Showing posts with label 3. Case Studies from TATA group. Show all posts
Showing posts with label 3. Case Studies from TATA group. Show all posts

Titan does wonders for Tata Ceramics

Tata Ceramics Ltd (TCL) was incorporated in 1991 as an associate company of Tata Power. Located in the Kochi SEZ, the company has close to 400 employees and exports most of what it makes. Tata Ceramics Ltd. makes bone china tableware for some of the best brands in the world such as Wedgewood, Royal Doulton and Churchill, however it was unable to scale up. Its large plant of 10 million pieces a year saw only half of it utilised, leading to losses. Nearly 90 per cent of the turnover used to come from European markets, Australia and New Zealand. But that is declining given the general downturn in those markets. As on March 31, 2013, the company’s turnover was Rs. 50 crore and it had accumulated losses of Rs. 14.09 crore.


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Bhaskar Bhat, the MD at Tata group's Titan Company Ltd. was then appointed Chairman of TCL and was entrusted with the task of injecting some vigour to its marketing to revive it. Bhat, who oversaw Titan’s diversification from a watch maker to a jewellery and eyewear retailer, planned to effect a similar transformation in TCL.

With Bhat taking over, the focus will shift to the domestic market. “We are currently testing the market and exploring its potential. TCL’s competence is in manufacturing, so we want to take it a step ahead. Also, tableware in India is largely unorganised. We need to grow the market and make it organised. Many Indian middle-class households are now moving from steel tumblers to crockery,” he explains. Soon, Bhat expects domestic sales to equal export sales. “Exports too are a growing area and the company will continue its thrust while establishing its presence in the domestic markets,” he adds.

Two years after Bhaskar Bhat took over as Chairman of TCL, Nalini Veeraghanta - Marketing Manager, Tata Ceramics, speaks about Titan's intervention in the business.

What is the nature of Titan's engagement with Tata Ceramics? Is it a long-term partnership or just initial support till TCL becomes profitable / breaks even?

Titan's mandate is to turnaround the profitability for Tata Ceramics Ltd.  Titan operating at arms-length in establishing the long and short term objectives of this turn-around while laying the path for a sustainable future.

In the short run, the year-on-year cash flow to turnover is being optimized through streamlining the production range, introduction of new products that are need-gap lead and have immense potential for offtake. Further measures are being taken for improving processes at the manufacturing back end, strengthening the existing HORECA and distributor accounts through well-planned replenishment, improved service standard and identifying new high-worth segments for the existing range of products (for instance, corporate gifting).

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In the long run, leveraging Titan's expertise in new market entry, there is a very strong pitch for a retail-brand to be launched by Titan with Tata Ceramics given latent demand that exists for the category along with the competitive space that exists in India above the high-end glass-based brands like Corelle and below porcelain, ceramics luxury brands like Good Earth, Noritake.

What was the design process? How many people from Titan contributed their expertise to this project?

The design direction evolved from the understanding of the Indian consumer. Given the degree of exposure today's consumer has through travel, TV shows like Master Chef that bring emphasis to plating, ready access to gourmet (fine) dining, changing definition of entertaining guests at home , increased disposable income there is a great appetite for niche categories like dinnerware. The brand was the outcome to cater to this space, with the possibility of category extensions like cutlery, beverage etc.

The language was contemporary, need-gap led forms with designs that are a balance of modern and classical, inspired by global trends. Michael Foley, one of the leading names in product design, has been brought on-board for lending his expertise on the creation of a new range.

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The teams from Titan anchoring the marketing and sales are focused on strengthening the product, pricing, packaging-led execution such a creating fresh designs that appeal to the evolving Indian consumer (e.g. a contemporary, rich peacock design or a peacock themed , cuboid form teapot ) , developing demand-led products to ensure need-gaps are successfully met in the Indian context (e.g. ceramic thali and roti holder ) , launching affordable decor items that are delightful in form and design  for the festive season (e.g. hanging tea light holders).

