This report summarizes a visit to the TVS Motor Company plant in Hosur. It describes three plants at the site that produce different vehicles. Plant 1 produces scooters and mopeds. Plant 2 produces motorcycles. Plant 3 produces critical parts like gears and cam shafts. The report identifies some problems observed, such as plastic bins increasing contamination, and provides suggestions for improvements such as using overhead conveyors and steel bags instead of plastic.

1. A REPORT ON THE VISIT TO TVS
MOTOR COMPANY, HOSUR
Submitted to : Submitted by :
Mr. Mukesh Krishna, C.Ganeshram,
Learning Centre, SASTRA University.
TVS Motor company,
Hosur.

2. Summary :
This is a report that is based on the personal visit to the TVS
Motor company plant in Hosur. This report briefly highlights the various
features (that are known to the employees of course) that makes the
company stand tall among its competitors. This report not only
highlights the various features, but also suggests some alternative
measures that could at least be useful to some of the employees in the
TVS family if implemented.

3. CONTENT
1. About TVS
2. Plant 1
3. Plant 2
4. Plant 3
5. Conclusion
About TVS:
TVS is a community that does not require any introduction.
But it is required to know about the organization that grooms over
thousands of individuals across the nation. The TVS motor company
started in 1978 is now the third largest two wheeler manufacturer in
India with a turnover of 1.7 USD in 2015-16 fiscal year. TVS can be
considered a company with pan world presence as it is present in about
60 different countries spanning in five continents.
It is also the second largest exporter in India. The TVS family employs
thousands of people from various parts of the nation. The organization is
has three plants in India at Hosur , Mysore and Nalagarh. It also owns a
plant in Karwang, Indonesia.
Plant 1 :
The plant-1 with a capacity of 1.09 million rolls out scooters
like Jupiter, Wego and mopeds like XL 100 and XL heavy duty.
As an OEM company TVS motor has many suppliers that provide it the
various small parts and castings required. The machining unit machines
the various parts like crank cases ( LH and RH) , cover variator, cylinder
block and cylinder head. The machining unit is the supplier for the
engine assembly unit, paint shop and vehicle assembly unit. The engine

4. assembly unit assembles the various parts in engine (180 parts on an
average) and supplies them to the vehicle assembly section.
Salient features :
 The overall plant layout is of combined with a product layout for
each and every unit within it.
 Provision of PPEs for the operators play a major role in reducing
in avoiding fatigue for the employees and also prevents accidents.
Problem identified :
The supply of kitting bins made of plastic is said to have increased the
plastic burr in engine and in the vehicle thereby contaminating the same.
Suggestions :
Instead of using plastic bins, properly woven steel bag like units with
proper stories can be used to palletize the entire parts(Just like CKD)
required for assembling a vehicle thereby reducing handling.
Plant-2:
The plant with a capacity of 1 million rolls out motorcycles like
Star city+, Victor (old and new), Phoenix, Jive. As the plant-1
the plant also has the same five units namely
1. Machining unit
2. Fabrication unit
3. Engine assembly
4. Painting
5. Vehicle assembly

5. Salient features :
 The painting process followed in the plant-2, facilitates
less rework thereby increasing the productivity of the
painting unit.
 The usage of TMOS facilitates standardization of
operations thereby creating a part family.
Problem identified :
The transportation of the frame work
through trolleys remains a problem
Suggestion :
The use of overhead conveyors can reduce the
traffic congestion at important sites and also can help in
focusing the labour time in a more productive way.
Plant-3
The plant-3 with a capacity of 0.69 million units produces
critical parts like gears(both primary drive and driven ) and
cam shafts for the vehicles produced in the Hosur plant.
Salient features :
 The SQF and CGCF are the highlights of the plant as they
play the major role of hardening the gears and shafts that
are the critical parts of the two wheelers.

6. Problem identified :
The handling of gear blanks and the
finished gears with plastics bins to palletize contaminates them.
Suggestions :
A suitable unit load carrying equipment for
handling the gears should be designed and implemented if
contamination exceeds the prescribed level.
Conclusions :
Various problems were identified and the following
are suggested as remedies:
 Steel bags for palletizing various parts of the vehicle.
 Specially designed unit load carrying equipment for
handling the gears.
 The use of overhead conveyors for reducing handling and
traffic at critical points.
 Quoting various thirukkural verses at vantage points in the
plants so as to have a better reach and connect with the
employees rather than using foreign terms like Kaizen,
Jishu hozen etc.