The TJCAL edge Products Services Engineering capabilities Customers Promoters and partners Manufacturing facilities Engineering facilities CEO Contact Corporate presentation (pdf 3.56 MB)

Manufacturing facilities
TJCAL uses Johnson Controls' manufacturing systems (JCMS) to deliver products of consistent quality at low costs. Driven by systems that assure quality, such as Six Sigma, Kaizen and continuous improvement, TJCAL's two manufacturing plants at Hinjewadi in Pune, India, and Chennai, India possess a range of facilities such as:

• Highly efficient cut-n-sew operations using a CNC Gerber cutter
• Microprocessor-based German Durkopp Adler sewing machines
• Automatic storage-and-retrieval
• Roll-through racking
• Mechanised seat loading
• Variable-speed conveyors
• Prototyping and trim engineering facility
• Fully equipped quality lab with 3D Faro arms, mannequins, foam hardness tester, profile projector and and composite durability machine
• Just-in-time-sequence (JIT-S) assembly
• Foam plant with robotic foam pouring
• Robotic welding metal plant for the welding of steel frames

All operations of the manufacturing facility are totally integrated through the MfgPro ERP system. The combined production area of Pune and Chennai plants is 7,550 square meter.

Engineering Facilities

As a part of the highly respected Tata Group, TJCAL Engineering is able to attract a team of the brightest Indian engineers. The team comprises specialists in the areas of structural engineering and analysis, design and tooling of plastic components, comfort and safety engineering, trim and aesthetics, product validation and testing, and prototype tooling development.

Access to Tata Johnson Controls' manufacturing division provides its engineers with experience of manufacturing technologies.

TJCAL Engineering's engineering facility uses all the leading design and analysis software to meet varied customer requirements. This includes:

	CAD	IDEAS, CATIA, C3P, PDGS, UG
	CAE	HYPERMESH, MEDINA, LS DYNA, ABAQUS
	PDM	TcAE (iMAN), E-Matrix

Quality systems
In the effort to exceed the expectations of our customers, TJCAL Manufacturing has earned the following certifications:

• ISO/TS16949:2002
• ISO 14001:2004
• OHSAS 18000:1999
• ISO 17025:1999
• Ford MS 9000
• Ford Q1
• Sox

Customer Recognitions

• Best Supplier Award by DaimlerChrysler for 6 years in a row from 1999
• World Excellence Award - Gold by Ford Motor Company in 2004

It has also earned recognition within the industry, having been awarded the following industry awards:

• Manufacturing Excellence Award from ACMA for the years 2003, 2004 and 2005
• CII Exim Commendation Certificate for 'Serious Commitment to Excel' for the years 2004 and 2005
• Merit Certificate for Energy Conservation from Ministry of Power, Government of India

TJC follows the best of Johnson Controls and Tata Group operating systems. It follows the JCI global Business Operating System (BOS) in all its operations and is audited by KPMG every year for compliance to this system.

TJC Manufacturing has also adopted the Tata Business Excellence Model and has been awarded the 'Serious Adoption Award' for the year 2004.

It has an impressive pool of 35 assessors, extensively trained by Tata Quality Management Services (TQMS). In an effort to share knowledge, TJC assessors also help other Tata Group companies in their journey to business excellence.