Implementation of crankshaft manufacturing process in India

Scope

Faircom undertook the planning and implementation of a crankshaft manufacturing process for an Indian contract manufacturer in Pune. The goal was cost-efficient production of crankshafts for final assembly at the Yaroslavl site in Russia.

The project commenced with a comprehensive feasibility study to select the supplier, which Faircom did under direct mandate from Daimler Management. A contract manufacturer was recommended as a production partner based on this analysis. Detailed planning was then undertaken to integrate the manufacturing process, including interfaces, technical requirements and quality specifications.

Faircom was responsible for project management and progress tracking from Yaroslavl during the entire implementation process. Regular reporting to management, including senior management at Mercedes-Benz, ensured transparency throughout all phases.

Project details

Sector: Automotive (combustion engines)/plant and mechanical engineering

Client: Mercedes-Benz Group (Daimler AG at the time)

Location: Yaroslavl, Russia (90 %) / Pune, India (10 %)

Undertaken by: Waldemar Graf, Rolf Thelen

Time period: 2015–2016

As part of an international production strategy, Daimler (Mercedes-Benz) was looking for a reliable, cost-efficient manufacturing partner for crankshafts. The goal was to stop producing all components exclusively in-house for the Russian market and start sourcing parts externally instead. Several suppliers were considered. Faircom was tasked with conducting a feasibility study and providing a recommendation based on technical, logistical and quality criteria.

The primary objective was to select a suitable supplier and subsequently implement the entire manufacturing process within the set time frame and budget while meeting all quality standards and the required production output.

The biggest challenge was integrating the manufacturing process with an Indian supplier in a way that was both cost-effective and met quality standards. Besides technical aspects, intercultural differences and communication channels between India and Russia also played a role. The project also needed to comply with a strict time schedule.

Faircom successfully completed implementation of the crankshaft manufacturing process at the contract manufacturer’s site within the set deadlines and the allocated budget. The process was firmly integrated into the entire supplier chain and complied with all quality requirements imposed by Mercedes-Benz.

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