Tata Motors expands global footprint

Domestic market still challenging

The Indian economy continued to register impressive GDP growth, although the rate of growth declined marginally over the previous year, reflecting inflationary trends driven by the increase in the cost of energy and raw materials. The level of industrial activity has also begun to decline as a result of fiscal constraints imposed on money supply and the raising of interest rates.

Investment flows into India increased by 20 per cent to a record level of about Rs. 120,000 crores. Investment and consequent growth could have been even greater but for the roadblocks to major investments arising from ideological differences, State-Centre conflicts and vested interests. Some of these self-serving obstacles delayed major projects, depriving the country of the opportunity to bridge the gap in infrastructure, energy, power generation, utilization of vast natural resources and to improve the quality of life of its people.

The Indian automotive sector grew by 10 per cent overall during the year with substantial growth in the light commercial vehicles sector and new passenger car introductions. A total of 499,978 new commercial vehicles were sold during the year, and passenger car sales grew to 1.53 million vehicles this year. Tata Motors registered a growth of 5.5 per cent.

The company introduced several new models and variants of commercial vehicles during the year but was unable to exploit its full market potential due to inadequate deliveries of powertrains and components from major suppliers. It also entered a new market segment through the introduction of a new mini van and mini people’s carrier which are expected to see substantial growth in the years ahead. Sales of Tata Daewoo commercial vehicles increased by 38 per cent and its market share in Korea improved from 26 per cent in 2006-07 to 33 per cent in 2007-08.

In the passenger car segment, delays of the mainstream line of the new Indica and Indigo passenger cars resulted in a decline in sales and market share of the company in the product segments. It is expected that this loss in market share will be regained with the New Indica range which is expected to be launched shortly. The market introduction of Sumo Grande towards the end of the year was well received and its true potential will be realized in the current year.

Perhaps the two most significant events during the year which have had a momentous impact on the scale of Tata Motors’ operations and its global image were the unveiling of its new low-cost car, Nano, and the acquisition of the Jaguar and Land Rover from Ford.

A path-breaking project

Tata Motors embarked on a path-breaking project of developing a ‘peoples’ car’ about four years ago to provide safe, all-weather personal and family transport at an affordable price of Rs. 1 lakh. The goal was considered to be unachievable by many global manufacturing and industry commentators at that time.

The goal was, however, achieved, and the Nano was unveiled at Auto Expo in Delhi in January last. It attracted unprecedented global attention and catapulted Tata Motors onto the world stage. The customer response in India was also unprecedented, and enormous interest in the car was shown by certain foreign countries. Several international manufactures are also now planning to be in the ultra low-cost segment and many of them are looking at India as a possible location for manufacturing such a vehicle.

The company’s new plant for the Nano at Singur in West Bengal is expected to go into operation in the last quarter of this calendar year. Here the manufacturing facilities would be expanded to meet the demand in the domestic and international markets in the future. New variants of the Nano are also currently under development to meet the new environmental and fuel price challenges, as also the market requirement of several international markets.

New acquisition

During the year, Tata Motors expressed its interest in participating in the Ford Motor Company’s intended sale of Jaguar and Land Rover on a going concern basis. Both the brands are highly regarded and have a long heritage in their respective segments. Jaguar has been a prestigious maker of high performance passenger cars with a racing history, and Land Rover has always been the ‘Gold Standard’ for off-road vehicles.
Several international private equity firms and one other Indian automotive manufacturer participated in the process. After a protracted negotiation through out the year, Tata Motors was considered by Ford for focused discussion, with the full support of the unions and the workforce. The two enterprises were formally transferred on June 2 at a signing ceremony at the Jaguar and Land Rover headquarters in West Midlands when history was made and these two globally-renowned brands became Indian-owned.

In these brands, Tata Motors has acquired impressive engineering capabilities, substantial manufacturing facilities, (which reflect the major investments by both Ford and BMW in the past years), and enormous goodwill amongst the dealer network and the Jaguar owners community. There is a need to introduce a greater number of attractive products for both brands, and to rekindle Jaguar’s past image connected with its sports car heritage. Both brands have tremendous unfulfilled market potential and a significant global presence.

To fund the acquisition of Jaguar and Land Rover, Tata Motors is raising Rs. 7,200 crores on a rights basis and $500/600 million through an international offering of equity and/or cost effective quasi equity instruments.

Commercial vehicles

The commercial vehicle industry (including exports) witnessed a moderate growth in 2007-08. The domestic market which accounts for nearly 90 per cent of total commercial vehicle sales was impacted by reduction in economic activity, poor credit availability, hardening of interest rates and increase in fuel prices. It grew by 6.9 per cent as compared to 33 per cent growth in the previous year.
Tata Motors reported a total sale of 3,52,785 commercial vehicles in the domestic and overseas markets representing a growth of 5.5 per cent over last fiscal. However, the company’s market share in the domestic commercial vehicle market declined by 1.3 per cent to 62.7 per cent due to non-availability of certain components/parts in the earlier part of the year and constraints on availability of vehicle finance from banks and NBFCs. Though in-house vehicle financing was strengthened, the company was unable to fully offset the decrease in credit availability from outside sources.

In the M&HCV segment, the company revamped its commercial vehicles portfolio and introduced a wide range of new products such as multi axle and heavy duty trucks, tractor trailers and fully-built solutions like tip trailers, customized factory built load bodies, etc., in the second half of the year. These introductions helped it gain market share in the tractor trailer and multi-axle vehicle sub-segments, and the full potential of these new products would be realized going forward.

The company also developed new products for the M&HCV passenger carrier sub-segment and displayed them at Auto Expo 2008: a 28-seater bus and an air-conditioned low-floor bus developed through the joint venture, Tata Marcopolo Motors Ltd. (TMML).

TMML is engaged in the business of manufacture and sale of fully-built buses and coaches in which the company has a 51 per cent holding with the balance 49 per cent held by Marcopolo S. A. of Brazil. The company started its commercial production in November 2007 and has sold 190 low entry CNG buses. TMML recorded a net turnover of Rs. 6.57 crores and loss after tax is Rs. 3.83 crores.

In the LCV segment, Tata Motors introduced two new products – the Magic and Winger – which have the potential to shape the future of commercial passenger transportation in India. Magic is expected to emerge as a safe and comfortable mode of public transport in urban and rural areas. Alongwith the goods carrier version, Magic helped the company to achieve a sale of over 1,00,000 vehicles on the Ace platform in a year for the first time since inception. Winger, India’s only maxi van offering, could become the preferred mode for intra-city and long-distance passenger transportation in the coming years.

The company also unveiled the 1 ton and CNG variant of Ace, Cargo Panel van, Xenon XT - a lifestyle pick-up truck and Winger Executive office concept vehicle, at Auto Expo 2008, and commenced production of Tata Ace at its manufacturing facility in Uttarakhand. Though the company’s market share in the LCV segment declined by 1.1 per cent to 64.3 per cent, introduction of new products would help the company to grow its market share in the coming years.

The company showcased its new range of tactical and armoured vehicles for military and para-military forces in the Defence Expo 2008. These included Tata light specialist vehicle, light armoured troop carrier, Tata 8x8 HMV and the armoured Tata Safari.

The company’s commercial vehicle exports grew by 11.8 per cent to 39,850 units. M&HCV exports accounting for 35 per cent of the company’s total commercial vehicle exports grew by 13 per cent.

Tata Daewoo

Tata Daewoo Commercial Vehicle Company Ltd. (TDCV), Korea, a 100 per cent subsidiary of Tata Motors is the second largest manufacturer of heavy and medium commercial vehicles in Korea. During the year under review, TDCV registered further growth both in the domestic market and exports. In volume terms, sales of 11,899 units were higher by 38 per cent than in 2006-07. This enabled TDCV to improve its market share from 24.3 per cent to 32.3 per cent in the HCV segment and from 28.2 per cent to 34.8 per cent in the MCV segment. TDCV exported 3,000 units of HCVs during the year (2,715 units in the previous year) and continued to be the largest exporter from Korea in this segment.