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Will the products be sold B2B or B2C as well? How will Titan help in distribution?

The nature of the material (fine bone china) and the global standards adhered to by Tata Ceramics, have resulted in a high-quality, high-cost product. While the quality is the leading in the industry it is not appealing for the price-responsive market segment. Moreover, with growing competition and increased ease of procurement of the category from Thailand, China and other Asian manufacturers and with B2B as a market being innately highly price sensitive, the way forward is to enter the B2C play. Therefore the brand strategy, segmentation, pricing, product design will be put in place for the consumer facing brand. While we explore and determine the go-to-market strategy for the B2C launch under the aegis of Titan, we will continue to build, grow and strategically expand the accounts of international retailers, global airline and HORECA.

Another key area that we will be exploring more actively is the gifting segment - especially corporate gifting - which holds tremendous promise and potential but tends to be low price outlay. Titan's experience of the in-house corporate sales teams with corporate clientele , festive gifting behavior from the World of Titan and Tanishq retail will be leveraged to the hilt. Effectively the brand , product and distribution architecture will be designed to build future potential while utilizing existing capabilities.

Titan is helping build the distribution by improving pricing in the B2B market, taking steps to ensure the back end is optimized for.
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Tata Motors Revotron Hologram

The award winning Tata Motors Revotron Hologram is an unconventional merchandise display, that is less display unit and more of an interactive, engaging experience. To enhance customer delight, the hologram is supported by an Augmented Reality App and offers a Virtual Photo Op with Narain Karthikeyan and players from the RCB team.

Badal Suchak, the head of Visual Merchandising at Tata Motors describes his experience of creating the hologram that was used for Zest and Bolt.

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What is Revotron technology? What was the thought behind displaying this new engine technology before the car launch?
The Revotron series is Tata Motors brand of Petrol Engines. The Revotron 1.2 T is the first in the series and India’s first Turbocharged Petrol Engine. Revotron 1.2T, has been developed in conjunction with global consultancies and suppliers to deliver world-class performance in terms of power, torque and efficiency.

It is three engines rolled into one - its multi-drive mode enables switching between three different modes - SPORT, ECO and CITY. The Revotron has helped Zest, our compact sedan launched in August, set a benchmark in fuel efficiency due to an innovative Smart ECU (Electronic Control Unit) that ensures a superlative performance on Indian roads.

The SPORT Mode gives the sharpest throttle response and quickest acceleration from the Zest. All 140Nm of torque from the Revotron engine is available to give a more dynamic drive enabling the driver to exploit the full acceleration and driveability of the Zest. In the ECO Mode, performance and throttle response is reduced to maximize fuel economy but with comfortable drivability. It is ideal for Highway cruising. In the City Mode the Zest has the perfect balance between performance and economy. Power delivery is smooth and throttle response is linear leading to agile drivability to easily navigate city traffic conditions.

While Tata Motors has always been known for its diesel engines, it was the petrol segment that we did not have a major presence in. Going forward the company wants to be fuel agnostic and have a balanced portfolio. The Revotron is a step in that direction.

What were the challenges faced while executing the displays at the showrooms ?
The main challenge was to conceptualize an engaging VM display for an engine that was yet to be launched. There are many segment first features that the engine comes with. The challenge at hand was to engage with customers in an effective and engaging manner and not make it very technical for him/ her to understand. Although we are not in the business of selling engines, the engine, nevertheless, is the most important part of a car, which was not launched. So, the primary challenge was to showcase an engine for cars that had not reached the showroom yet. Therefore we came up with the idea of showcasing it virtually through hologram.

Even if the actual engine was to be displayed, it would have been almost impossible to display the engineering inside it in detail. It was a challenge to draw customer attention and engage them with subtle nuances of the engine and convince them about the next-gen technology used in it. The computer generated animation we created especially for the hologram helped us showcase the features of Revotron much more effectively and in greater detail.

