Industrial Heavy Machinery Engineering Solutions...design integration have become fundamental objectives for OEMs worldwide. The global Industrial Heavy Machinery market is experiencing

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.


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.


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


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


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.


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


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


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.


• 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


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.


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.


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


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.


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


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

Tokyo

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) - Tokyo (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.


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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Industrial Heavy Machinery Engineering Solutions...design integration have become fundamental objectives for OEMs worldwide. The global Industrial Heavy Machinery market is experiencing

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