TDCV recorded a turnover of Rs. 2,865.02 crores which was higher by 45 per cent compared to Rs. 2,248.81 crores for the previous year. Profit after tax was Rs. 153.11 crores (Rs. 97.46 crores), an increase of 78%.

Looking ahead

The year ahead will pose major challenges. Higher fuel prices will negatively impact both commercial vehicles and passenger car sales. There will be an unprecedented rise in material costs following hike in prices of steel and tyres, besides the impact of tighter money supply and higher interest rates. In addition, the company will have to complete Singur plant construction and introduce its new vehicle Nano in the market. While tackling these challenges, Tata Motors operations will also have to absorb the cost of the JLR acquisition and its integration.

These challenges appear daunting, but to the people in Tata Motors, the year ahead will be no more daunting than the challenges they have faced in difficult years in the past. No words would ever adequately recognize the spirit, dedication and commitment of the people in Tata Motors who have faced adversity and major crises, delivered products which were not considered possible and repeatedly found solutions for situations which have thwarted many an organization. I therefore feel confident that the same spirit, dedication and commitment will enable them to face the challenges ahead and find solutions to ensure the sustainability of Tata Motors’ long term future growth and viability.

Despite the challenges mentioned, Tata Motors will have an exciting future. Apart from its own growth domestically in both the commercial vehicle and passenger car areas, for which it has ambitious plans, the high volumes of the NANO range will dramatically change Tata Motors’ market position, reach and visibility. Internationally the Jaguar and Land Rover brands will add global scale, profits and visibility to Tata Motors, enabling it to take its place in the global auto industry as a credible international automobile company.

WABCO expands operations in India

Software centre extention underway

WABCO Holdings Inc. has announced the inauguration of two manufacturing facilities located in India and extension of an existing software design center owned by WABCO-TVS (India) Ltd., an affiliate of WABCO and its joint venture partner from the TVS Group.

Currently manufacturing crankshafts, crankcases and vacuum pumps, one of the new facilities is located in Mahindra World City (MWC), on the outskirts of Chennai. Recently, the foundation for the second phase extension of the Mahindra manufacturing facility was laid by Mr. Jacques Esculier, WABCO Chief Executive Officer, at a ceremony attended by Mr. H. Lakshmanan, Executive Director, Sundaram-Clayton Ltd., and other senior executives of WABCO and WABCO-TVS (India) Ltd. This extension will help double capacity at the Mahindra facility, which is dedicated to exporting products and serving WABCO customers worldwide.

Another new facility, located in Jamshedpur, supplies production lines for Tata Motors by manufacturing brake chambers, spring brake actuators and other braking aggregate parts. The new WABCO-TVS factories presently employ approximately 150 people.

Situated at Tidel Park in Chennai, India’s largest information technology park, the WABCO Software Design Center has completed its expansion program, doubling its capacity and upgrading its technology platform. This expansion will support the center’s expected innovation and growth of engineering capabilities. Currently, approximately 85 engineers develop embedded software for automotive applications in electronic braking, stability, transmission and climate control.

Recently, the WABCO-TVS-owned, brake-manufacturing facility in Ambattur in Chennai received the prestigious Total Productive Maintenance (TPM) Excellence Award from the Japan Institute of Plant Maintenance. Combining operations and maintenance, the TPM approach creates a production environment that performs at world-beating levels of efficiency and quality.
“Innovation and manufacturing excellence will continue to contribute strongly to our business growth in India and across Asia,” said Mr. Jacques Esculier. “By expanding engineering and production capabilities in India, we can continually improve the supply chain and better serve customers locally as well as globally. We expect our newest factories in India to join the same world-class TPM excellence league as our brakes factory in Ambattur.”

WABCO Vehicle Control Systems is one of the world's leading providers of electronic braking, stability, suspension and transmission automation systems for heavy duty commercial vehicles. Customers include the world’s leading commercial truck, trailer and bus manufacturers.

Founded in the US in 1869 as Westinghouse Air Brake Company, WABCO was acquired by American Standard in 1968 and spun off in 2007. Headquartered in Brussels, Belgium, WABCO employs more than 7,700 people in 31 countries worldwide. In 2007, its total sales were $2.4 billion.

Big boost to WABCO growth in China

WABCO Holdings Inc. has announced that the Beijing Public Transport Corporation (BPTC) has awarded the company a new contract to provide braking products and aftermarket services for BPTC’s fleet of more than 20,000 buses before and during the Beijing 2008 Olympic Games in August and the Beijing Paralympics Games in September, the sport movement for disabled persons.

As operator of the world’s largest municipal bus service, BPTC has chosen WABCO to supply a range of braking products, including customized solutions for foot brake valves, air dryers and cartridges, and multi-functional air processing units as well as electronically controlled air suspension products. In addition, WABCO will support BPTC to improve its service and maintenance capabilities through technical training and advanced diagnostic systems. Details of the new contract are not disclosed.

“The superlative size of our public bus network and the higher demand on its service associated with the upcoming Olympic activities in Beijing further reinforce our commitment to safety, reliability, efficiency and comfort,” said Mr. Zhong Qianghua, Deputy Technical Director of BPTC. “WABCO understands our aftermarket needs, contributes technical knowhow and offers expert teamwork. We expect WABCO to partner with us to achieve our Olympic objectives and, furthermore, help increase vehicle service life while reducing downtime and driving down operating costs.”

Previously, WABCO reported that its sales in China in the first quarter of 2008 increased by 87 per cent versus a year ago while the market grew by three per cent in the same period year on year. WABCO has been expanding its distribution channels for aftermarket products and services from Europe to other regions, resulting in 2007 in a compound annual growth rate of 10 per cent for its aftermarket sales over the past three years.


“Connecting with customers and understanding their challenges will continue to contribute strongly to our aftermarket growth in China and internationally,” said Mr. Jean-Francois Barth, WABCO Vice President, Aftermarket. “By enriching our product offering and adding new services such as training and diagnostic capabilities, we can continually anticipate and meet each customer’s expectations. We are delighted to partner with BPTC and passionate about delivering outstanding results for their world-class fleet before, during and well after the 2008 Olympic events.”

EPK Group of Russia bullish on Indian bearings market

‘Indian subsidiary to start production early next year’



-K. Gopalakrishnan

Global demand for bearings is projected to rise by five per cent annually to over $40 billion in 2010. Bearings demand will be stimulated by acceleration in world economic growth, expanding manufacturing operations and rising aerospace equipment and motor vehicle output.

Market advances in developing parts of the world, including the Asia/Pacific, Africa/Middle East, Eastern Europe and Latin America regions, will considerably outpace demand in the US, Western Europe and Japan. India and China will register the largest gains as both the countries continue to develop as economic centres with sustained growth in manufacturing and investment.

European Bearing Corporation (EBC), part of the EPK Group of Russia, is one of the largest manufacturers of all bearings for automotive, power, coal, cement, stone crusher and steel industries. In its endeavour to expand outside Russia, EBC has identified India as a potential market, and in 2007 it established its 100 per cent subsidiary, EPK Bearings India Private Ltd., headquartered in Hyderabad. Mr. S.S. Rao, with more than 30 years of experience in automotive and bearing industry, has been appointed its Managing Director. Right now bearings are being imported from EPK - Russia, and sold locally. EPK India will start production in Hyderabad by the middle of 2009.

European Bearing Corporation has plants in Moscow, Volzhsky, Stepnogorsk, Samara and Saratov. Managed by EPK Holding Company, it is the largest bearing manufacturer in Europe, with its share in the CIS market of more than 33 per cent which is twice that of its nearest competitors. The total annual plant capacity is 52 million bearings of more than 6,300 types.

EPK has six manufacturing plants, an R&D wing and a centralized sales department known as EPK Trade House based in Moscow. The plants manufacture all types of bearings with the outer ring diameter ranging from 20 to 2200 mm used in automotive, metallurgy, heavy engineering, mining, energy and machine tool industries.

