering Services
Our Global Delivery Execution Model (GDEM)
ensures that off-shore activity is invisible to the
on-site, client technical centre. Team members
on-site manage the distribution of work and
the Tata Technologies technical lead will assign
this to the off-shore engineering and design
resources as well as having the responsibility for
cultural liaison and the quality of work.
Managing and delivering projects in this
way means that local workloads and project
management becomes inherently non-
geographic. On-site and near-shore teams
instantly feel at home dealing with off-shore
resources. There are no technical barriers and in
some situations work is able to continue around
the clock, completing tasks and projects in
record time.
We developed the benchmark process for global off-shore delivery of engineering services 25 years ago. This experience, combined with streamlined processes and practices enables us to quickly deploy off-shore teams to develop or directly connect with existing PLM, data management and company-wide systems.
IHM Engineering Solutions 9
Building BetterMachines
The Industrial Heavy Machinery Market Today
With escalating costs, technical innovations,
product development and socio-economic
implications being most prevalent, there
are additional hurdles manufacturers must
overcome. Adhering to government mandates,
policies and standards that differ from
country to country, make the playing field
even more complex for OEMs. It is imperative
for organizations to continue investing in
engineering research, product development
and innovation to develop solutions to meet
the demands of the evolving marketplace.
Identifying best-in-class solutions to
overcome challenges like set-up cost, supply
chain integration, product development and
design integration have become fundamental
objectives for OEMs worldwide.
The global Industrial Heavy Machinery market is experiencing a paradigm shift, primarily due to growth in development and increased spend in areas like construction, education, healthcare, manufacturing, oil and gas, forestry, the military, public works and infrastructure. With developed nations showing steady growth, emerging economies are expected to grow much faster. The global construction machinery market is predicted to grow steadily during the forecast period and post a CAGR of more than 11% by 2020.¹
Our workforce, comprising thousands of skilled designers, engineers
and program managers, is the best in the business.
Key Industry Takeaways:• Manufacturers will continually need to invest in technology tools such as Computer Aided Design
(CAD)
• Computer Aided Engineering (CAE), Customer Relationship Management (CRM), Product Lifecycle Management (PLM) and Enterprise Resource Planning (ERP) to support Research & Development (R&D) and New Product Introduction (NPI)
• Supply chain standardization and homologation is a priority in the industry
• Increasing demand for autonomous equipment 1Technavio’s Global Construction Machinery Market 2016-2020
IHM Engineering Solutions10
All-Encompassing Portfolio
StructuresCasting
Fabricated
Cost & Weight Reduction
Electrical SystemDiagram Troubleshooting
Routing & Documentation
Machine, Engine Auxiliary Harnesses
Powertrain DevelopmentElectric and Hybrid Power Systems
Driveshafts
4WD & 2WD
Axles
Integration
Cabs And BodyComplete Cab Development
Structures and ROPS
Operator Controls
HVAC
Common Cab Platform
Vehicle Body
Machine LocalizationCommon Platform
Localized Product
(Features, Cost, Performance)
Engine InstallationDesign Support
Engine Packaging
Engine Support/Mounting Structure
Air System Routings
Air Filtration/Pre-cleaners
Cooling Package
Hydraulic SystemsSystem Level Development (1D)
Component Selection
Vehicle Routing Optimization
Manufacturing SupportTooling & Fixtures
Test & Validation Assembly Instructions
Service Manuals
Supplier Coordination
Emissions ComplianceIncluding Tier4/Stage IV
Lesser Regulated Country Applications
• Off-highway Equipment
• Earth Moving Equipment
• Construction Equipment
• Mining Equipment
• Rail Equipment
• Agricultural Equipment
• Forestry Equipment
• Material Handling Equipment
• Port Handling Equipment
• Airport Handling Equipment
• Military/Armored Vehicles
• Mobility Special Equipment
• Process Equipment
• Food/Beverage Equipment
IHM Engineering Solutions 11
Industrial heavy machinery
capabilities throughout
our core domains,
manufacturing engineering
and complementary
services, enable complete
automotive product
development. Working with
our customers we use best
in-class processes, tools
and technologies, providing
better access to our global
skill base (including domain
experts) with fast response
times in a tailor-made
or turnkey, value-driven
package.