Finally executing the Hologram at the showrooms was also a challenge as it was sent flat packed in a dismantled condition to 75 showrooms across India. Teams were sent out to each of these showrooms to assemble them. We now even control the content to be played in the hologram centrally.

Badal Suchak receiving an award for the design of the Revotron Hologram

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Describe the Revotron Hologram. Presently how many showrooms have the hologram?
The futuristic technology form of the hologram attracts attention of customers in the showroom, with stunning body graphics and bold branding. What immediately draws attention of customers is a virtual revolving engine displaying top five features sequentially over it. As the customer comes closer to the hologram, hidden proximity sensor in the hologram body senses it and our brand ambassador, Formula One racer, Narain Karthikeyan appears in the hologram next to the engine. He explains the technical aspects of the engine in a simple manner pointing out consumer benefits of each aspect. Finally he invites the customer to experience the Revotron engine in soon to be launched car Zest.

Presently 75 showrooms pan India have the hologram on display.

Do you have a technical team or have you collaborated with any company for the technical and app development?
We have collaborated with Xdlab for the technology and app development.

Tell us about the Augmented Reality app placed in the showrooms.
Beyond the key showrooms where we have placed the hologram, there are 200 other showrooms where we have the Augmented Reality App Display Unit. It is a low cost version to display the same content as in the hologram. Since it is Augmented Reality, the customer uses her own smart phone to see the AV content of Revotron. On the display unit we have a cutout of the Revotron engine. Customer is invited to scan this cutout with the Revotron App downloaded from Playstore. The Revotron App recognizes this cutout and plays the same content as the hologram. The interesting aspect of this AR app is that it works on various other platforms as well, wherever the Revotron engine image is present. We have used it on various collaterals like leaflets, standees, banners etc. to give a unique engaging experience to our customers.

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The floor mats, one checkered and the other plain, are seen at the Tata Motor showrooms. What is the idea behind this design?
This is a fun app that we have developed to engage customers. The App recognizes this checkered mat and a life size virtual image of our brand ambassador, Narain Karthikeyan appears over it. Customers are invited to stand next to the virtual Narain Karthikeyan and click photographs. They can upload these photos on social networking sites with #Revotron which gives them a delight factor as they get a virtual photo-op with a celebrity.

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How do you assess the responses from clients?
We have had over 1000 downloads of Revotron App as seen on Playstore. We have also made it mandatory for our customer advisors to show the App and the Hologram to every customer in the showroom and this is being tracked with a weekly audit system.

Tell us about the VM for the car launch. Do you plan to use this hologram and augmented reality app in the future?
We had magnetic feature highlighters and lifestyle imagery backdrop for the car in the showroom once the Zest was launched. To make the most of our investment in the Hologram and AR App, after having used it for Revotron launch, we re-branded the same elements and used it for the launch of our compact sedan Zest. The AV content was changed to showcase 29 key features of Zest concluding with an invitation to customers for a test drive.
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Tata Motors Revotron Engine

Tata Motors introduced a new range of turbocharged, fuel-injected engines in India christened the ‘Revotron’, the first of its kind to be indigenously developed in India. The new Tata Zest is the first car to get an all-new 1.2-litre four-cylinder, turbocharged, intercooled, MPFI equipped petrol Revotron engine. In its current state of tune, the motor produces 85PS of peak power and 140Nm of peak torque.

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The Revotron engine has been developed in association with international experts like AVL, the Austrian global engine consultant, along with key engine and component developers like Bosch and Honeywell. The new 1.2-litre Revotron engine has been designed to restrict noise and vibration levels and is compatible with various fuel options including CNG and LPG. It’s turbocharger features advanced technology like a water cooling system working in tandem with the intercooler. Moreover, a built-in catalytic converter reduces toxic emissions, minimising the harm caused to the environment.

Another interesting feature of the Revotron is its multiple drive options which will allow the driver to select between pre-set engine management maps – varying from Sport, Eco to City driving modes. But this is only the beginning, as Tata Motors is set to unleash a whole new range of Revotron engines in the coming years.

