A leading automotive manufacturer undertook a major expansion of its car production facilities to meet growing market demand. The project aimed to increase annual production capacity from 125,000 vehicles to 200,000 vehicles in the first phase, followed by a second phase scaling up to 320,000 vehicles per year. This large-scale expansion required advanced planning and engineering to integrate new infrastructure with existing operations while maintaining efficiency and safety. Tata Consulting Engineers (TCE) was responsible for delivering end-to-end engineering solutions for both phases of the project.

TCE’s Scope

TCE provided comprehensive services covering basic and detailed design engineering, procurement support, inspection and construction advisory. The scope included structural, mechanical, electrical and environmental systems for the entire facility. Key responsibilities involved designing new buildings for the press shop, weld shop, paint shop and assembly shop, while optimising existing spaces for machine and engine assembly.

The team engineered layouts for underground trench systems, overhead conveyors and monorails to ensure smooth material flow and obstruction-free shop floors. Secondary framing systems were developed for suspending welding transformers, conveyors and monorails from roof trusses. TCE integrated main piping, cable trays and ventilation ducts through roof structures to minimise building height and implemented an evaporative cooling system with air washers, supply fans and water spray sections to maintain comfortable working conditions. Systems for dust control, positive air pressure and efficient exhaust ventilation were also designed.

In the second phase, TCE’s scope expanded to include installation of a 2400-ton press in a newly created bay, coil storage and unloading facilities, water treatment plant, firefighting system, air cooling system and dust suppression system. Additional responsibilities included effluent collection and recycling systems, an industrial incinerator and electrical infrastructure upgrades with HT and LT packages.

Impact

The project demonstrated TCE’s ability to deliver large-scale automotive plant expansions with a focus on operational efficiency, worker comfort and sustainable engineering practices. The facilities were commissioned in stages over 30 months, ensuring timely delivery and seamless integration with existing production lines. By combining innovative design with practical solutions, TCE enabled the client to achieve significant capacity growth while maintaining high standards of safety and productivity.