A leading two-wheeler manufacturer expanded its existing scooter production facility in Kanpur, Uttar Pradesh, to increase manufacturing capacity and meet rising market demand. The project involved designing new structures, modifying existing facilities and ensuring seamless integration with the operational plant. Tata Consulting Engineers (TCE) was entrusted with delivering structural engineering and design solutions for this significant expansion.

TCE’s engineering approach focused on optimising layouts for production efficiency while maintaining structural integrity and safety standards. The expansion required careful planning to accommodate new units and specialised areas without disrupting ongoing operations.

TCE’s Scope

TCE provided comprehensive engineering services for the project. This included structural design for the Completed Body Unit, CRCA stores, welding shop and vehicle assembly shop. The team also designed structural systems for stores receipt holding components, canteen, utility buildings and covered passages.

Specialised areas such as the Zip/Free and Skipper machine shop were part of the scope, along with minor modifications to existing structures in the press shop and paint shop. TCE also designed a 250 cubic metre elevated water tank with two compartments positioned at 26 metres above ground level. In addition, the team planned and designed roads and drainage systems for the plant area to ensure smooth site development.

Impact

This expansion project demonstrated TCE’s expertise in industrial structural design, utility planning and site development for large-scale automotive facilities. By combining innovative engineering with practical solutions, TCE enabled the client to achieve higher production capacity while ensuring operational efficiency and safety. The project stands as an example of how thoughtful design and execution can support growth in a competitive market.