There were plenty of interesting technologies introduced in the Indian automobile segment in 2014. But it was the the newly developed Tata Motors Revotron petrol engine which pipped competition to win the Technology of the Year Award.

2014 ET ZigWheels Award: Technology of the Year Tata Zest for Revotron

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Girish Wagh, Senior VP Programme, Planning and Product Management, Tata Motors accepting the Technology of the Year award for the Revotron engine.

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The Revotron Series has been developed with inputs from global players in the areas of combustion, boosting, friction and calibration. Tata Motors worked with AVL (Austria) and key technology partners like Bosch, Honeywell, Mahle and INA to bring in technology. According to the company, the engine series has been tested for global standards along with a testing car by TEnergy of Korea to ensure that the engine performance is best-in-class. The Revotron series will include three- and four-cylinder petrol engines aimed at offering superior performance and high fuel efficiency.

The engine itself is lightweight and powerful, with a stiffened crankcase that minimises NVH. It has been refined with a tuned intake and exhaust system for improved combustion; NVH has been reduced with the use of a silent-steel oil pan and lower auxiliary system noise. Enhanced with an ECU for precise control, the engine is powered by wire technology for a smooth drive experience. An optimised water jacket and head gasket, using computational fluid dynamics (CFD) technology, ensure efficient combustion and reduce thermal inertia. In addition, the engine has been incorporated with an eight-hole fuel injector for superior efficiency and assisted by innovative calibration strategies.

The Revotron series was designed based on feedback from car owners, car enthusiasts and expert drivers from across the globe, observing their driving habits followed by extensive testing in gruelling climatic conditions in India as well as in countries like the UK and Korea. With enhanced customer benefits, Tata has positioned the Revotron series as a blend of performance, refinement and economy.

via: www.zigwheels.com, www.indiatoday.in
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TATA Projects + Cairn India = water ATMs

Tata Projects Limited (SBU - Oil, Gas & Hydrocarbon) in partnership with Cairn India has provided the Engineering, Procurement and Construction of Well Pad Development Works at Barmer in Rajasthan, to bring about a revolution in access to drinking water in the state.

Thanks to water ATMs, many otherwise arid villages here have 24X7 access to the commodity at the swipe of a card - at 20 litres for Rs.5.

Under Cairn India's "Jeevan Amrit Project", kiosks with reverse osmosis (RO) plants have been installed to provide safe drinking water in villages like Bhakharpur, Kawas, Guda, Jogasar, Aakdada and Baytu to benefit 22,000 people.

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"The project is a good example of a PPP model ( Public-Private Partnership), where Cairn India has partnered with the Rajasthan government's Public Health Engineering Department (PHED), Tata Projects and the respective village panchayats to provide potable drinking water at the doorsteps of the local community," says Cairn India CSR head Nilesh Jain.

Rajasthan is one of the driest states of the country. Rainfall is erratic and there is a large variation in its distribution pattern in the state. The average annual rainfall ranges from 100 mm in Jaisalmer to 800 mm in Jhalawar.

At present, 22 RO plants (17 with the swipe facility) catering to drinking water needs of 22,000 villagers on a daily basis are up and running. The project is expected to scale up in the coming years in terms of number of plants and locations. Through this technology, villagers can now get clean drinking water by swiping their smart cards in the machines installed at the plant," says Cairn India general manager (CSR) Ritu Jhingon.

The cards come with an initial value of Rs 150 and can be recharged for a similar amount. Plans are afoot to also provide Rs 20 recharges. This makes the dispensers self-sustaining, with the revenue earned used by the village's water committee to meet the running expenses of the RO plant, such as salary of the operator, electricity and maintenance. The surplus money is used to undertake developmental work in the village.