EBC plants produce the widest range of ball and roller bearings in the CIS for Russian and foreign automobiles. EBC Holding is a major OEM bearings supplier to Russian auto manufacturers. In fact, seven of 10 cars of Avtovaz, the largest Russian automaker, are equipped with EBC bearings. They are also used in every UAZ car, in six out of 10 Kamaz trucks and in many other cars, vans, buses and trailers made in Russia.

Taper roller bearings constitute a major portion of EBC production volumes, and durability of roller bearings exceeds that of ball bearings. High reliability of EBC wheel roller bearings installed in Kamaz rally trucks has contributed to the success of the company team which won many international races, including Paris-Dakar.

EBC Holding, operating through its wide dealer network, has a significant share in the aftermarket sales. Demand for these bearings keeps growing due to the steady increase in the number of customers who have confidence in the high quality of EBC products. One of the reasons is that EBC has been supplying Russian automakers with bearings for many years. Another reason is that EBC is the only Russian bearings producer who has a special joint marketing program together with Autovaz selling EBC bearings in a package under the Lada brand. It means that the leading national auto manufacturer trusts EBC and recommends using its bearings.

Indian business

EPK is quite bullish about the growth prospects in India, thanks to the enormous grow in demand for bearings. Most of the major manufacturers have got their capacities booked till 2010. Understandably, companies are looking for alternate sources for bearing supplies. This offers a huge opportunity for a company like EPK with adequate capacity available at the existing plants.

Early this year, EPK launched its products in the Indian market. The company has already received excellent response from industries like steel, power and sugar. “We have already received significant orders from Bhushan Steel, Bhushan Power, BHEL-Ranipet, Bhilai Steel Plant, etc. We are targeting a turnover of Rs. 60 crores in 2008-09 which is on first full year of operations”, says Mr. Rao.

In the automotive segment, the company is mainly targeting the after-market business in heavy truck, tractor and utility vehicle segments. It has already appointed distributors in all major centres all over India. Initially the focus will be on the aftermarket. In due course it would look at the OEM segment as well. The company is also exploring the possibilities to market wheel hub bearings and gear box bearings in the aftermarket.


“We are expanding our sales and marketing team across India. By the second half of 2009 we will start our manufacturing operations in India. We have already placed orders for machinery and are in the process of creating a vendor base for supplies. We want to create a manufacturing hub for our products in India as this will be the first manufacturing base for the EPK group outside Russia. EPK India will have the right to export from India to any destination except Russia. This offers a very huge opportunity for the Indian company and if things work out as planned, we have set an ambitious turnover target of Rs. 250 crores by 2012”, adds Mr. Rao.

RBL invests in new facility for brake disc pads

At a time when the Indian auto industry is facing recession and many manufacturers are rethinking their expansion plans, the Rane Group has bucked the trend and opened its third manufacturing facility in this calendar year. It was in January last that Rane Engine Valves (REV) set up a manufacturing facility near Trichy. Soon, in May, Rane NSK established another major facility at Bawal in Haryana. The third and the latest addition is Rane Brake Linings’ (RBL) state-of-the-art plant in Trichy for manufacturing disc pads.

RBL is India’s leading manufacturer of friction parts and the flagship company of the Rane Group. The new facility, which is the fourth major facility for RBL in its 44-year history, is a major milestone as it has truly set up a state-of-the-art and environment-friendly factory for manufacturing brake pads. The plant was inaugurated by Mr. M. S. Maitra, Executive Director & Managing Executive Officer (Supply Chain), Maruti Suzuki India Ltd., in the presence of Mr. L. Lakshman, Executive Chairman, Rane Holdings Ltd., Mr. L. Ganesh, Chairman, Rane Group, Mr. Viji, Managing Director, Brakes India, and others.

The trend in the global technology is changing from asbestos to asbestos-free brake products. Globally the change is happening due to legislation, but in India it is changing faster because of the entry of global vehicle manufacturers who adopt global standards and also of higher customer expectations on braking. Today customers are getting used to a superior braking performance in terms of lower noise levels and smoothness in braking. Considering all these factors RBL has established a technology intensive manufacturing facility in close co-operation with its collaborator Nisshinbo.
RBL’s current capacity for manufacturing disc pads is 10 million units at its Chennai and Puducherry facilities. The new plant is built for a capacity to manufacture 10 million units, which will be achieved by 2001-12. The company proposes an investment of Rs. 60 crores for this project. Once this plant fully operational, RBL will have a capacity to manufacture 20 million disc pads by 2011-12. The company clocked a turnover of Rs. 180 crores for 2007-08.

Mr. PS Rao, President, RBL, cited two major reasons for the expansion: “The first is to invest in latest manufacturing technology in close co-operation with our collaborator, Nisshinbo Industries Inc., Japan, in order to provide high quality products meeting emerging customer requirements. The second is to increase capacity ahead of market requirements in order to meet our customers’ growing demand. This facility will remain testimony to our relentless drive to improve all aspects of our operations and to maintain our status as one of the best suppliers in the industry”.

“The new facility is born out of extensive interaction and participation by Nisshinbo executives. Some of the critical equipments have been imported from Japan to match manufacturing processes between RBL & Nisshinbo”, said Mr. Bheemsingh Melchisedec, Plant Head of the RBL, Trichy Plant. “We also improved the overall layout of the various functional areas of the factory to ensure a more efficient flow of materials, from receiving and storage to assembly, packaging and finally shipment. The facility emphasizes on poka yoke (mistake proofing) in all manufacturing processes to ensure defect-free products to our customers”, he added.

RBL produces world-class brake friction products for automotive, industrial and railway applications. It also makes clutch friction products, including clutch facings and sintered ceramic clutch buttons. The products are sold in export and domestic markets.

A Rane Group company, it is a leading supplier of friction material products to major vehicle OEMs through its Tier-1 customers, namely brake assembly and clutch assembly manufacturers in the domestic market. RBL has a strong distribution network for sales & distribution of replacement parts for automobiles. It exports its products to the SAARC countries, Europe, Australia and the Middle East. RBL generates around Rs. 180 crores in annual revenue, with eight per cent of it coming from exports.
“Manufacturing Excellence and Benchmarking of Quality will continue to contribute strongly to our business growth as a group,” said Mr. Ganesh. “By expanding our capacities and capabilities, our constant endeavour is to continually improve the supply chain and better serve customers locally as well as globally. The new RBL plant in Trichy is a state-of-the-art facility. This will be the most modern asbestos-free disc pad plant in India”.

An important feature of this manufacturing facility is the computerized quality traceability from start to finish. Starting from the mixing process where the company has introduced auto batch system till the completion stage, the entire process is checked for quality using a computerised system with poka yoke at all stages. Mistake proofing at each stage reduces the scope for quality deviation.

Indo-US MIM bid to emerge global technology leader

-K. Gopalakrishnan

We hear and read a lot about injection molding as a technology being used to manufacture parts from thermoplastics material. Not much is known about Metal Injection Molding (MIM), and even among those who know about this, the general impression is that this technology is too expensive and that there are very few manufacturers in the world, mostly in the US and Europe, who can provide such solutions. To clear the air and to know more about MIM, I met Mr. Ajeet Khare, Managing Director of Indo-US MIM Tec, the world’s leading manufacturer of MIM components.

Indo US MIM Tec Pvt. Ltd. is a Bangalore-based company specializing in Metal Injection Molded parts. Mr. Krishna Chivukula, an NRI based out of the US, started this company and was instrumental in bringing this technology into India. MIM as a technology is just 15 to 20 years old worldwide. So, in a sense this technology is very recent.

“By 2010 we want to be a global leader for MIM parts”, says Mr. Ajeet Khare, Managing Director of the company. This is the vision he set for the company way back in 2001 when he joined. From a turnover of Rs. 4 crores in 2001, Indo US MIM ended the financial year 2007-08 with turnover of Rs. 120 crores. Out of the total turnover 90% of the business comes from exports and the balance 10% comes from the domestic market.

