Submitted by: Anand Kumar Amanpreet Singh Amit Attrey Karan Bhateja Parvesh Kumar Piyush Malhotra Utkarsh

Singh Vibhu Sharma

Purpose of the Project

To Undertake expansion of existing capacity for a high end car in India.

To keep the standards of the process of assembly world class

Project Objective
To design and implement an Assembly line for the production of a high end car

Production Quantity 11000 units per year

Time Span of the project 3.5 Years

To make sure that highest standards of quality are maintained once the assembly line is implemented

To keep the process and the resulted Assembly Line environmental friendly

Financial Feasibility
PM Financial analysis.xlsx

BMW : Production Process

All computers and controls in Assembly are linked together by nearly 16,000 miles of communications cables. Ergonomics are very important in the Tilt area. Carriers position the car so associates can install parts on the underbody.

Doors are removed from the car body and travel via an overhead conveyor to a separate door assembly line.

On the door line, the glass, water seals, mirrors, airbags, speakers and other trim pieces are installed.

The doors then travel on an overhead conveyor back to the main line and are reunited with the same car body.

BMW : Production Process

The Wiring Harness is the nervous system of the cars electronics. The contents of the Wiring Harness bag are heated to about 100 degrees, which makes the thick wiring harness pieces more flexible and easier to install.

The Wiring Harness is routed throughout the cabin, trunk, and engine area and fastened to the car body with clips and wire ties. A transponder is on every hood. This device helps track the car throughout the Assembly process.

The paper taped to the car is the Build Sheet. Digit codes tell associates which part goes on the car.

BMW : Production Process

About 8,000 parts are installed on every BMW X5 and X6. Power train is a separate assembly area. The engine, transmission, front/rear axles, and other parts are assembled here.

BMW gets six and eight cylinder gas and diesel engines for the X5 and X6 from Steyr, Austria. Its Motorsport engines for the X5 M and X6 M come from Munich.
A floor transport system is used to move the power train to the Marriage area.

Engine Marriage is where every car becomes a BMW. The entire power train is raised as the car body is lowered

BMW : Production Process

Robots tighten ten primary bolts that hold the engine and power train in place.

Fluid Fill: Most all fluids (radiator, brake, power steering, coolant, gas) are added here.

BMW uses a special gas that has additional cleaning agents and lubricants to help with the first car start-up.

Roll Booth: The car is driven on rollers at speeds up to 85 mph, giving the engine and transmission its first good test.

At Final Inspection, associates closely inspect the interior and exterior. Then the car is driven off the line.

Time Line
June 2012 Financial Planning Dec 2012 Sales Projection Planning May 2013 Developing Contingency Plan

April 2012 Plant Expansion Planning

Sept 2012 Production Forecasting

Mar 2013 Evaluation of Expansion Plan

July 2013 Vendor Management

Sept 2013 Expansion Phase Initiation

Feb 2014 Installation

March 2015 Testing Equipment's Functionality July 2015 Full Scale Production

Dec 2013 Finalizing Purchases

Dec 2014 Completion of Installation

May 2015 Commissionin g and Test Production

Managing Risks in the Project

Political Risk
For example: Tata Nano in Singur Indifference of political parties and scenarios

Environmental
Hazards such as indifferent weather, cyclones and tsunamis may cause a disruption in the supply and delivery of parts

Time
More than one critical paths can be there Projects cannot be crashed and hence the selection of the correct critical path is paramount

Safety Risk
Non statutory compliance of labour laws Workers working during the installation of different plant and machineries for the assembly line should be secure

Managing Risks in the Project

Technological
Outdated technology and loss of competitive advantage Delays due to importing new technology Efficiency in the operation of new technology

Economic
Depreciation of Rupee leading to increased import costs The prevalent nature of the industry is in decline at present

Legal
Changes in taxation policies and duties depending on the area of operation Cross boundary tariffs in transportation of goods

Evaluation
We will be conducting formative evaluation to make

sure that any deviation from the standard outcomes is nipped in the bud and does not impact the process. The evaluation will be done by the internal party and a team of senior managers and supervisors will be formed to oversee it. The evaluation will be both ongoing as well as terminal for effective monitoring and control.

Project Closure

Inspection
Equipped with Robots & automated conveyance machinery. Pressing.

Body.

Painting.

Inspection.

Quality Check.

Performance
Flow of parts.

Precisely Timed Processes.

No of Problems encountered.

Exit check-ups that tests all systems & controls.