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It is said that since it has been launched, water-borne diseases have come down and change has been observed in the social behaviours of the villagers – where women usually carry the task of fetching water, men are now happily involved. The number of water-borne diseases, such as diarrhea in children, has come down. Cases of joint pain caused by high fluoride content in drinking water have also decreased.

Cairn India funds the cost of the RO plants, which are delivered and installed by Tata Projects, PHED provides the premises and the source water connection and a 15-member village water committee, formed under the panchayat, is responsible for operation and maintenance of the kiosks. Dhara, the local NGO partner for this project, spreads awareness about safe drinking water among locals and hand-holds the water committee for better success.

Apart from providing an innovative solution to a grave problem, these water kiosks have also proved to be a model of good self-governance. The water committees have created an identity for themselves and are looked upon as an effective social group in the villages. Along with efficiently running the RO plants, the committees are also undertaking many developmental projects.
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Project Meadow - Titan Company

Empowering rural women - "Project Meadow"
By : Muruganandam Basuvaiyan
Company : Titan
Location : Hosur
Valuable contributors : Naihad Mohan, Sathiyaseelan S, G Rajendran, Elangovan A

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Project Meadow is one of the key projects being driven at Titan Jewellery Division which aims at ensuring better livelihood through engagement of rural women with jewellery industry by endowing them with necessary support to function as a self help group.
Meadow aims at ensuring livelihood of rural women by imparting education and jewellery making skill, making them self-sufficient to take care of their family. Uneducated young women, widows and mothers from Krishnagiri district are the prime focus group for this project owing to the close proximity to Titan's existing manufacturing setup. After counselling the families these women were brought to Hosur and provided required infrastructure. These women were trained for 2 years in the skill of all aspects of jewellery manufacturing like Stone sorting and bagging, waxing, benchwork, stone setting and polishing by skilled karigars. Allowing them to compete with the best vendors in India, the Best Vendor award bagged by Meadow is testament to this fact. They have formed a self-help group and themselves function as owners of the company, taking responsibility for profit sharing and recruitment of new members. Two-hundred families from rural Tamil Nadu are benefiting from this initiative.

 

Inauguration of the new Production Unitmeadow03meadow06

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C.K.Venkatraman addressing the Project Meadow employeesmeadow02

Mr. G.Rajendran, Head of Manufacturing & Mr. Elangovan with the TBEM team meadow04

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How it all started
Titan started its manufacturing setup in a small village bordering Karnataka, with the help of the Tamil Nadu government. Women in rural India are continuously plagued by social stigmas like female foeticide, limited access to education and poor social standing. The situation in Hosur, Krishnagiri, was no better. Traditionally, women in these villages worked as daily wage workers earning a mere INR 700 per month with minimal say in the day-to-day activities of their families. The traditional and social mores never let them improve their consciousness, self confidence, and their situation remained pitiful. Child marriages, female foeticides, lack of education - all contributed to their woes.

Incidentally, taking a look into Titan's business; traditionally, jewellery has been manufactured by karigars with a family lineage in jewellery manufacturing. The lack of skilled karigars has been a persistent problem in jewellery manufacturing. Karigar attrition had resulted in huge loss for the company, and Titan was looking for alternatives. Thus, ideas started propping up that resulted in mutual benefit. The Meadow project aims at transferring jewellery-making skills and knowledge to underprivileged women and training them in the same, allowing them to become self-sufficient, gain confidence and progress in their personal life.

Building trust
The success story of Meadow was not written in a few days. It was built block by block, step by step and today has become a livelihood for hundreds of families in Krishnagiri district. But the job was no less demanding.

The project is primarily focussed at widows, single mothers and uneducated women with no support from the community. As a first step, help was taken from an NGO named 'Myrada' to identify the women who were worst affected, like widows and school dropouts. These women were the only bread earners for their family. They were confined to their homes, not being allowed to go out and look for opportunities to progress. They used to work in fields or in other households to make a living. They have not been used to work in an organised way and hesitated to go out of their villages. Titan along with Myrada volunteers went to their villages and counselled the family members and relatives of these women, took them to the Titan factory and explained the working atmosphere. An assurance was given for taking care of all the initial expenses and stay and a commitment was made to change their lifestyle.