Mr. Khare says: “We manufacture those products which cannot be manufactured by another technology. Indo-US MIM has a unique ability to mold components of highly complex geometries. This ensures that our customers’ requirements - both small and large - can be met with quality and speed. Also, our capability to offer the best of world-class technology at competitive prices, provides a significant advantage to our customers all over the world”.
Technology

The Metal Injection Molding manufacturing process uses fine metal powder as the raw stock, which is sourced from various manufacturers. This is then thoroughly blended under compounding, where it mixes with thermoplastic binders into a feedstock. This feedstock is injection molded to form green parts, which is then taken to the debinding stage where the partial binders are removed. The net shape of the component is ready after the last stage of sintering process, wherein there is inter- particle diffusion taking place in a controlled atmosphere.

As mentioned earlier, the technology is fairly recent and globally there are not many large scale manufacturers providing this technology. The reason being, its high on investment and the initial development cost is also on the higher, given the need to prepare the basic mold for manufacturing the product. All this meant longer lead time for product development. Indo-US MIM identified an opportunity, and changed the way it approached the business. The company provided total end-to-end solutions right from conceptualizing, designing, to the manufacturing of complex precision components and sub-assemblies. All the necessary infrastructure has been created in-house and as a result, in some cases, the development time reduced from 20 weeks to 8 weeks, enabling customer to realize significant reduction in cost.

Clients

Indo US MIM Tec caters to a vast segment of clients manufacturing about 650 components under its domain catering to electronics & peripherals industry, auto industry, firearm industry, consumer industry, telecom industry, surgical instruments and implants units. Some of the major OEMs include Nokia, Motorola, Cummins, Honeywell, Caterpillar, etc.

In the automotive segment the company supplies to global auto majors like Mercedes Benz and to component manufacturers like Honeywell, Cummins and Caterpillar. In India, the company supplies gear box components for Tata Motors and is in discussions with the latter for supplying a few critical parts for Nano.

“Research and Development is an ongoing process for us and is a must in our business. The focus is on how we bring out new components and materials, shorten time and improve yield, resulting in more output. We are constantly trying to improvise the products, production process, fast and flexible, and produce millions of parts per year. Further, the technology guarantees superior surface finish and shape integrity. We attempted to improve in this aspect of Research and Development, and are far ahead than others. We have a very young team of engineers who are no less than anyone else in the world. We have over 400 people working in both plants put together”, adds Mr. Khare.

MIM, as a technology, is clearly an alternative to forged and machined parts. When parts are forged and machined, it induces a lot of stress on the part. The advantage of MIM technology is that MIM parts hardly have any stress at the stage of manufacturing and ensures longer work life than machined components. There is also a possibility of experimenting with metal composition. This means that if a client wants more hardness or softness, it can be done accordingly by changing the input material composition. Typically for components which need to be machined, you cannot make it very hard as you cannot machine it. In this process, you have the flexibility to offer different compositions based on the customer requirement.
Indo US MIM currently has two manufacturing facilities located on the outskirts of Bangalore city. Both the plants are certified to ISO 9001:2000 and to ISO/TS 16949:2002. The company has so far invested over Rs. 100 crores since inception.

So the next time you need complex metal parts, you don’t have to look too far.

Customer-centric approach behind Kesineni Travels' runaway success

- K. Gopalakrishnan

Full flat beds, DVD quality movies to watch on an individual drop down TV with 12 different channels to choose from, refrigerators to provide cool drinking water and a completely air-conditioned ambience...wait a minute, I am not referring to the first class flight by Jet Airways. These are the facilities offered on board the new sleeper buses launched by Kesineni Travels. The company operates over 30 such sleeper buses for all important destinations. “We want to provide a whole new experience for bus travellers”, says Mr. Srinivas Kesineni, Chairman and Managing Director, Kesineni Tours and Travels Ltd.

Mr. Srinivas Kesineni, fondly known as Nani, is a people’s person. He spends much of his time trying to understand his customer’s needs and acts accordingly. This has made Kesineni Tours & Travels the largest provider of inter-city bus transportation across Andhra Pradesh, Karnataka, Maharashtra and Tamil Nadu. Kesineni Travels is driven by Mr. Srinivas Kesineni’s passion and desire to be considered by the traveller as the best in the industry.

Operating buses is in his blood. His grandfather, Mr. Venkaiah Kesineni, started operating buses way back in 1928 from Vijayawada. [One of the first inter-city bus operators in India itself. Prior to the introduction of diesel engines, buses were operated with steam engines].
The family has been associated with the bus business for over 80 years now and Mr. Kesineni has been personally in charge of the business for over 25 years. It was in 1992 that he started his own bus company Kesineni Tours and Travels. Today it is the largest provider of inter-city bus transportation, serving more than 75 destinations with about 430 schedules daily across Andhra Pradesh, Karnataka, Maharashtra and Tamil Nadu. More than 15 lakh customers travel each year on Kesineni’s buses.

Mr. Kesineni attributes the growth in bus travel to the boom in the economy and better road infrastructure growth which has led to more travel by road. Southern India has particularly witnessed phenomenal growth in IT and manufacturing, and this has created huge employment opportunities in all major metros. Hyderabad, in particular, has seen spectacular growth in IT industry resulting in a lot of professionals migrating from other towns and States. Places like Vizag and Vijaywada are also growing rapidly as IT hubs. All this growth is resulting in more people travelling by road both for personal and business purpose, particularly in buses, says Mr. Kesineni.

Kesineni Travels caters to all segment of bus travellers. The company owns a fleet of 150 buses which includes 30 Volvo semi sleeper buses, 30 air conditioned Sleeper coaches built on Ashok Leyland chassis, 30 semi sleeper buses AC buses built on Ashok Leyland chassis branded as ‘Classy’ and the balance are non AC buses. This balanced fleet has helped Kesineni Travels to cater to customers from all segment, from non AC to high end sleeper coaches. The company has recently added a couple of Cerita AC buses to its fleet.

Online reservation system

The online reservation system is one of the major initiatives of Kesineni Travels. Today all the offices and booking centers of Kesineni Travels have been connected online, and this has resulted in streamlining of the whole reservations system. Customers can log on to the site and book their tickets, even select their seats based on their preference and availability. This system has ensured that the tickets are not blocked by agents. The company worked on this system for well over a year before making it fully operational without any problems.
The online bus ticketing system was inaugurated last year, precisely on July 7. While some bus operators keep a quota of seats on the Internet booking, Kesineni’s Online reservation system ensures that all the seats are kept open for booking on the Net. The system is the main foundation for the future expansion plans of the company, says Mr. Kesineni.

Kesineni’s new generation fleet is backed up by cutting edge technology, well trained man power and infrastructure to ensure the highest standards of operating efficiency. Complete maintenance support is provided by Kesineni’s own state of the art technology workshops in Hyderabad and Vijayawada capable of servicing over 100 vehicles and are equipped with paint booths. “There will be no compromise on safety, reliability, comfort and on time travel”, adds Mr. Kesineni.

24-hour helpline

The motto of Kesineni Travels is “Driven by Dedication” and as part of its commitment towards its customers, the company has set up a 24-hour helpline for the convenience of its passengers. Customers can call the helpline and get any clarification or even make a complaint or offer suggestions for improvement. Immediate action is taken based on the call and the customer is also kept informed about the action taken. The call center is based at the corporate office in Hyderabad and is under the direct control of Mr. Srinivas Kesineni.

Another important initiative, never heared of in bus travel, is that every day and in every bus six passengers are picked up in random and a feedback is obtained from them to understand the overall travel experience, cleanliness and hygiene conditions inside the bus and behaviour of staff. Immediate action is taken if there is any deviation or complain.

While Kesineni is well known for its regularity and on-time performance, its group companies also provide value added services to its customers. The company’s tour service offers charter and tour packages for business, conventions, schools and other groups at affordable rates. Kesineni Cargo Carriers offers value-priced overnight parcel delivery to all its destinations.

Be it the management, the fleet, the ground staff or the bus crew, the focus is on performance and customer satisfaction. Every Kesineni employee is groomed to be smart, friendly, proficient and well-informed ensuring that their interaction will make the passengers feel welcomed and looked after. The drivers are well trained to make the journey a safe and comfortable one.

Today Kesineni Travels has a network of 41 offices spread all across South India and Maharashtra. All these offices have customer lounge for passengers to wait before boarding the bus.

