The document summarizes information about Motherson Sumi Systems Limited (MSSL), a leading automotive components manufacturer in India. MSSL has a diversified product range serving multiple industries, with automotive being the main industry. It has a presence in over 20 countries globally and over 31,000 employees. MSSL is a joint venture between Motherson Group and Sumitomo Wiring Systems, and is a flagship company of Motherson Group specialized in production of wiring harnesses and door trims.

1. Summer Training M/s Motherson Automotive Technologies and Engineering, Noida Presented by ADITI MBA IB

2. Focused, dynamic and progressive group providing customers with value added products, services and innovative solutions. The Group has a diversified product range to serve multiple industries, with automotive industry being the main industry served. SAMVARDHANA MOTHERSON GROUP

3. GROUP MISSION: Ensure customer delight Involve employees as partners in progress Set new standards in good corporate citizenship Enhance shareholder value GROUP VISION: To be a Globally Preferred Solutions Provider

4. GROUP VALUES: Be a lean, responsive & learning organization Continuously improve to achieve world class standards and total customer satisfaction Proactively manage change Maintain high standards of integrity and safety Ensure a common culture & a common set of values throughout the organization Recognize individuals’ contributions Develop stronger leadership skills, greater teamwork and a global perspective Constantly upgrade skill levels across the organization through knowledge sharing programs

5. KEY FACTS: Largest automotive wiring harnesses manufacturer. Largest automotive wire manufacturer. Largest manufacturer of rear view mirrors for passenger cars in India. One of the largest suppliers of molded plastic components, assemblies & modules for automotive industry. One of the largest manufacturers of gear cutting tools in India. Largest suppliers of rear view mirror in the world. Presence in 20 countries across the globe Group sales over $USD 851 Million (FY 2008-09). Joint ventures in key technology areas. Over 31,000 qualified professionals.

6. 1975 : Motherson was founded 1977 : First cable factory started 1983 : Technical agreement with Tokai Electric Co. for Wiring Harness . 1986 : JV with Sumitomo Wiring Systems Japan 1989 : Injection Molding 1992 : Cutting Tool Manufacturing 1994 : Tool Room for small and Medium sized Molds (upto 650 Tons) 1995 : Cockpit Assemblies , Automotive Mirrors 1997 : Blow Molding 1998 : Rubber Injection Molding 1999 : First Overseas office established (Austria) 2000 : IT and Design Company , Representetive Office at Singapore 2001 : Liquid Silicon Rubber Injection molding , Machined Metal Components Historical Milestones

7. 2002 : Wiring Harness manufacturing at Sharjah , Design Centre at Ireland 2003 : Offices in USA & UK established , Tool Room at Sharjah , Automotive Sunroofs 2004 : European Headquaters at Germany , Sheet Metal Die Design 2005 : Injection Molding & metal Machining in Germany , Plastic Molding & Metal Machining at Germany , PVC Tube Manufacturing 2006 : Wiring Harness Manufacturing in UK ,Bus Airconditioning Systems , Auxiliary Equipment for Injection molding machines 2007 : Rubber parts Manufacturing in Australia 2008 : JV for Lighting Systems, Pedal Box Assembly & Air Intake manifolds , JV for Precision machined metal components 2009 : Visiocorp becomes a part of Samvardhana Motherson Group and renamed Samvardhana Motherson Reflectec (SMR) 2009 : Gear cutting tool manufacturing through a new venture Motherson Advanced Tooling Solutions , Polymer Compounding Cabins for off road vehicles in India The Group has a diversified product range to serve multiple industries, with automotive industry being the main industry served. Historical Milestones

8. SAMVARDHANA MOTHERSON GROUP - FLAGSHIP COMPANY Motherson Sumi Systems Limited FLAGSHIP COMPANY OF SAMVARDHANA MOTHERSON GROUP ESTABLISHED IN 1986. JV BETWEEN SAMVARDHANA MOTHERSON GROUP AND SUMITOMO WIRING SYSTEMS (JAPAN)

9. SAMVARDHANA MOTHERSON GROUP COMPANIES A Basic Concepts Designs Pty. Ltd. . AES (India) Engineering Limited ANEST IWATA Motherson Coating Equipment ANEST IWATA Motherson Limited Calsonic Kansei Motherson Auto Products Limited CTM India Ltd. Fritzmeier Motherson Cabin Engineering Ltd. Global Environment Management (FZC) Magneti Marelli Motherson Auto System Ltd. Matsui Technologies India Ltd. Miyazu Motherson Engineering Design Limited