But there were bigger challenges ahead. Since these women were from remote villages, they had little knowledge of jewellery manufacturing, and it was very difficult to train them. Understanding the job, knowledge of hand-skill and language were also barriers to training. Training involved a phased strategy involving specialised karigars being placed at Meadow for a full year, taking them through extensive training in all aspects of manufacturing. A new trainer was recruited and placed in Meadow itself. They started from the basic filling exercise and slowly imparted the technical training - starting from low cost 9kt jewellery, then to 14kt jewellery with low-cost stones and finally to 18kt jewellery with diamonds as they got confidence on working with expensive and delicate materials. And today, these once-uneducated women do all the jewellery operations from waxing to total jewellery manufacturing. They have now reached a level where their products can match up to the quality of any other core vendor. The Best Vendor award being bagged by Meadow is testament to this fact.

Results
Today Titan stands with the pride and honour of having helped women who were once sidelined by society to rediscover their lost self-confidence and imbue courage. Started with just four women, Meadow has grown to reach over 200 strong-willed women. 200 families have increased their monthly income from INR 15 per day to INR 7,000 per month. Today they work as a self-help group, in an organisation of their own called Meadow, which is run by the women themselves, and they make decisions related to their organisation, including profit sharing and further investment, themselves. The structure followed is eight board director members, four operation managers, and employees. Currently, 200 women are working at Meadow, performing all activities of jewellery manufacturing, such as waxing, wax setting, stone sorting and bagging, bench work, stone setting and polishing, along with all the systemised activities such as inwarding and dispatch. A production load is given to them, and upon completion of production and quality checks, the corresponding payment is given to the organisation, thus ensuring a regular stream of income to them. They are also ensuring conformity to all government norms and statutory requirements. This has allowed the women to contribute majorly to the upliftment of their community and village, provide good living conditions for their family and good education to their children.

Additionally, Titan Jewellery Division organises regular programmes for the benefit of the women employees, such as free medical camps, eye-check up camps and family gatherings. Hindi and English classes are organised for the women to improve their language skills and effectiveness in communication.

Titan believes in the virtue of serving society. As of November 2012, production worth INR 213 crore was completed through the Meadow team, which has resulted in a cost saving of INR 400 lakh. The forecast for 2015 showed overwhelming results of more than INR 900 lakh. Gold loss has been reduced from 3 percent to 2 percent, generating even more revenue. To add to this, Meadow is complying with all environmental and statutory norms. They do not use any hazardous chemicals in their process, and the disposal of waste is done in a controlled and environmentally friendly manner and by 2015, the benefits are to extend to 500 families in the district.

The journey doesn't end here. There is always a better way to do it. Continuous improvement has always been Titan's motto. Studies have already begun on how this model can be expanded to other karigarparks. Another major step is to equip Meadow with renewable energy, increasing dependence on solar and wind energy.
Mr Rahul Gandhi visited Meadow and spent two days interacting with the women and understanding the business model.

Succinctly, project Meadow has helped women to come out of the fields and to master the art of jewellery-making to produce world-class jewellery. The experiences of Meadow have proved that the philanthropic aspirations of a company or an institution can be achieved throughout the operations rather than just through donations. Meadow has not only transformed the lives of hundreds of people in Krishnagiri, but also the way corporates look at community service. Success depends on longer commitment of resources to help build lasting relationships. At the end of the day, one reaps what one sows.
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India’s 1st- 5 Axle Truck, TATA Motors

Project name : Game Changer- India’s 1st- 5 Axle Truck- LPT3723
By : Amit Gupta
Company : Tata Motors
Location : Indian market
Valuable contributors : SK Agarwal, Dr AK Jindal