Kesineni Travels has always been a trend-setter for the rest of the industry. Be it the cargo business started part of its buses, online ticketing and 24-hour helpline, Kesineni has been a pioneer in providing outstanding service to its customers.

Growth rate

Kesineni Travels has been growing at a compounded annual growth rate of 57 per cent during 2003-2008. The company clocked a turnover of Rs. 100 crores for 2007-08. The switch-over from manual to online booking systems has enabled the company to approach the business more professionally and has also resulted in increased profitability.

“From these reports, combined with our past enormous experience on demand and supply factors of this industry, we have identified a major, untapped, potential and lucrative customer segment in the inter city bus transportation industry. We call it as the Second A.C. Sleeper Class and the First A.C. Sleeper Class segments,” adds Mr. Kesineni. The next big step for the group will be to enter the speed cargo business. The company is preparing a business plan wherein the cargo can even be tracked online.

Personally Mr. Kesineni Srinivas has done his bit for the betterment of the society. He has donated Rs. 25 lakhs to the Kakatiya Seva Samithi’s Poor Merit Students Hostel & Old Age Home. Besides, land worth a couple of crores was willingly donated to the Government, for the laying of an essential road for the neighbouring Auto Nagar at his home town, Vijayawada. Also, another essential road near benz circle, Vijayawada, which was continuously post poned by government due to paucity of funds, costing Rs. 9.50 lakhs, was totally sponsored by us.

Mr. Kesineni has also been supporting sporting events which don’t get much attention in India like the All India Billiards & Snookers Championship, 2007, Hyderabad, the All India Veterans Cricket Championship held in Chennai and Indian Olympic Association’s Local Chapter’s Sports man spirit encouraging “Olympic Run”, 2008 Andhra Pradesh.

But the path to success has not been so smooth. Mr. Kesineni has faced many challenges and obstacles in his career spanning over 25 years. Despite, all the obstacles, he has succeeded purely because of his conviction, passion and his strong belief in providing customer satisfaction. The management, fleet, ground staff and bus crew are guided by Mr. Kesineni’s focus on performance and customer satisfaction.

Being a bus operator is full of challenges. Its is a high investment business with competition from railways, Government-run transport corporations and even low-cost airlines to some extent. The government has also not been supportive of bus operators and the taxes levied are quite exorbitant, making this business unviable. Andhra Pradesh government levies tax of Rs. 3,750 per seat per quarter and in Tamil Nadu its Rs. 3,000 per seat per quarter. The rising fuel and maintenance cost has practically eroded the profit margins of operators added to this the competition from Government-run transport corporations. Another major challenge is the non availability of trained drivers.


But despite all these challenges, bus operators have managed to fight the odds and are providing commendable service to the general public large. They have literally been the savior for lakhs of people who want to get back to their homes during weekends or during festive season. What I admire about these operators is the spirit to fight and overcome all these challenges and further innovate by providing facilities which is on par or even better than other modes of transport.

Veera Vahana emerging as India’s fastest growing bus-body builder

- K. Gopalakrishnan

Recently we wrote about how China could well become the bus manufacturing hub of the world. There are more than 50 established bus manufacturers catering to both the domestic and export market. In sharp contrast, India’s bus industry is still a long way to go. We just have a handful of bus body builders spread across the country catering to most of the domestic requirement.

As in the other industries, India is catching up in bus business as well with the emergence of new bus manufacturers who aspire to become global players in the years to come. One such company is the Bangalore-based Veera Vahana Udyog Private Ltd., which has made tremendous progress in a very short period of time.

With 1,100 buses on road in a short span of three years since inception in 2004, Veera is clearly India’s fastest growing bus manufacturer. And it’s not stopping there. “By 2015, we want to be India’s leading manufacturer of buses”, says Mr. K. Srinivas Reddy, Managing Director of the company.

Veera was founded in 2004 by a young team of professionals headed by Mr. Srinivas Reddy. His passion was to establish a modern manufacturing facility for building luxury buses. Accordingly, the company set up a state-of-the-art bus body building facility on the outskirts of Bangalore over an area of 8.5 acres.

Mr. Srinivas Reddy is a first generation entrepreneur. An engineer from REC, he has been a technocrat right from day one. After working on a few turnkey projects, including fabricating paint booths for auto majors, executing power projects and even implementing some IT projects, he decided to focus on his dream project of bus building.

“We established Veera Vahana Udyog towards the end of 2004, and by May 2005 the first bus rolled out of the production line”, says Mr. Reddy. Once the company started commercial production, there was no looking back. In the very first year Veera sold 206 buses, in the second year 311 buses and in the third year 434 buses. The company has established the facility to manufacture 1,000 buses and hopes to achieve this volume by 2009-10.

“Right from the first year there was no dearth of orders. Thanks to the efforts put up by all the members of the team in delivering a high quality buses. In the current year we are targeting to sell 600 buses”, says Mr. Srinivas. From the very beginning, he has nurtured a pioneering spirit, one that still drives innovation and exploration of new technologies. Veera today prides itself on manufacturing buses that deliver passenger safety, cutting-edge technology and a genuine focus on customer needs.
The company is dedicated to the highest quality bus manufacturing and believes in continuous improvement, setting new standards and pushing technology to new heights. Thorough attention to detail in the design stage and in the manufacturing process, Veera’s buses provide greater reliability and less vehicle down-time.

Veera currently manufacturers AC deluxe buses, non-AC deluxe buses, AC sleeper coaches, non-AC sleeper coaches, as well as AC mofussil and tarmac coaches. “We build according to specifications that confirm to customer requirements. We have standardised body frame works by building them off jig. We also have our own fibre glass front and fibre glass rear on all our buses”, adds Mr. Srinivas Reddy.

Veera is also one of the major players in the air-conditioned bus segment. The company has till date built over 250 air-conditioned buses. There is a growing demand for AC buses, and this year the company is targeting more such buses. In fact, KSRTC has now introduced Sheetal A/C Bus, similar to the Garib Rath introduced by Railways. These buses have a seating capacity of over 60 seats and are fitted with AC. The idea is to provide AC comfort to customers at a nominal cost. The response has been overwhelming, and KSRTC plans to add more such buses for the convenience of passengers.

Veera has managed to establish very strong relationship with its customers and in the last three years the company has been receiving repeat orders from most of its customers. Veera has over 100 customers as on date, including transport corporations like KSRTC, APSRTC and NWKRTC.

Infrastructure and production facility

Veera has set up a state-of-the-art manufacturing facility for buses, fully equipped with all the necessary manufacturing processes right from day one. The factory has been set up on a 8.5 acres of land with the main floor built on an area of 68,000 sq. ft. This whole area is pillarless and can accommodate construction of 65 to 70 buses at any given time. The company has installed a Sophisticated & Ultra Modern Paint Booth in which Painting & painting preparation can be carried out for 10 vehicles at a time. For ferrous materials an anticorrosive treatment and hot phosphating plant has been installed. Veera has also set up a manufacturing facility for FRP Assemblies. The company has so far invested Rs. 16 crores on establishing this facility.

Veera is working on a new bus model which it plans to launch before the end of this year. The new product, Mr. Srinivas says, will be completely different from the existing product in terms of the exterior and interior. The company is also trying to use new material and there will be vast difference in the quality and design of the product.
In the next phase, Veera is planning to establish its second manufacturing facility where it plans to get into mass production of buses, particularly for the city bus segment. Mr. Srinivas Reddy feels that the city bus market will witness exponential growth as most of transport corporations are replenishing their fleet.

“Today a high-end city bus costs Rs. 80 lakhs, and if we can provide a good city bus with comparable features at half the price, then most of the transport corporations will look at even replacing the entire fleet. We would like to position ourselves as a premium bus manufacturer. Even if we get into the mass segment we will still continue to operate in the premium segment. We are also planning to get into the Integral coach business by launching our own Veera range of buses”, adds Mr. Srinivas.
Intergral coaches is another very big opportunity which Veera is looking to capitalise on. As more and more private bus operators and even transport corporations are looking at fully built solutions, the market for integral coaches will witness exponential growth in the coming years. The company is already working on its Integral coach business and hopes to roll out the first bus by 2010.