10. SAMVARDHANA MOTHERSON GROUP COMPANIES Motherson Advanced Tooling Solutions Limited Motherson Automotive Technologies & Engineering (A Division of MSSL) Motherson Elastomers Pty Limited Motherson Electrical Wire Lanka Pvt. Ltd. Motherson Machinery and Automations Limited Motherson ORCA Precision Technology GmbH Motherson Sumi Electric Wires (A Division of MSSL) Motherson Sumi Wiring System Ltd. (FZC) Motherson Techno Tools Limited Motherson Zanotti Refrigeration System Limited Motherson Sumi INfotech & Designs Limited Motoman Motherson Robotics Limited

11. SAMVARDHANA MOTHERSON GROUP COMPANIES MSSL Advanced Polymers s.r.o. MSSL GB Ltd. MSSL Polymers GmbH Nachi Motherson Tool Technology Ltd. Sumi Motherson Innovative Engineering Limited Tigers Connect Webasto Motherson Sunroofs Limited Woco Motherson Advanced Rubber Technologies Ltd Woco Motherson Elastomer Limited Woco Motherson Limited (FZC)

12. PRODUCTS

13. GLOBAL PRESENCE

14. MOTHERSON SUMI SYSTEMS LIMITED

15. Specialized in production of wire harnesses, door trims. Recently received US $ 125 million order placed by Ford. Company is listed at stock exchange in 1993. Company is at position one in India for manufacturing rear view mirror . MSSL have presence in 21 countries. Manufacturing base in five continents.

17. INDUSTRIES SERVED Automotive Off-Road Vehicles Earthmoving and Material Handling Equipment Agriculture and Farm Equipment Medical Diagnostics Rubber and Tyre Industry IT Hardware Test and Measuring Scientific Equipment Elevators Electrical Equipment Lawn Equipment White Goods

18. AWARDS GAIN BY MSSL Customer Recognition- Quality Award 2001-02 Performance Award VA-VE-2005-06 Performance Award Incoming Quality Improvement–2008-09 Overall excellence 2008-09 Vendor Quality Awareness Quiz Award 2008-09 Performance Award Part Development 2008-09 Performance Award MPS 2008-09 Performance Award System Audit 2008-09 Award for Zero Defect Supplier 2008 Supplier of The Year Gold Award 2008 Vendor Quality Awareness Quiz Award 2008-09

19. COMPETITORS OF MSSL Minda Industries Ltd. India Nippon Electricals Hella India Lighting Ltd. Denso India Ltd.

20. Motherson Automotive Technologies and Engineering

21. Division of MSSL Specialized in injection molding , blow molding. Manufactures a wide range of plastic components for automotives. MATE has a turnover of 4593 million rupees for the year 2009-10. Future estimate of turnover for the year 2010-11 is 6995 million rupees.

22. Manufacturing Capabilities Injection Molding machines from 40 ton to 3200 ton capacity Gas Injection Molding facility State-of-the-art Blow Molding machines Compression Molding facility Post Molding Operations Product Finishing with Fabric Upholstery and Vinyl Lamination Robotic Trimming Operations Ultrasonic Welding Painting Silk screen printing Auto screen printing Pad printing In house tool maintenance

23. Organizational Chart Of MATE

24. LIST OF DEPARTMENTS IN MATE NOIDA UNIT PURCHASE MARKETING ENGENEERING FACT (FINANCING ,ACCOUNTING, COSTING, TAXATION) HUMAN RESOURCE EXPORT-IMPORT PRODUCTION QUALITY

25. FUNCTIONS OF VARIOUS DEPARTMENTS

26. FUNCTIONS OF VARIOUS DEPARTMENTS (CONTD..)

27. PRODUCT RANGE Blow Molded Components : Heating, Ventilation and Air Conditioning Ducts Engine and Air Intake Ducts Wind Shield Washer Bottles Radiator Reservoir Tanks Resonator/Pipe Air Intake Arm Rests Bellows Body styling Kit-spoilers

