A glistening grey Swift Zxi was the 2.5 millionth vehicle that rolled out from the
Manesar B Line.
Spread over 600 acres, the Manesar facility houses three plants, Manesar A, B and
C with total annual capacity of 800,000 units. In addition, the Manesar campus also
has the diesel engine plant and a suppliers park.
Explaining some of the salient features of the Manesar facility, Mr Rajiv Gandhi,
Executive Director (Plants) says, “The Manesar facility achieved the 25 lakh production
milestone in 7 years and 8 months. The Manesar plant manufactures some of the top
selling models of the country like Swift, DZire and now Celerio. This milestone
would be the fastest for any car manufacturing plant in the country.”
Expressing gratitude towards the employees, Mr Gandhi said, “We are overwhelmed
by the enthusiasm of employees for their regular and active participation in forums
like Suggestion Scheme and Quality Circles. While we achieve the milestone, we have
successfully implemented several ideas from the employees on the important production
pillars of productivity, cost, quality and safety.”
Recently, the Manesar facility received the CII 5S Excellence Award (Northern region)
for its best practices in observing the acclaimed Japanese 5S philosophy which improves
shop floor productivity and efficiency.
Like the Gurgaon facility, the three Manesar plants have several in-built quality
checks and systems to ensure that cars being manufactured here are of top quality.
There is a high degree of automation and robotic control in the press shop, weld
shop and paint shop to carry on manufacturing work with precision and higher quality.
Areas where manual operations are challenging and difficult are supported by automation
and robotics.
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Manesar Facilities
Smart statistics
- > Feb 2007 : “A Line” commissioned
(Capacity 300,000 units/annum)
- > Sep 2011 : “B Line” commissioned
(Capacity 250,000 units/annum)
- > Sept 2013 : “C Line” commissioned
(Capacity 250,000 units/annum)
- > Total: 800,000 annually
- > Total investment: in the range of Rs 5100 Cr.
Models manufactured:
- > Over 1 million Swift
- > Over 0.5 million A-star
- > Over 0.7 million DZire
- > Over 0.1 million SX4
- > Over 45,000 Celerio
High points:
- > Most modern facility
- > Fully robotized Weld and Paint Shops
- > High on energy conservation
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