A strategic partner in the global automotive industry - A Tata Steel Case Study Mr Anand Sen, President TQM and Steel Business, Tata Steel Ltd

Transcription

1 5 th International Conference on Steels in Cars and Trucks June 18 22, 2017 Amsterdam-Schiphol, NL A strategic partner in the global automotive industry - A Case Study Mr Anand Sen, President TQM and Steel Business, Ltd

2 2 Contents 1 Global context 2 Asia Growth a catalyst for change in India 3 Two decades of automotive focus 4 Drawing on global R&D and technology capability 5 Results show the success of effort

3 3 Contents 1 Global context 2 Asia Growth a catalyst for change in India 3 Two decades of automotive focus 4 Drawing on global R&D and technology capability 5 Results show the success of effort

4 4 The Tata Group is

5 Amongst the most global dispersed steel partner 5 UK & Ireland 4 Production facilities 33 distribution centres Netherlands 1 Production facility 3 distribution centres USA Distribution centres EU (Excluding UK & Netherlands) 13 distribution centres Major Production facilities India Thailand 3 Production facilities 3 distribution centres Singapore 1 Production facility 4 distribution centres FY17 deliveries: MT. FY17 Group turnover: ~ $18.3bn. Manufacturing units in 26 countries, Amongst the Fortune 500 companies MT from Indian operations. Group EBITDA: ~ $2.6bn. ~77,000 employees worldwide

6 Automotive focused assets of 6 IJMUIDEN, NL PORT TALBOT, UK Hot Rolled products for chassis and wheels HDG for FF application as well as internals AHSS up to 800 MPa in HR AHSS up to 1000 MPa in HDG Hot Rolled products for chassis and wheels HDG for FF application as well as internals AHSS up to 800 MPa in HR AHSS up to 1000 MPa in HDG JAMSHEDPUR, IN KALINGANAGAR, IN Hot Rolled products up to 800 MPa CRCA up to 590 Mpa (upgradeable to 780 MPa) GA/GI up to 590 Mpa Capability for FF (exposed panels) Secondary coatings (e.g. polymer) for FT application Hot Rolled products up to 1200 MPa Hot Stamped grade capability Wider widths up to 2050 mm Thickness up to 25 mm

7 7 Contents 1 Global context 2 Asia Growth a catalyst for change in India 3 Two decades of automotive focus 4 Drawing on global R&D and technology capability 5 Results show the success of effort

8 Chinese share of global car market A strategic partner in the global automotive industry 8 Chinese dominance 35.0% 30.0% 30.0% 25.0% 24.9% 20.0% 19.1% 20.7% 15.0% 10.0% 9.0% 5.0% 4.0% 0.0% Source: Statista

9 Million A strategic partner in the global automotive industry 9 Motor vehicles production in Total global production 2016: 95 million China USA Japan Germany India S. Korea Source: Organisation Internationale des Constructeurs d'automobiles (OICA)

10 10 Headroom for further growth Motor vehicles per capita USA Japan Germany S. Korea China India 32

11 11 Indian growth early days 5,000,000 4,500,000 Passenger Vehicles Commercial Vehicles 4,000,000 3,500,000 3,000,000 2,500,000 2,000, Source: Society of Indian Automobile Manufacturers (SIAM)

12 Year of introduction A strategic partner in the global automotive industry 12 Tightening emission norms Bhatat/Euro II Bharat/Euro III Bharat/Euro IV Bharat/Euro V Bharat/Euro VI

13 13 Different geographies, common goals Legislative Drive Consumer Preferences Vehicle Safety Performance Emission Control Lifestyle End-of-Life Appeal

14 14 Contents 1 Global context 2 Asia Growth a catalyst for change in India 3 Two decades of automotive focus 4 Drawing on global R&D and technology capability 5 Results show the success of effort

15 15 Multiple initiatives Customer engagement framework: VAVE, customer service teams Investment in facilities and technology Increasing customer base and reach

16 16 Multi-facetted effort over two decades

17 Increasing level of engagement with customer A strategic partner in the global automotive industry 17 Customer engagement framework Early Vendor Involvement & Downstream Solutions Complete product portfolio and capability offerings***, Structural supplies in Construction Duration > 2 year Cost and weight reduction Value analysis / Value Engineering: Grade Change, elimination and integration of parts and engineering solutions**, < 2 year Customer Service Teams Review Idea Generation New grade and product development* Operational efficiency improvement Elimination of hygiene problems Idea Implementation Idea Evaluation < 2 year < 1 year < 3 months FY02 FY10 FY12 FY14 FY17 * Technical support by NSC **Cooperation with TSL-Europe ***enhanced product portfolio through KPO