28. Injection Molded Components: Interior/Exterior Trims and parts Scuff Plates Auto A.C. Components Mirror housings Under bonnet parts Structured Plastic components Inside Handles Body colored painted parts

29. SWOT ANALYSIS OF THE COMPANY THREATS China The presence of a large counterfeit components market poses a significant threat Pressure on prices from OEMs continues OPPORTUNITIES Serve as a sourcing hub for global automobile majors Significant export opportunities are realized through diversification of export basket OEM’s focusing on low cost outsourcing

30. SPECIAL ACTIVITIES HUMAN RESOURCE Proper Induction and orientation is stressed upon which provides a sense of belongings. Skill enhancement is conducted as an ongoing process. MSSL provides an environment to its employees to take higher level of Responsibilities. Another way of involving employees outside the ambit of their jobs is in extra-curricular activities. MSSL has 84 quality circles operating within the company.

31. SPECIAL ACTIVITIES CSR Leading to help deprived children of society through various programmes in the communities. Various CSR programmes for children of the deprived communities are being supported by the company. It strives to achieve goals of achieving symbiosis With nature, and has been proceeding with efforts toward Environmental protection in all aspects of its business activities.

32. Plastic Fuel Tank A Technological breakthrough for Efficient Fuel System in Cars “ An in depth study on Product Development and A Feasibility Study of European Market”

33. CHAPTER -1 INTRODUCTION TO INDIAN AUTO-COMPONENT INDUSTRY

34. The Indian auto components industry started out in the 1940s. Global auto components industry is estimated at US$1.2 trillion. The Indian auto component sector has been growing at 20% per annum since 2007 and is projected to maintain the high-growth phase of 15-20% till 2015. It has distinct global competitive advantage in terms of cost and quality. The value in sourcing auto components from India includes low labor cost, raw material availability, technically skilled manpower and quality assurance. Indian auto component industry likely to be $ 40bn in 2015

35. (ACMA) classifies the auto ancillary : Engine and engine parts: Pistons, piston rings, piston pins, gaskets, carburetors, fuel injection pumps, etc. Drive transmission and steering parts: Transmission gears, steering gears, crown wheels and pinions, axles, wheels, etc. Suspension and braking parts: Leaf springs, shock absorbers, brake assemblies, etc. Electricals: Spark plugs, starter motors, generators, distributors, voltage regulators, flywheel magnetos, ignition coils, etc. Equipment: Dashboard instruments, headlights, horns, wipers, etc. Others: Fan belts, sheet metal parts, plastic mouldings etc.

37. The India Advantage : Steered here by the country's high engineering skills, established production lines, a thriving domestic automobile industry and competitive costs, global auto majors are rapidly ramping up the value of components they source from India. The industry is poised to jump from exports of Rs. 61 billion in 2005-06 to Rs. 296 billion in 2011-12. According to the Automotive Component Manufacturers Association of India, more than a third (36 per cent) of Indian auto component exports head for Europe, with North America a close second at 26 per cent.

39. The major players in Auto-component industry are Apollo Tyres Balkrishna Industries Bharat Forge MICO Omax Autos Rico Auto Industries Sona Koyo Sundram Fasteners Clutch Auto Motherson Sumi

42. CHAPTER –2 REVIEW OF LITERATURE

43. Review of literature: A literature review is a body of text that aims to review the critical points of current knowledge including substantive findings as well as theoretical and methodological contributions to a particular topic. Literature reviews are secondary sources, and as such, do not report any new or original experimental work.

44. LITERATURES REFFERED : Yuuki Kurihara and Keiji Nakazawa (1987) Peter J. Alvado (1996) Gregory A. Keoleian and Sabrina Spatari (1998) Knights and Mikell (1998) C-Y Tung and M H Wang (1999) By Schut and Jan H. (2000) Omar Usman (2001) D. Ross Brennan et al (2002) P. Matthyssens and W. Faes (2002) B. BONAZZA et al (2004) Molinaro (2004) James R. Griffith et al (2005) Jim Doty (2005) Dr. Bartholomeus P.G. Kamp (2007) Matthew Beecham (2009) Auburn Hills and Mich. (2010)

45. GAP IN THE STUDY The plastic fuel tanks are not yet very popular in India .Its a developed concept in European countries, and America. In India as such not much previous researches are being conducted on it more of researches are conducted in western Countries. It being tried through research to fill this gap by proposing manufacturability of Multi layer plastic fuel tanks in India.