CORE DOMAINS
Emissions Compliance
Engine Installation Design Support
Electrical System
Manufacturing Support
Hydraulic Systems
PowertrainDevelopment
Machine Localization
INDU
STRI
AL HEAVY MACHINERY ENGINEERIN
G
Structures
Cabs and Body
FULL MACHINE DEVELOPMENT
AND SYSTEM INTEGRATION
CONSTRUCTIONMINING
FARMING
Industrial Heavy Machinery Engineering Capabilities
Better Solutions for the Manufacturing Industry
Improving engineering, design and manufacturing
The Tata Technologies value proposition is
presented as a portfolio of Better Solutions,
utilizing the full value of a technology-driven
workflow to enable our clients to enjoy more
products, delivered faster and better. Each
can benefit independently, however when
an organization pursues optimization across
the complete product realization lifecycle,
then people, processes and technology can be
combined to achieve the seamless execution of
product and manufacturing goals.
Our combination of deep industry knowledge, breadth of value proposition and a proven global delivery model positions Tata Technologies as the premier product development and manufacturing execution partner for the industries we serve.
IHM Engineering Solutions12
• Identifying core and non-core activities
to define effective sourcing strategies.
• Identifying sources of value addition,
including essential non value-added
(ENVA) activities through our proven
strategies.
• Mapping skills with organizational
structures from formal and informal
roles and responsibilities.
• Defining change roadmaps to maximize
product creation and innovation
activities.
• Well defined project schedules, charters
and project management plans, along
with the establishment of local project
organization and relevant working
committees.
• Build and Test (BAT) of all business
process requirements based on a
formulated blueprint.
• Finalization of the project “go-live”
stage by ensuring complete preparation
through business support activities.
• Assessing product design and
manufacturing engineers to establish
what are core & non-core activities.
• Defining and implementing Global
Engineering Centres (GECs), near-
site, near-shore or offshore with best
in class processes and operations for
collaborative outsourcing.
• Optimizing skill usage against existing
processes and tools to improve
operations.
Tata Technologies helps businesses optimise valuable and scarce engineering resources. Using proven models leveraging globally distributed engineering talent and capacity, we define and implement sourcing strategies to free up the capacity to create and innovate.
Collaborating in a customer’s digital journey with an innovative approach and incorporating best industry practices (Dev Ops and Agile) through Digital Customer Experiences, IIoT Solutions, Digital Manufacturing Automation, Next Gen ERP and supply chain solutions, Analytics, Mobility and Connected platforms.
Tata Technologies provides access to global talent and capacity to deliver “best-in-class” operations for cost-effective, global on/off-shore engineering centres in a dedicated or shared engagement model depending on your needs.
Business Transformation
Global Engineering Services
Designing and Implementing Demand Fulfilment Strategies
An Intelligent Approach to Business Transformation
Global Engineering Talent At Your Fingertips
• Identifying areas to generate value in
research and development projects.
• Optimizing innovation and development
of smart technologies.
• Developing cutting-edge solutions using
analytical methods.
• Defining areas to improve effectiveness
of services.
• Defining strategies to reconnect
management with products, enabling
visual decision-making with automated
reporting and real-time analytics.
• Aligning people, processes and
technology which includes learning and
skill development programs.
• Enabling smart, virtual and digital
factories (towards Industry 4.0).
• Defining PLM and IT integration
landscape, technical architecture, digital
roadmaps, enabling IT legacy application
retirement strategies.
• Defining enterprise data models,
standardising common message models,
security policies, corporate IT standards
and governance.
• Converting data into intelligent
information, coupled with feedback loop
learning mechanisms.
• Leveraging cloud, big data, IoT and
hyper-connectivity to enable data
mining and traceability.
• Implementing data migration solutions
(Extract-Transform-Load framework).
Proven methodologies for enabling digitalization and implementation of PLM solutions across the extended enterprise. Supported by our experience in using and configuring PLM technologies in addition to leveraging new IT infrastructure, cloud, big data, and the Internet of Things (IoT).
Tata Technologies brings capabilities around data integration and optimization to provide a platform for knowledge and information sharing across all business functions. This helps to bridge organizational silos to ensure that integrated teams have up-to-date and accurate data, enabling them to make better decisions.
Product Digitalization
Effective Collaboration
Going Digital Across the Entire Product Realization Lifecycle
Optimizing Digital Product Data for Better Knowledge Management
Right Sourcing
Tata Technologies’ R&D capabilities are expanding and include new material research, lightweighting methodologies, leveraging teardown and benchmark data and business analytics.