18 18 Focussed engagement Forums / Initiatives Auto CST Non CST Sr. Management interaction VAVE initiative PP PP Greater degree of interaction with CST customers through multiple forums and touch points helps in cementing relationship Driving Steel / Technology Day PP R&D Support Circle Grid analysis / Die Scanning Vendor Service Model P P PAG Support / Customer Feedback Customer Satisfaction Survey P P P P P P

19 Key aspect of Value Driver is to stay relevant 19 NPD sales to CST Customers % NPD Sales 300 Increase in NPD from new facility 23.4% 25% % 20% Development of hi-end grades for Nissan, Toyota and Hyundai 7.3% 7.6% 217 % of Auto Sales % 10% % FY12 FY13 FY14 FY15 FY16 5% 0% No. of NPD

20 20 Offer differentiated services VA/VE Vehicle Type / Class When Potential Saving ($) per vehicle Input Stage Passenger Car (Mini Segment) Oct Production Compact SUV Oct Production Heavy Commercial Vehicle Apr Production B-class Passenger Car Jun Production Pick-up truck Dec Production Passenger Car (B-class) Mar Production Passenger Car (C-class) Mar Production Passenger Car (B-class) Sep Development SUV Apr Production 3 - Wheeler Nov Production VA/VE Value Analysis Value Engineering

21 21 Contents 1 Global context 2 Asia Growth a catalyst for change in India 3 Two decades of automotive focus 4 Drawing on global R&D and technology capability 5 Results show the success of effort

22 Investment in Automotive Technology Centres 22 Europe R&D Product Applications Centre The Netherlands Europe R&D Warwick Technology Centre United Kingdom

23 Advanced Centre for Welding & Joining 23 Welding and joining research and application Testing and Characterization of welded joints Can provide process parameters for different steel grades. Help resolving weld shop issues. Simulate weld shop joining at lab scale for process optimisation. Suggestions about advanced welding / joining methods.

24 24 Advanced product application support Material data Robustness in analysis FLC modelling Material modelling Model for springback prediction Fracture & damage modelling Combined hardening models 1.5 s2/sref DP600 rolling direction Measurement von Mises Hill'48 Hill'90 Barlat'91 Corus-Vegter s 1/s ref EVI services VA/VE Concept development Design optimisation New product introduction Simulation techniques Formability simulations Sheet Metal forming / rollforming etc. Springback & compensation In-service performance modelling Forming-to-X Applicable to crash / fatigue / strength /..

25 Case study: ultra light tipper load body 25 Lighter tipper load body Extensive use of Ultra High Strength Steels Design innovation to maintain stiffness Over 12% weight reduction with better performance. Old Design One of the new designs

26 NO. OF MODELS A strategic partner in the global automotive industry 26 Value Analysis and Value Engineering Rolled out in India in More than 35 models, which includes 4W, 2W and heavy commercial trucks, covered. With both domestic and global OEMs like Renault Nissan and Volkswagon Average wt. save 20 kg and average cost save of $30 per vehicle VAVE in India FINANCIAL YEAR

27 27 With global automotive companies Cost down-weight down exercise on 9 different models from Renault, Nissan and Volkswagon in India with average saving potential of $15-20 per vehicle. Forming Simulation Advanced analysis support Tool Buy-Off Reverse Engineering

28 28 Advanced model for springback Integrated in commercial software Good prediction with In-house Model ** Also refer benchmark problem - 4 at NUMISHEET-2011.

29 29 Contents 1 Global context 2 Asia Growth a catalyst for change in India 3 Two decades of automotive focus 4 Drawing on global R&D and technology capability 5 Results show the success of effort

30 30 Indian volume growth 2500 Figures in 000 MT FY03 FY04 FY05 FY06 FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15 FY16 FY17 FY20 P

31 % market share A strategic partner in the global automotive industry 31 Domestic Indian market: share growth

32 supports global players on four continents 32 Developing with OEM and its tiers solutions to supply into NAFTA, Europe and Asia Design and development and supply into growing global operations European, Asia and South Africa supply for global platforms. Design support in UK, France and Japan Supply to Europe, Mexico and local sourcing for India Full service supplier to global operations in Car, Bus and Truck. Supporting design and development in Pune and Coventry, UK NAFTA, Europe, South Africa and Asia supply relationships, long established Supporting developing positions in Africa and Asia Supporting expansion ventures in NAFTA and the development of other Geely brands globally

33 33 Thank you Together we make the difference