46. OBJECTIVES To identify a new polymer product for MATE To study why plastic fuel tanks are better than steel fuel tanks. To study the technical requirements. To estimate the cost involved. To study the domestic market of plastic fuel tanks. To analyze the market for export. To study the biggest competitors in European export market. To get the feedback from the OEM’s in Europe regarding the product offered.

47. SCOPE Scope of research is to identify a new polymer product to diversify for MATE with true market acceptability worldwide.

48. CHAPTER –3 RESEARCH METHODOLOGY

49. RESERCH DESIGN : A research design is an arrangement of conditions for collection and analysis of data in a manner that aims to combine relevance to the research purpose with economy in procedure. It constitutes the blueprint for collection, measurement and analysis of data. The research design for this research is exploratory and descriptive, as It being exploring some new facts as well as using some previous researches to know what is the feasibility of new identified product for MATE to manufacture.

50. DATA COLLECTION : For research study the data has been collected by both the primary & secondary means. Primary data collection: For respective research primary data has been collected by: E-mailing Telephonic interviews Secondary data collection: And the secondary data collection was done through: Internet Previous researches

51. UNIVERSE : Universe refers to all the eligible respondents of a particular research around the World. The universe for research is all the OEM’s manufacturing cars all over the world. POPULATION : Population refers to part of universe from which the sample for conducting the research is selected. Universe & population can be same in some researches. The population of research is all the OEM’s manufacturing cars in Europe. SAMPLING DESIGN : A sample design is a definite plan for obtaining a sample from a given population. It refers to the technique or the procedure the researcher would adopt in selecting items for the sample. In this research probability sampling technique with simple random sampling is used .

52. SAMPLING UNIT : Sampling unit refers to smallest possible individual eligible respondent. In our study the sampling unit is single respondent OEM . SAMPLING SIZE: Sampling size refers to total number of respondents targeted for collecting the data for the research. The sampling size of our study is 15 respondent OEM’s. LIMITATIONS : Time constraint Reach Generalization of results Company policies

53. CHAPTER –4 DATA ANALYSIS AND INTERPETATION

54. PART –1 An in depth study on Product Development

56. PRODUCT IDENTIFICATION It has been the MATE’s Endeavour to constantly add new products in its product line, within the objective of emerging as a single- service interface for multiple customer needs. MATE’s diversity of product range; coupled with sheer depth within each product portfolio, has helped the company garner the leadership in its area of operations. continuously strengthening its position as a globally preferred solutions provider. A new product i.e. plastic fuel tanks been identified, if it proved to be a feasible , can prove to be a good step for entry into the market Then MATE will be the second largest manufacturer of Plastic fuel tanks in India after Yapp – Zoom Chennai.

57. PRODUCT DESCRIPTION Product is multi layer plastic fuel tank . Manufactured with 6 layer extrusion blow molding. Multilayer blow molded fuel tanks with 6 layer construction utilize an EVOH (Ethyl Vinyl Alcohol) layer that reduces permeation to below 0.05 g/m2/day. High-density polyethylene (HDPE) has been the resin of choice for plastic gas tanks, and production capacity has been on the increase. Barrier layer of ethylene-vinyl alcohol (EVOH) that is sandwiched between two layers of HDPE. Properties of High Density Polyethylene (HDPE) High impact strength Low temperature toughness, Excellent resistance to chemicals, Good electrical insulating properties, and Poor ultraviolet resistance. Melting Point 266°F 130°C Properties of EVOH: EVOH resins are fuel barriers and also its adhesion performances towards rubbers Its an excellent barrier to gases such as hydrogen, co2 and other gases. It gives high resistance to hydrocarbons, oils and organic solvents. Permeation rate of chemical solvents through an EVOH layer is very slow compared to other materials.

