This Report about all things of Volkswagen in India, Specially about VW's Pune Plant

1. Industrial Visit
Submitted to Padmashree Dr. D. Y. Patil Institute of Management Studies, Akurdi Pune. Industrial Visit Industrial Visit Report Mr. Ritesh M. Gholap VolksWagen Pvt. Ltd.

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Name and Address of Plant
Volkswagen
Contact person- Chaitanya Halbe
Phase 3, village Nigoje, Kharab Wadi, E1 MIDC, Mahalunge Ingale, Chakan, Pune, Maharashtra - 410501
Phone- +91-2135-331777, 331024

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About the Volkswagen
Volkswagen is a German automobile manufacturer headquartered in Wolfsburg, Lower Saxony, Germany. Volkswagen is the top-selling and original marque of the Volkswagen Group, the biggest German automaker and the second largest automaker in the world.
 Nature of Business : - Manufacturer
 Major Markets :- Automobile
About the Plant
 Year of Company Establishment 28th May 1937
 Year of Plant Establishment 31st March 2009
 Nature of Business- Manufacturer
 Production Capacity of Plant – 130000/year
 President & Managing Director – Jorg Muller
 Investment – INR 3800 cr.
 Employees – 3500*
 Area – 575 Acre

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What did we do...
 We have visited Body Shop
 We have visited Assembly Shop
 We have visited Paint Shop
 Prof. Iftekhar khan & Prof. Amitabh led 50 students on the Visit.
 On behalf of Company Mr. Chaitanya Halbe (Assistant Manager) welcomed us. Later on, gives us valuable information regarding VolksWagen Group. he also accompanied us and explained us the various processes in the plant.
 Later, at the end of visit, Mr. Chaitanya Halbe addressed students about Company, in which students actively participated.

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VolksWagen in India
Volkswagen Group in India is represented by five brands: SKODA, Volkswagen, Audi, Porsche and Lamborghini. The Volkswagen Group India is a part of Volkswagen AG, which is globally represented by 12 brands from 7 European countries.
11 automotive brands:
 Volkswagen Passenger Cars
 Audi
 Bentley
 Bugatti
 Lamborghini
 Porsche
 Scania
 SEAT
 SKODA
 Volkswagen Commercial Vehicles
 MAN
1 motorcycle brand:
 Ducati
From low-consumption small cars to luxury class vehicles, each car is convincingly worthy of its place on the road. Even in the commercial vehicle sector - where

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products range from pick-ups to buses and heavy trucks - the Group's cars successfully partner businesses and are known to far exceed the industry standard. This benchmark, that is truly gold standard, has helmed the group in its operations across 100 production plants around the world. More than 572,000 employees are involved in vehicle-manufacturing services and their related processes. Together, they produce about 39,000 vehicles each working day.
Volkswagen Group India has about 5,000 employees working at its various locations in India. Over 3,500 employees work at the Pune plant with about 1,000 employees dedicated to the Aurangabad plant and around 300 people employed at the National Group Sales Office in Mumbai.
Volkswagen has invested some INR 3800 cr. in the plant, making it the largest investment project undertaken by a Germany company in India till today.
The Pune plant is the only production facility in India to be started by a German automotive manufacturer and covers the entire production chain — from pressing plant to body shop and paint shop, extending all the way through to final assembly.

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About The Pune Plant
The Volkswagen plant in Chakan occupies a total area of over 2.3 million square meters (575 acres), with buildings covering about 1,15,000 square meters. A workforce of over 3,500 people was engaged in building it during its peak construction stages. The plant was built in a record time of 17 months, with an investment commitment of INR 3,800 Crore (580 million Euros) by Volkswagen India Private Limited. It is the largest investment by a German company to date in the growing Indian market.
Production
The plant has a production capacity of 130,000 vehicles a year, which in capacity was maximized in 2011. The construction of the plant commenced in 2007.