Veera is also looking at tie-up with European bus manufacturers. When Volvo launched its buses in India, it had a tie-up with Jaico for building bus bodies. Mercedes has tied up with Sutlej for building its buses. Marcopolo has a JV with Tata Motors, and Scania has also announced its intention to enter the Indian bus market.

Veera is actively looking for an opportunity to have a tie-up with a global bus manufacturer. Discussion is on with a few manufacturers, and a final decision will be taken in the next few months. Veera is also looking at the opportunity of exporting its buses.

Once the bus business is established, the company is planning to look at the opportunity for manufacturing tippers and special-purpose vehicles. This will again be a major growth area, according to Mr. Srinivas.

Veera has managed to do what many other manufacturers take decades to achieve. The success of the company is mainly due to untiring efforts of Mr. Srinivas Reddy and his dedicated team of professionals. Veera today employs over 450 people. Given the kind of growth the company has achieved in the first few years, Veera is well on its way to become a leader in the bus manufacturing industry.

Piaggio emerges market leader in three-wheeler segment

- K. Gopalakrishnan

Recently I was driving down the National highway from Chennai to Bangalore. The new four-lane highway cuts across some important towns like Ranipet, Vellore, Krishnagiri and Hosur. Much to my surprise, I could see that 8 out of the 10 three-wheelers (both cargo and passenger) on road were from Piaggio. Quite undoubtedly, Piaggio has established its market leadership in a segment which was for decades dominated by Bajaj Auto.

In fact, when Piaggio entered the Indian market in 1998, the sustainability of its project was doubled by most players in the Indian automobile industry. However, in 1999 the company sold 2,000 units, and it ended the year 2007 with sales of 1,59,000 units.

Today, Piaggio has emerged as the market leader in the three-wheeler segment out-beating the so far undisputed market leader Bajaj Auto in the domestic market. In the first five months of the calendar year 2008 Piaggio has sold 62,236 vehicles compared to 55,108 vehicles sold by Bajaj Auto in the domestic market.

Behind the success of Piaggio is a dedicated team led by Mr. Ravi Chopra, Managing Director, Piaggio Vehicles Private Ltd. (PVPL). In a lot of ways Mr. Chopra has been the face of Piaggio in India right from day one and after years of hard work and commitment, its a great feeling for him to see the company emerge as the market leader in the segment.

“I am proud to say that Piaggio is No.1 in the total three-wheeler segment in the domestic market. We are ahead of everybody both in the passenger and goods segments”, says Mr. Ravi Chopra.

Driven mainly by the local management, today the company is seeing its vision unfold into a reality. Its remarkable growth and achievements today are the result of the total commitment, dedication and hard work of a “winning team”.

In 2007 Piaggio sold a total of 159,000 units comprising 85,000 passenger carriers, 65,000 goods vehicles, 4,000 Ape Truks and 5,000 CNG/LPG-powered passenger and goods carriers. The company logged a positive growth when the industry as a whole registered a negative growth last year. Piaggio has always been the leader in the cargo segment, and in recent months the company has strengthened its position in the passenger segment as well. In 2008 Piaggio is targeting eight per cent growth in three-wheeler sales. It is currently hitting volumes of about 13,000 units per month.
“We have been growing in a falling market. The industry has seen a slowdown not because of the market needs or potential but more because of the reluctance of the financing agencies to support retail financing. That has now come to a very critical situation. In 2008, particularly in the last 2 to 3 months the situation has become more stressful for the industry. The financing companies are selective in financing and have not been as generous and liberal as they have been in the past. Their expectations of higher down payments, and higher EMIs has certainly impacted the growth”, adds Mr. Chopra.

Piaggio’s success story in India is a typical case example of how a global company can effectively use its global processes in a local environment by customizing its product and fine-tuning its business model to suit the Indian market. The company’s growth and performance reflects a creditable and empowered local management, which has effectively evolved its business model on the basis of three principles: commitment at the global level, empowered local level management and localised product / market mix.

Till 2002 the company was selling just under 40,000 units per annum, far behind the market leader Bajaj Auto. Since then, Piaggio has more than tripled its sales volumes, from 49,600 vehicles in 2003 to more than 159,000 vehicles sold in 2007. The man who has spearheaded much of this transformation is Mr. Ashutosh Khosla, Director - Sales & Marketing of Piaggio Vehicles Private Ltd.

One should admit that selling a three-wheeler is not like selling any other automobile. The customer who buys a three-wheeler is usually an owner operator and the vehicle is his lively hood. So unless he is capable of making money out of the vehicle, he will not be in a position to repay his monthly dues.

Mr. Khosla says: “First we sell a business proposition to our customer and then our three wheeler. As a pioneer in the business we have always believed in creating new markets and segments. In Piaggio we say that you need to identify a customer, understand his needs and capability and sell an appropriate solution which he will be able to sustain”.

He cites key reasons for the success of Piaggio in India, the first being the company’s focus on offering a superior quality product. In 1998 when the company entered India, it found that the cargo segment was a neglected segment. It was inadequate in terms of technologies and product variants. Piaggio can take much of the credit for creating the cargo segment. The second important reason is that the company understood the way the business should be done.

“The approach at Piaggio is very clear. We believe in selling a business proposition first to our customer, and this approach of ours has created trust and a strong long-term relationship with customers. The customer believes in our brand and our dedicated approach has helped us in generating further reference from our satisfied customers. Thirdly, Piaggio understand that the vehicle is a breadwinner for its customer and thus the responsibility lies with company to provide a truly world class customer care. These are the key reasons for the growth of Piaggio in India. We are here to build and nurture life long partnerships with our customers”, says Mr. Khosla.

Piaggio Vehicles began with the realisation that with improving road infrastructure, the country was moving towards a hub-and-spoke mode of conveying goods. This meant that heavier trucks would do the inter-city movement of goods while the intra-city, the last-mile connectivity through narrow, inner-city roads would require smaller, more manoeuvrable vehicles. That was its chosen slot, of moving goods on congested roads using its sub-1 tonne three-wheeler. Piaggio already has more than 6,00,000 satisfied Ape customers in India today.

Piaggio has pioneered the three-wheeler goods transportation in India and has achieved and sustained a leadership status in the cargo segment and today it has emerged a leader both in passenger and cargo segments as well. Piaggio is now recognized not just as a leader in its class, but has also set standards in fuel efficiency, load carrying capacity and lowest operating costs.

Piaggio’s current product range includes half-tonner cargo vehicles (pick-up and delivery van), and 3-seater passenger vehicles in various fuel variants like diesel, CNG and LPG, and sub-one ton four-wheeler Ape truk.

The three-wheeler segment has been witnessing robust growth in the last few years with domestic volumes crossing 400,000 units in 2006-07. But the year 2007-08 has not been very encouraging for the market. The industry witnessed a decline of almost 10 per cent last year as it sold 364,000 units.

Mr. Khosla says he is not worried about the slowdown. “The demand for three-wheelers is still very strong in the market. But owing to due to lack of financial support we are witnessing a significant drop in retail sales”.

Easy to manufacture, tough to sell

A three-wheeler is probably the most easiest to manufacture and the most difficult to sell. But identifying an opportunity in this segment many new players have entered the segment and in the process have flooded the market with vehicles due to availability of cheap finance in the previous years.

Some of the manufacturers oversold their products to certain customers who didn’t have the capacity to repay their dues and in the process it has impacted the confidence of the financiers on a segment of customers who don’t have banking habits.

But one important fact that needs to be mentioned here is that these customers are more reliable and dependable and definitely have the genuine intentions of repaying their dues.

Mr. R. Sridhar, Managing Director, Shriram Transport Finance Company Ltd., says: “These customers have better intentions of paying back their dues”.

In fact, some of the vehicle finance companies like Shriram Transport Finance and IndusInd Bank have mastered the art of financing the three-wheeler segment and have perfect understanding of the customers. Seeing this, even banks like ICICI are creating a rural vertical to tap the untapped potential.