58. TYPICAL TANK CONSTRUCTION

59. PLASTIC VS. STEEL

60. FUEL SYSTEM ARCHITECTURE FILLING OF THE FUEL TANK STORAGE OF FUEL GAUGING VENTING FEEDING

61. 6-7 LAYER EXTRUSION BLOW MOLDING MACHINE

62. The Extrusion Blow Molding Process

63. FUEL SYSTEM COSTING: THE FULL FUEL SYSTEM COST US AROUND 39,098 INR.

64. PART –2 “Feasibility Study of European Market”

66. Domestic plastic fuel tank market The plastic fuel tanks are not yet very popular in India .Its a developed concept in European countries, and America. Presently the plastic fuel tanks are imported by OEM’s in India by Ford and SIEL for few of their models The first mover in plastic fuel tank manufacturing is “ ZOOM AUTOMOBILE ANCILLARIES PVT. LTD.” YAPP is an established player in plastic fuel tank business and is an 'A' grade supplier to Ford, General Motors and Volkswagen in China. The company started with capacity of 180,000 units per year and has the flexibility to increase the capacity to 240,000 per annum by adding additional platform to the existin g facility.

67. Domestic plastic fuel tank market The company has an array of major carmakers including Volkswagen India, Ford India and Mahindra . Currently, the Chennai facility has the capacity to manufacture 2.50-lakh plastic fuel tanks a year and the firm is aiming at Rs 80-million sales growth for the first year. What is more, the company has also planned to set up its second production line in 2011 that would double the annual production. The company is also scouting for land in Pune to set up another manufacturing unit, following the concept of being closer to the client as Volkswagen India is one of its main clients in the Indian Automotive spectrum. The JV has invested around $14 million in the first phase. The new facility will cater to the car and SUV segments with the product in the 30-75 litre capacity.

68. WORLD PLASTIC FUEL TANK MARKET The first test for plastic fuel tanks was done in 1960’s in Europe. In 1966 the Porsche was the first to use the light weight plastic fuel tanks in it. VW due to corrosion problem in steel fuel tanks used plastic fuel tanks in PUGAT in 1974. In 1980 VW used the first HDPE plastic fuel tank in their cars. It is estimated that some 90 % of all new cars in Europe have plastics tanks, and the technology has been exported to North America, where about 70 % of cars now use this system. In Japan, the market share is considerably lower, at about 7 %.

69. Fuel tank worldwide in million units

70. WORLD MARKET REVIEW

71. LARGEST EUROPEAN FUEL SYSTEM PROVIDERS Inergy automotive system Kautex Textron TI Automotive Visteon

72. Inergy Automotive Systems Inergy Automotive Systems is the Leader in plastic Fuel Systems. Inergy, headquartered in Paris, employs 4 000 people around the world Has 22 facilities located in 17 different countries. Integration and Innovation are the foundation of their activity. In 2008, Inergy has delivered more than 11.2 million Fuel Systems with a turnover of EUR 1.1 billion. Their global footprint enables them to respond to their customers’ engineering and industrial challenges in any Region of the world. 600 engineers and technicians working in 5 R&D centers based in Europe (3), Asia (1) and North America (1) lead the development INERGY is committed to offering OEMs a complete range of simulation analysis and results and has developed its own simulation tools. The use of virtual prototyping in the Fuel System development has allowed for increased product quality and process efficiency.

73. MARKET VIEW

74. INERGY CUSTOMER PORTFOLIO

75. INERGY INTERNATIONAL LOCATIONS:

76. Kautex Textron Kautex has grown into a network of businesses with total revenues of $10.5 billion , And approximately 32,000 employees with facilities and presence in 25 countries Serves a diverse and global customer base. Headquartered in Providence, Rhode Island, U.S.A., Textron is ranked 220th on the FORTUNE 500 list of largest U.S. companies. Kautex is the leading global automotive supplier of plastic fuel systems. They are the leader across the total fuel system with innovative features and excellent full-service supply. With 33 locations in 25 countries, Kautex is well positioned as the partner of choice for customers around the world.

77. Textron worldwide

78. INDUSTRIAL 2009 SALES BY GEOGRAPHY

79. Sales volume by region

80. TI AUTOMOTIVE TI Automotive Ltd. engages in the design, development, and manufacture of integrated fuel storage and delivery systems and components for cars and trucks. The company offers multi-layer blow molded plastic fuel tanks.. TI Automotive was founded in 2001 and is headquartered in Oxford, the United Kingdom with an additional office in Warren, Michigan. The company also has locations in Europe, Africa, Australia, South America, North America, and the Asia/Pacific, as well as facilities in Auburn Hills and Caro, Michigan; Rastatt and Fuldabruck, Germany; Greeneville, Tennessee; Chalons, France; and Cacapava, Brazil. TI Automotive Limited is a former subsidiary of Smiths Group plc. TI does 55% of its business in Europe, 25% in the Asia/Pacific region and 20% in North America.