Research & DevelopmentExpanded R&D Capabilities Fostering Innovation
IHM Engineering Solutions 13
Case Studies
Delivering results, manufacturing success
These case studies are just some of the
hundreds of success stories we have enjoyed
over the past 25 years. They demonstrate
the capabilities present throughout our
organization, how they work seamlessly
with one another and how we pioneer new
technologies for our customers around the
world.
It’s this expertise in manufacturing engineering
that enables us to deliver more products, faster
and better than ever before. Driving efficiencies
throughout the engineering chain, from
conception to launch and beyond.
As a pioneer of technology solutions within the manufacturing sector, Tata Technologies measures success against that of our clients. Analyzing the impact of our work in attaining their goals, exceeding expectations and delivering real results.
IHM Engineering Solutions14
Tata Technologies used its expertise in engine installlation to deliver and optimise the components.
Solution Result
• Using its proven engine installation expertise, Tata Technologies designed the
SCR after-treatment system components.
• Placed the SCR muffler under hood.
• Developed and validated all supporting brackets for the after-treatment
system components.
• Rerouted all fluid lines.
• Designed, integrated and validated the SCR urea tank together with all
supporting brackets.
• Reduced the number of fittings including adapters, couplings, and elbows.
Designed components for ease of assembly and
maintenance
Urea tank could be used on various equipment
models with different engine configurations
Reduced costs
Wheel Loader Challenge
Engine Integration
• Designing all the after-treatment components
while keeping space constraints in mind.
• Reducing the number of fittings required for the
after-treatment system.
A large manufacturer of construction equipment wanted a new tier 4 wheel loader and asked Tata Technologies to package the selective catalytic reduction (SCR) after-treatment system.The company is one of the world’s leading manufacturers of
construction and mining equipment, diesel and natural gas
engines, industrial turbines and diesel-electric locomotives.
It has corporate offices based in the United States, and over
100,000 employees.
IHM Engineering Solutions 15
Tata Technologies delivered a competitive backhoe loader for the client, thus positioning them higher on the market.
Backhoe Loader Challenge
Full Vehicle Development & System Integration
• Producing a complete machine development and
full system integration.
• Ensuring the product was competitive, with an
enhanced aesthetic and a functional appeal to
increase market share.
• Improving resale value, fuel efficiency,
productivity and cabin space.
• Extending operating altitude, temperature and
life span.
• Designing mechanisms that allow ‘Duck-Walk’.
• Future-proofing the design for the advance
electronics.
• Designing a product for the Indian marketplace.
The company’s previous backhoe loader was underperforming significantly in a lucrative and fast- growing market. They selected Tata Technologies based on our extensive market knowledge and depth of specialist domain expertise.
The company is a leading provider of equipment and services
in the construction and earth-moving industries. The company
has three manufacturing plants across India and over 200
other sites as part of a large distribution network.
Solution Result
• The complete product program was outsourced to Tata Technologies.
• Specialist skills and scalable resources were seamlessly aligned using Tata Technologies’ globally distributed execution model.
• Used our own New Product Introduction (NPI) methodologies, the scope extended from pre-concept to production.
• In-depth analysis of both the competitive environment and the current vehicle was performed.
• Analysis of the current vehicle produced by each assembly included advantages and disadvantages: leakage, cabin space, reduce the number of keys used to operate the vehicle, safety etc.
• Completed engine research to reduce fuel consumption.
Competitive advantage in target market
15% Improved productivity
Reduced production costs
Improved fuel economy with 10%, reliability
and serviceability
IHM Engineering Solutions16
The project was delivered on time while also increasing the client’s development speed for the product.
Solution Result
• Provided design and simulation support for various cab structures including anti-climbers and components to increase impact energy dissipation, provided concepts of various layouts and configurations for global applications.
• Performed in depth studies of existing locomotive cabins and designed cabin welded structure assembly, welded sheet metal, cabin doors and hinges, handrails, and other removable components based on the results.
• Redesigned the cabin interior, including: consoles, electrical enclosures, display enclosures, window frames, interior lighting supports, seat supports, floor, cabin seats, and cabin interior isolation.
• Designed the heating, ventilation, and air conditioning (HVAC) ducts and supports, electrical cabinet welded structure assembly and mechanical supports for the electrical wire harness, lavatory arrangement, including the sink, water tank, draining and ventilation lines.
Increased the development velocity
Adhered to required timeline
Deployed design for manufacturing (DFM)
approach during the concept phase
Locomotive Cabin Challenge
Product Design
• Designing the cabin structure in accordance with
Federal Railroad Administration (FRA) Standards.