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The Pune plant is one of the most modern in the Volkswagen Group. It has a high level of vertical integration and a large share of local suppliers. The facility is the only production plant operated by a German automaker in India that covers the entire production process, from press shop through body shop and paint shop to final assembly. The Car employs a combination of manual and robotized manufacturing operations.
The plant uses futuristically designed state-of-the-art equipment. For example, we saw the body shop uses the Diode Laser Brazing (DLB) technology, whereas the Roof & Side Framer laser technology by KUKA robots is used for welding the roof to the body of the car.

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Process of Manufacturing & Assembling
The body shop, where the car essentially starts to take shape, employs a combination of Manual and Robotized manufacturing operations. Kuka robots were seen by us at work in the weld shop. The highlight of the body shop is the Diode Laser Brazing Technology. Interestingly, the roof and side framer laser technology is used for welding the roof to the body of the car. Car's body-in-white is transported to the Paint Shop. Painted bodies are transported to the final assembly through an overhead conveyor. It is one of the few Environment Friendly Manufacturing plants around the area, the exhaust of the paint shop is re-burnt and the resultant heat and energy is reused. Once the painted body enters the final assembly, the doors are separated

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and sent to the door sub-assembly. Various peripherals are added. A combined complex layout of the final assembly, measuring 46,080 square meters, has the Car body being fitted with the trim, cockpit, etc., followed by the Marriage of the Powertrain, which essentially consists of the engine-gearbox, exhaust, suspension and axles. The wheels are also fitted as the car travels over flexible conveyors. The car is then transported to the finish line where the doors are attached and the final bits added. Further on, the Car is subjected to final tests, including the shower test. Part of the final assembly is a 'Profi-room', which according to a Volkswagen official, is the place to provide field training to the technical staff. The final assembly

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hall also has enclosed logistics area between the lines that holds inventory and parts, which are readily supplied to the line. There's also a 'wailing wall' where everybody assembles in case of a problem and the line shutting down. Discussion on the further course of action and the decisions are taken here.
Here Are Some Of The Brands
 Skoda Fabia
 VolksWagen Polo
 Skoda Rapid
 VolksWagen Vento

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Quality assurance
Quality is the Habit of them. This believes in providing to Customer with the premium quality Car’s as per their specifications and requirements.
In our observation we found that their quality control is impressive so that they are now 2nd largest manufacturer.
They assure that VW will be the 1st largest manufacturer till 2018.
The quality control analyst working inspects strictly the quality of cars at every stage of Manufacturing and Assembling.
Body Shop : They have the Body Shop in which latest technology from Germany is installed. This ensures the quality and fast production of Cars.
Future Expansions: In our conversation with Mr. Chaitanya, he briefed us about the future plans. As VW becoming popular in market, VW setting up a new diesel engine assembly line and a full-fledged engine testing facility at its plant. This move will further hike the local content in the vehicles made at the plant.

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Mr. Chaitanya said that the assembly of the new 1.5- litre TDI engine would commence at the end of 2014. The company had invested (Rs.240 crore) in the facility. the new line can assemble over 98,000 engines in a three- shift system at full capacity.

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Our Experience from the Industrial Visit
 ‘See & Know’ is better motto than ‘Read & Learn’.
 After completing the industrial visit, we have upgraded our knowledge at a very great level. It was a good learning experience. In each & every department, we got some or the other new ideas and new thinking which was very necessary for development.
 We have visited the entire process department. They are using new technologies.
 They are strictly following quality & safety aspects. It is desirable to review various aspects & sum up the industrial visit.
 During industrial visit, we feel very much satisfied by acquiring information of various departments & knowing many new things.

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Conclusion
 We conclude that, while going through the entire industrial visit, the co-operation is found to be very well organized, developed & most ideal industry in every walk of its production, administration & management aspects.
 We extend our heartiest thanks to VolksWagen India Pvt. Ltd., Pune, for making 30th Sep. 2014 a day to cherish for some of the lucky students like us who are honored with your humble gesture to get an opportunity to visit such an esteemed organization.
 We also want to thank our director Dr. Kailash Chand Sir and Prof. Amitabh Sir, especially to Prof. Iftekhar Khan Sir for coordinating the visit.