Three-wheeler segment

When Tata Ace was launched a couple of years back, the general feeling was that the three-wheeler segment would vanish over a period of time. It did have an impact on the on the bigger three wheelers which are the 0.75 tonner vehicles.

Mr. Khosla observes: “There is no replacement for a three-wheeler. The cost per tonne km on a three-wheeler is much lower when compared to the cost per tonne of a four-wheeled truck. The initial enthusiasm of owning a four-wheeler pushed sales in this segment but very soon customers will check their pockets and in certain segments there could be a realisation that the three-wheeler made more economic sense than a four-wheeled truck. I strongly feel that the game has just begun”.

In 2007 Piaggio sold close 1,60,000 units and for 2008 the company is planning to grow by 8% in an industry which is already facing a negative 9% growth. There is no dearth of potential, says Mr. Khosla. The three-wheeler segment in China is 3 times the size of the Indian market because there are more motarable roads in China. Three-wheelers can be driven even in deep rural and countryside markets in China, which is not possible in India in absence of good rural road infrastructure. Now since there is a heavy thrust in rural road infrastructure development we see future growth coming from rural markets.

Mr. Khosla further observes: “In India, the three wheeler cargo segment is a ten-year-old story in a 60 year old economy. We strongly believe that opportunity of growth exists and three-wheeler industry is going to build numbers going forward”.

Ape Truk

In mid-2007 Piaggio launched Ape Truck, a four-wheeled mini-truck, to take on competition from the Tata Ace. The company has launched the product in most part of the country. Currently it is selling approx. 800 units every month and the company plans to double the volumes in the next few months. “We will surely be able to replicate the success of our three wheelers in the four-wheelers as well. Our strength is our network. Currently the Ape Truck is sold from 180 out of our 671 dealer network points, which is roughly 35% of our network reach. This offers huge potential for future growth once we make the product available our dealer network point”, adds Mr. Khosla.

It is a challenge to find the appropriate customer for the four-wheeler. We are educating our front line people to identify customers who are most appropriate for the four-wheeler segment, adds Mr. Khosla. At the end of the day, in the commercial vehicle industry, we believe that facts are going to rule the game. In a long run the product has to clearly make money for the customer.

Currently there is a very narrow gap, in terms of carry capacity, between the three wheelers and the entry level four-wheeled mini trucks available in the market. But once the sub one-tonner four-wheeler segment moves to the next level, which could be sub two-tonner, there will be a clear differentiation in the market and this could result in volume growth.

Sales and service

Piaggio has created a truly world class organisation in India with supporting infrastructure in terms of sales and service. Mr. Khosla says that, “Piaggio has the highest post warranty ratio which is the best across all automobiles manufacturers in the country”. Last year the company invested a lot on promoting service activities. Including the Ape Maha Utsav, which generated references through existing satisfied customers.

Piaggio has established a network of 670 sales and service outlets across India. The company has established a pan India network from Baramula in the North to Nagerkoil in the South and from Bikaner in the West to Imphal in the East.

Piaggio has always laid emphasis on service. The company follows a scorecard system that is called the DEECORE system wherein each dealership is audited for efficiency, quality and reach. This system was started last year and the results have been very encouraging, says Mr. Khosla.

In fact, Piaggio has significantly improved its market share in markets like Bihar, Jharkhand, Rajasthan, Madhya Pradesh, North East and Karnataka.

Investment in engines

Globally, Piaggio as a group has announced plans to invest In India quite aggressively. The group plans to invest 60-65 million euros in the development and industrialization of twin-cylinder turbodiesel and diesel engines (upto 1,200 cc) and construction of a powertrain plant in Baramati. Daihatsu will partner the group on development and industrialization of the new powertrains.

The group, through its Indian subsidiary, has also signed an 8-year agreement with Greaves Cotton Ltd. under which Greaves will continue to supply PVPL with the GL 400 BSII monocylinder diesel engine and will also supply PVPL with the G 435 BSIII monocylinder diesel engine, beginning 2010 to coincide with the pan-Indian introduction of the Bharat III emissions regulations in India.

Greaves will provide Piaggio with the engines, as the sole supplier of monocylinder diesel engines for Ape three-wheelers, thus enabling the Piaggio Group to meet its objectives for eco-compatibility, efficient fuel consumption and general product price competitiveness.

In addition to the supply agreement with Greaves, the Piaggio Group has a close partnership with Kohler (earlier Lombardini), which supplies Piaggio with the 482cc liquid-cooled 5-speed diesel engine mounted on the Ape Truk four-wheeler.

The rapid industrialization and growth in the Indian economy and the resulting need for logistics management has driven Piaggio’s growth in the country. Going forward, transportation of men and material will continue to improve, given the growth targets of the Indian economy. The need will further get enhanced with the development of the rural sector. Given this growth potential the company envisages a growth of 15 per cent per annum for itself over the next five years.

The goods transportation sector in India is also witnessing a major shift in focus and is developing into a “hub and spoke” model. Whilst multiple axle, tractor-trailer large size vehicles are today dominating inter city transportation system, smaller three-wheeler and light commercial vehicles are catering to the movement of goods within a city. This shift in focus is expected to generate a large requirement for the smaller commercial vehicles, including the three-wheeler.

Piaggio has also begun to export its Ape vehicles from India to many countries including Argentina, Peru, Sudan, Sri Lanka, Mexico, South Africa, Cuba and Bangladesh. Till recently PVPL’s focus was on catering to the increasing domestic market needs in India. However it now has aggressive plans for a major thrust on the export front in the coming years. The company expects 10-15 per cent contribution to its turnover from exports in the future years.

Globally Piaggio’s interest in Asia and more particularly in India is well known. For Piaggio, India is a significant destination because of its large population needing inexpensive and basic transportation facilities. In a span of 10 years, Piaggio has become the market leader in the three-wheeler segment. The challenge is clearly in sustaining this leadership in the long run.

Caterpillar India to raise capacity

Caterpillar has announced expansion of operation in India with $200 million investment to increase machinery and engine production at the existing facilities.

As part of its strategic plan to increase its manufacturing footprint in the rapidly growing Asia-Pacific region, Caterpillar Inc. plans a four-year, $200 million investment to increase manufacturing capacity in India. The announcement was made during a visit to Caterpillar’s India facilities by Caterpillar Chairman and Chief Executive Officer Jim Owens.

“Caterpillar machines and engines are being used by our customers in India to drive sustainable development and to support economic growth in the areas of infrastructure development, commercial and residential construction, mining, power generation and energy production,” Owens said. “We are pleased to continue contributing to the growth and development of India. This additional investment demonstrates Caterpillar’s commitment to customers in India and the importance of such emerging markets as we build our proven global business model across the Asia-Pacific region, an area that is critical to Caterpillar’s 2010 and Vision 2020 goals.”

Caterpillar will invest to significantly increase production for off-highway trucks made at its facility near Chennai. These trucks are used for coal and other mining applications in India. The company also plans to expand engine production at its facility in Hosur, adding production of the Caterpillar 3508 engine. The 3508 engines will be used primarily in off highway trucks produced by Caterpillar in India.

The company is investing to increase Indian production capability for backhoe loaders. The backhoe loader is the most widely used construction machine in India, and Caterpillar has already more than quadrupled production of backhoe loaders in the country in recent years.

The company is also studying the possibility of increasing its range of products made in India, with the possibility of building additional manufacturing facilities to meet demand for other earth-moving products.

“This increased capacity will help Caterpillar serve customers in India and Asia-Pacific with world-class machines and engines produced in the region and serviced by our unmatched dealer organization,” said Tom Bluth, Caterpillar Vice President with responsibility for Asia-Pacific manufacturing operations. “For the industries we serve, Caterpillar already has the widest base of operations and product support in the world, and we will continue to invest in our business in the rapidly growing Asia-Pacific region to meet the needs of our expanding customer base in these critical markets.”