81. TI AUTOMOTIVE In the 1990s, TI purchased Bundy Tubing, a U.S. company founded in 1919 by Harry Bunding. It then went on to acquire plastic-tank producer Walbro Corp. in 1999. Walbro helped advance the trend of plastic fuel tanks, The tank is intended to minimize hydrocarbon emissions that result from the vaporization of fuel. A decade ago, fuel tanks were allowed to emit 2,500 mg of hydrocarbons in a 24-hour period. Five years ago, the limit was about 250 mg. Today’s Partial Zero Emission Vehicle mandate is 54 mg. TI’s new tank emits less than 10 mg of hydrocarbons, thanks to the company’s Tank Advanced Process Technology to create a nearly air-tight seal.

82. GLOBAL CUSTOMER BASE

83. VISTEON As a leading global supplier of automotive systems, modules and components to global vehicle manufacturers and the automotive aftermarket, Visteon is proud of the recognition received from customers and industry groups alike. Visteon is committed to delivering value in the European marketplace. Visteon has a substantial European network of facilities, including a European Corporate Office and Innovation Centre in Chelmsford, UK. GLOBAL PRESENCE: Asia pacific Europe North America South America

84. PART –3 “ Data analysis and interpretations on Feedback received from European ”

85. Sample size= 15 respondents q1) E xisting customers of Motherson

86. q2) Familiarity with existing product

87. Q3) Existing user of multilayer plastic fuel tanks

88. q4) Suppliers of plastic fuel tanks to these OEM’s

89. q5) Usage period of plastic fuel tanks

90. q6) Overall reaction to described product

91. Q7a) Rating of factor quality as per importance

92. Q7b) Rating of factor Innovative Design as per importance

93. Q7c) Rating of factor Safety as per importance

94. Q7d) Rating of factor Pricing as per importance

95. Q7e) Rating of factor functionality as per importance

96. Q8) Comparison of our product with other company’s product

97. Q9) Description of Need for the product offered

98. Q10) Interest level to buy the product from Motherson India

99. CHAPTER –5 FINDINGS AND SUGGESTIONS

100. FINDINGS: It has been the MATE’S Endeavour to constantly add new products in its product line. A new product i.e. plastic fuel tanks been identified. As it involves the life risk, we have to meet all the safety standards. so related finding are: to use those materials which are meeting the standards of safety, design, corrosion, weight, emissions etc. The technological requirements are: extrusion blow molding machine used to manufacture plastic fuel tanks. The cost involved in manufacture of complete fuel tank system assembly is INR 39,098. Which is very less comparable to the manufacturing price what world other players are offering.

101. FINDINGS: INDUSTRY: Plastic fuel tanks, for passenger/light commercial/heavy vehicles , are not very popular in India. However, it is an established and well-accepted concept in developed countries in Western Europe and USA. Considering this, establishing plastic fuel tank manufacturing capacity in India is expected to provide good opportunity in the automobile industry. European market response for our product is positive.

102. Suggestion: MATE can spread awareness about the product to the OEM’s in the country. As Indian automobile industry is growing at a very high pace, it can attract even domestic market also for the same product. Since most of these major OEMs are based in developed countries of Europe and America and are already using plastic fuel tanks in their existing models . They can be the potential target market for MATE. And also the OEM’s outsource the components from India, due to low cost involved, it can be a great opportunity for the company to enter into plastic fuel tanks. It is a very technical component, so we have to have technological expertise. Already riding on the economies of scale, India offers availability of low cost raw material, cheap and high skilled labour. These advantages combine with the existing facilities and product line of MATE makes it good product to invest in.

103. Suggestion: Being a technical and highly précised product, in house development of the product involves high R&D cost. To save on the development cost, it is better to go for a technical agreement or JV with one of the major manufacturer identified. The JV can aim at catering to the huge demand-supply gap. Other Global Safety and Quality standards need to be adhered to. Need to abide with local government regulations on manufacturing similar kinds of product.