• Ensuring the locomotive cabin complied with
crash energy management objectives and
analysis.
The customer needed support from Tata Technologies for a variety of operator cabins for new and repowered locomotives.
One of the largest global manufacturers of rail equipment,
which provides total solutions, products and services for the
railroad industry. Their corporate offices are in the United
States and they have more than 8,000 employees.
IHM Engineering Solutions 17
Tata Technologies managed to cut down the manufacturing costs using the client’s list.
Longwall Shearer Challenge
• Analysing the design of the housings for the
horizontal gearbox and vertical gearbox, for a
potential 10% cost reduction.
• Designing modifications that would not cause
changes in shape, materials, heat treatments and
placements of shafts, gears, bearings and sealing
systems.
An important manufacturer of underground mining equipment wanted to reduce the manufacturing costs for its new longwall shearer and redesign the platform rig frame so it could be mounted on either truck or tracks.
The company is one of the world’s leading manufacturers of
construction and mining equipment, diesel and natural gas
engines, industrial turbines and diesel-electric locomotives.
It has corporate offices based in the United States, and over
100,000 employees.
Solution Result
• Analysed the stiffness of the housings and determined areas where they were oversized, and where there was an opportunity to optimize shape and configuration – while keeping the minimum safety factor.
• Identified alternative materials to be used for the housings, changed the plate thickness for some components.
• Based on Finite Elements Analysis (FEA) results, changed the housings geometry in order to reduce the number of components and consumption of materials.
• Reduced the number of welded components and therefore the length of the welding seam.
• Provided cost reduction analysis using only materials and sheet metal plate thicknesses from the client’s lists.
11.5% Cost savings
Reduced vertical gearbox housing costs by
9.2%
Reduced horizontal gearbox housing costs
by 15%
Cost Reduction
IHM Engineering Solutions18
Engineering services for the manufacturing sector
Our Operations
USA
Detroit
Troy, Detroit
UK
Warwick
Sweden
Gothenburg
Romania
Brasov
Craiova
Iasi
India
New Delhi
BlueRidge, Pune
Hinjawadi, Pune
Bengaluru
Thane
Thailand
Bangkok
China
Shanghai
Japan
Osaka
Singapore
Singapore
17 Global Delivery CentersUSA (Headcount: 429) - Troy, Detroit |
Europe (Headcount: 1325) - Warwick
(UK), Gothenburg (Sweden), Brasov,
Craiova & Iasi (Romania) | India
(Headcount: 6727) - New Delhi, Blue
Ridge & Hinjawadi - Pune, Bengaluru,
Thane | China (Headcount: 86)
-Shanghai (China) | SEA (Headcount:
56) - Osaka (Japan), Bangkok
(Thailand), Singapore
Europe, North America,
Asia Pacific
3 Active Regions
8,600+Professionals
$400M USD CONSOLIDATED REVENUE
Tata Technologies is a global engineering and product development digital services company focused on fulfilling its mission of helping the world drive, fly, build and farm by enabling manufacturing clients across the automotive, industrial machinery and aerospace verticals realize better products and drive efficiencies in their businesses, leading to the development of products which are better for the end customer, environment and society at large.
There are two components to the company’s value proposition; the first one being outsourced product engineering services for our clients helping them conceptualize, design and develop better products, and the second one is helping them identify and deploy technologies and solutions that are used to manufacture, service and realize better products. These offerings are delivered through two lines of business: a) Engineering, Research and Development (ER&D) services, and b) Digital Enterprise Solutions which includes offerings in Connected Enterprise IT (CEIT) and Product Lifecycle Management (PLM) services and products.
We are committed to ‘Engineering a better world’ through collaborative innovation and adoption of sustainable technologies and processes. Tata Technologies has over 8600 employees serving clients across three continents through our uniquely balanced on-shore/offshore global delivery model that enables us to provide aligned on-shore customer proximity required to support the iterative nature of product development services together with the capacity and cost-effectiveness of offshore locations.
IHM Engineering Solutions 19
ASIA PACIFIC25 Rajiv Gandhi Infotech Park
Hinjawadi, PuneIndia
411057
Tel. +91 20 6652 9090
EUROPEThe European Innovation and Development Centre (EIDC)
Olympus AvenueTachbrook Park, Warwick, UK
CV34 6RJTel. +44 (0) 8443 759685
NORTH AMERICA6001 Cass Avenue
Detroit, MIUSA
48202
Tel. +1 248 426 1482
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