Caterpillar currently manufactures off highway trucks, backhoe loaders, engines, engine components and generator sets in India. In addition, Caterpillar established an Engineering Design Center in Chennai in 2002 to provide engineering support for product design and development.
Caterpillar Logistics Services India Private Ltd. in Bangalore develops logistics technologies and provides logistics services for Caterpillar in India. Together, Caterpillar and its dealers in India have nearly 4,500 employees. Due to the investment in operations and anticipated increases in its business to support a growing base of customers, Caterpillar plans to significantly increase employment in India over the next several years.

For more than 80 years, Caterpillar Inc. has been making progress possible and driving positive and sustainable change on every continent. With 2007 sales and revenues of $44.958 billion, it is the world’s leading manufacturer of construction and mining equipment, diesel and natural gas engines and industrial gas turbines. The company also is a leading services provider through Caterpillar Financial Services, Caterpillar Remanufacturing Services, Caterpillar Logistics Services and Progress Rail Services.

ATC Tires to set up plant in India

ATC Tires Private Ltd. has been jointly floated by Yogesh Agencies & Investments Ltd., and Warburg Pincus, a US-based Fund and a global leader in private equity industry, for setting up a tyre manufacturing facility in SIPCOT's Industrial Park at Gangaikondan in Tirunelveli district. This company has been formed by them after taking over Alliance Tire Company Ltd., Israel, with more than 50 years of experience in developing and manufacturing a wide range of tyres.

A memorandum of understanding (MoU) for setting up the tyre project was signed by Mr. M.F. Farooqui, Secretary to the Tamil Nadu Government, Industries Department, and Mr. Ashok Mahansaria, Chairman & Managing Director, ATC Tires Private Ltd., in the presence of the State Chief Minister, Mr. M. Karunanidhi.

Mr. L.K. Tripathy, Chief Secretary to the Tamil Nadu Government, Mr. K. Gnanadesikan, Secretary to the Government, Finance Department, and senior officials of ATC Tires were also present on the occasion.

ATC Tires will be investing Rs. 300 crores in three years and another Rs. 100 crores in the fourth and fifth years. The project will provide direct employment to about 1,000 persons and indirect employment to about 800 persons. The setting up of this project in Tirunelveli district will encourage other investors to locate their projects in the southern districts to which the Government accords high priority.

Caparo identifies site for bus manufacturing unit

Work on Caparo’s 2000-acre industrial park in the Nellore district of Andhra Predesh was launched with Group Chief Executive, Mr. Angad Paul saying he was contemplating more investments in the country.

Mr. Angad Paul explained that Caparo’s new industrial park will house units for luxury buses, special vehicles and automobile components. It also plans to develop world-class social and other infrastructure facilities, including roads, power plants, housing units and hotels in the area.

In April, Caparo signed a technical agreement with Hyundai Motor Company of South Korea to manufacture fully assembled luxury buses in India. The plant, which is due to commence production in 2009, will be located in southern India. The buses produced will be engineered to provide higher durability, outstanding stability and ease during high-speed cruising. They will also be fitted with powerful and fuel-efficient Euro III/IV engines, air-wide suspension and ABS systems.

Hyundai Motor Company will provide technical support that will enable the partnership to meet all the Government regulations concerning supply and manufacture of commercial vehicles in India.

“The industrial park aims to bring further medium-sized auto component manufacturers to the State, and we want to create something that Caparo and India can be proud of”, Mr. Angad Paul said.
The park, which would be completed in phases with the first phase operational by 2010 is estimated to provide both direct and indirect employment to thousands of people. Caparo has acquired 2,000 acres for the industrial park, part of which will be earmarked as a Special Economic Zone. The site was selected because of its proximity to Chennai and Krishnapatnam ports.

The Caparo Group currently operates 16 component manufacturing units in India.

The first customer of Mercedes-Benz now owns 100 Actros tippers

Messrs B. Girijapathy Reddy, Umapathy Reddy, Sudhakara Reddy and Raguram Reddy, who are partners of BGR & Co., had purchased the first Mercedes-Benz Actros on June 23, 2006. The company operates the SCCL mines of Ramagundam and Kothagundam in Andhra Pradesh.

Dr. Wilfried Aulbur, Managing Director and CEO of Mercedes-Benz India, and Mr. Ravi Gogia, Head of Commercial Vehicles, Mercedes-Benz India, recently handed over keys to BGR’s 100th Actros.

“Actros offers impressive return on investment as compared with any other product”, maintains Mr. Sudhakar Reddy who was given the key of the 100th Actros truck at the mining site by Dr. Wilfried Aulbur, and Mr. Ravi Gogia, Head of Commercial Vehicles, Mercedes-Benz India.

BGR & Co. was the first customer in India of the Mercedes-Benz Actros. It is also the first to own a fleet of 100 Mercedes-Benz trucks in India. “BGR & Co’s fleet of Actros trucks covered a cumulative of one billion ton-km at their mining sites of Ramagundam and Kothagundam of Andhra Pradesh during this period. It is a perfect testimony of the output that our rugged Actros trucks are capable of”, indicated Dr. Wilfried Aulbur.

The searing heat, the dusty and tough terrains and steep gradients of the mines are the probing grounds for the Mercedes-Benz Actros. These tough conditions test the man and machine to the limits. It is here that the Actros comes on its own.

Mr. Sudhakar Reddy elaborates: “The Actros is the most technologically advanced heavy-end truck in India. Its advanced technology makes the Actros a reliable and robust carrier. In the end this translates into enhanced productivity. The auto transmission, thoughtful fitments and comfort ensure low driver fatigue; the on-board maintenance system ensures optimized efficiencies while efficient on-site support from Mercedes-Benz ensures that there is minimum downtime, if any. These make the Actros an obvious choice for my mines.”

The 12-litre engine of the Actros delivers about 400 hp, which makes it one of the most powerful vehicles in the tipper segment in India.
Mr. Gogia further said: “Actros is the fastest growing product in its segment and has helped optimize return on investment for its customers because of its low operating costs, minimal maintenance requirements and driver-friendly technology. For example, the pollen-grain filter prevents dust from entering the cabin, thus improving the working ambience of the drivers. The sum of many small and big measures ultimately make the Actros a product that delivers optimum returns.”

With the local production of the Actros, Mercedes-Benz has ensured that they can meet the increasing demands from their customers in India. The footprint of the Actros has grown over the last two years, and the trucks now operate across seven mines in five States of India. The service and after-sales footprint has also kept pace with this growth: presently having four after-sales hubs in India, Mercedes-Benz plans to extend to 11 service- hubs, in addition to providing on-site service for customers.

The growing economy and focus on infrastructural development has increased the scope and demand for high-tonnage applications in India. The company is also evaluating Actros offerings for other segments in India.

Exhaust after-treatment: Ashok Leyland floats new company in Germany

Ashok Leyland, the Hinduja Group flagship, has announced the formation of a new company, Albonair GmbH, in Dortmund, Germany, which will focus on the development, production and sales of exhaust after-treatment systems for environment-friendly diesel engines. Albonair will engage in R&D and product development initially in the area of SCR after-treatment systems with an emphasis on design innovation and enhanced customer value.

Dr. Georg Huethwohl, who has been a pioneer in this technology, and Dr. Rene Ruedinger have been appointed Managing Directors of the company.

Said Mr. R. Seshasayee, Managing Director: “We already had a group of scientists and technologists who were assisting us in our R&D efforts to develop vehicle emission treatment systems and products. Therefore, it made eminent sense to start a company with them and formalize the working arrangement”.

While the Dortmund headquarters will be the central hub for research and development, it will cater to the requirements of emerging markets to conduct local customer application development for vehicle and engine manufacturers. A decision on production locations is expected in the coming months.

The compelling rationale for formation of the new company is that regulations for diesel exhaust emissions are getting stricter, worldwide. The Euro 4 norms, currently in vogue in Europe, are expected to be introduced in India and China soon.


The Asian region offers enormous market opportunities for innovative exhaust after-treatment systems. While the demand will increase significantly in the next few years, these markets will look for cost-effective products, requiring innovative solutions. Over the longer term, these cost-effective systems are also expected to find application in Europe and the US. Eventually, Albonair expects to branch out into a broader range of technologies aimed at reduced vehicle emissions in conformance to evolving standards of regulations worldwide.