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"The LPT 3723-10X4 vehicle was envisaged by Tata Motors as a market need to develop a new multi-axle rigid truck to provide the best operating economics and reduced payback period by creating a new platform in between the existing 31-tonne truck and 40/49 tonne tractor trailer segment. This is win-win situation for business and customer as revenue for both increases with this invention," says Amit Gupta

Turning the tide
Sixteen tonne (2 axle) and 25 tonne (3 axle) gross vehicle weight (GVW) vehicles were ruling the road. In 2007, the rated load regime was partially implemented in the country, and at the same time 31 tonne (4 axle) vehicles were launched in the country. Industry volumes of 31 tonne vehicles grew from negligible in 2007 to the highest in M& HCV category 2011. Hence, the 31 tonne truck has become the market leader over time, which triggered the innovation of even higher GVW vehicle on the rigid truck platform. While working out the operating economics, the 37 tonne (5 axle) truck showed the best operating economics. The rated load regime, which came into force recently, has increased the viability of the innovation in market.

In view of operating economics, two factors are most important in the Indian context i.e. fuel economy and tyre mileage. For tyre mileage, the number of tyres per ton of GVW/GCW should be least and it is the least for 37 Tonne - 5 Axle vehicle as 25T, 31T and 37T use 10, 12 and 14 tyres respectively. 40T and 49T tractors use 18 and 22 tyres respectively. Hence 37T- 5 Axle vehicle gives best tyre mileage. Although tyre life for the individual vehicle also plays an important role, which can be maximized by better design of steering system, these parameters are considered while vehicle design to yield best tyre life for each axle.

For fuel economy, fuel consumed per tonne of payload per km of running is the most important factor. By this factor, many fleet operators decide the freight charges. If the vehicle is loaded in onward and return journey then 31T -Rigid, 37T-Rigid and 40T-tractor trailer will yield more revenue by 40 percent, 70 percent and 50 percent respectively over 25T rigid vehicle. This shows that 37T is the best combination. Over and above this, the figures will be better for any vehicle with lift axle (e.g 3723) if vehicle is empty in return condition because of lift axle.

Key differentiators
Differentiators of TML 3723 rigid truck vis-a-vis internationally available 5 axle truck are numerous. The self-steered tag lift axle, which is unique globally, provides best manoeuvrability including turning circle diameter to any load and freedom of customisation. The balanced front tandem suspension provides better performance even with improperly distributed load, a better ride, and increased life of aggregates. The tag lift axle, suitable to Ackermann's geometry, is also unique in that it provides best tyre life, which in turn increases revenue of the operator.

Economic benefit
Since the market scenario is unfavourable to commercial vehicles, it will take some time for maturation of this product however project is envisaged as market leader in due course.

For a green world
As the product is designed to be best-in-class, it will consume less natural resources in terms of diesel and ultimately lead to less carbon emission. Reduced rubber consumption in view of higher tyre mileage will also help the environment.
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Building Blocks, TRL Krosaki Refactories

Project name : Light Weight Silica Brick from Recycled Material
By : Dr Raghunath Prasad Rana
Company : TRL Krosaki Refractories (Tata Refractories Ltd)
Location : Belapahar
Valuable contributors : Atanusuvrajit Bal, Biswajit Ghosh, Subrat Kumar Sahoo and Prosenjit Das

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When confronted with the problem of shrinking raw material sources owing to mining restrictions, TRL Krosaki Refractories decided to look within for a sustainable solution. Transforming this challenge into an opportunity to deal with another mounting problem-solid waste generated during the production of silica bricks-the company developed a revolutionary new process that would generate saleable bricks from this waste.

A major producer of basic and high alumina silica specialities, TRL Krosaki Refractories has its operations in Orissa, Gujarat, Jamshedpur and Salem in India, and in China. The company is also the only commercial manufacturer of dolomite refractories in India and caters to a large and diverse global customer base. TRL Krosaki Refractories recently found itself up against the challenge of managing solid wastes generated as a result of the silica brick production process. The waste had to be disposed of properly, adding to the production costs of silica bricks, which, in turn, meant higher market prices for customers, further adding to the company's woes.

Besides, the company was also simultaneously battling the growing problem of quartzite raw material shortages, due to mining restrictions levied by the government at various mines.

Looking within
When researching ways and means to find some productive use for solid wastes, the TRL Krosaki team, led by Dr Raghunath Prasad Rana, chanced upon a remarkable discovery. They found that a given silica polymorph could be transformed into another by way of reconstructive transformation, under the proper conditions.
Accompanied by Atanusuvrajit Bal, Biswajit Ghosh, Subrat Kumar Sahoo and Prosenjit Das, Dr Rana found that during firing, quartzite changes into tridymite at the temperature of 870 degrees C. This tridymite is further converted into cristobalite at 1,470 degrees C. The transformation kinetics for each of these reactions is governed by various factors such as silica crystal size, impurities and the quartzite source. For instance, large crystal sizes for silica and a smaller content of impurities slow down the transformation of silica. Besides, the amount of residual quartz must be low enough to avoid expansion during application.
The team worked on optimising the firing cycle, so as to avoid cracking during firing, and thereby achieving a homogeneous residual quartz level. During the production of silica bricks, close to 30 percent of the wastage is caused due to lack of necessary properties, causing the material to break and crack during the firing cycle. The rejected material had a bulk density that was lower than that of quartzite, along with lower density and low amount of residual quartz. These qualities made the waste material especially useful for production of lightweight bricks. The team then got to work, optimising the maximum amount of rejected material to 75 percent. This rejected material was combined with 25 percent fresh raw material, and blended together with the binder and pore former in the Eirich Mixer.

The moulded bricks, thus formed, are air-dried and then, later, oven-dried at a temperature of 150-200 degrees C to avoid cracking during the firing cycle. These lightweight bricks are then stacked in a single layer above the dense bricks, so as to avoid gravity loading, which may cause crack ignition and black core formation upon surface contact.

The lightweight bricks, so manufactured, satisfy customers' expectations, while also serving as an additional source of income for the company. Besides, by sidestepping expensive storage, logistics and disposal cost, TRL Krosaki Refractories was able to accrue valuable cost savings, which it passed on to its customers in the form of lower market prices.

Building the pathway to success
Developing this process was no mean feat for Dr Rana and his team, who ran into numerous roadblocks before they could come up with a perfectly functional solution.
For one, during trials, the waste material could not be mixed with the other additives due to variations in density. Further, the resultant improper mixing could lead to variations in the bricks' properties and texture. The team set about developing an inclined mixer with a high-speed rotor to overcome this problem, thereby enabling better homogeneity and distribution of both types of materials.

The low density of the waste materials meant that a higher amount of water had to be used to improve workability of the mix. This was a problem because the use of more water lowers the bricks' surface smoothness and green strength. Lower green strength implies that the bricks are more prone to breaking during processing, and can also crack during the later stages of drying due to the water vapour that escapes from the surface. These issues were overcome by streamlining the type and amount of binder used during the process.
Lastly, the traditional brick-setting pattern in the kiln was contributing to improper heat transfer and, consequently, under-fired bricks. To resolve the same, quartzite sand was added to the surface of each brick, so that the heat can easily be transferred to the bottom surface, eliminating the formation of black core. Also, the packaging of the quartzite grains and granulometry were optimised to reduce the black core and firing irregularities inside the bricks. In spite of all attempts was taken to avoid black core and lamination inside the brick but this problem was continued till July-2012 and during that time; it became a threat to receive any order from customer on this product. There was only one alternative not to do any production of such bricks. The root cause of this problem was investigated and found the binder creates such type of defects inside the brick. During drying of the bricks, the outer surface gets hardened and entraps the core moisture which on heating at high temperature forms lamination and forms reducing atmosphere to form black core. By replacement of suitable alternative binder with optimum amount was able to sort out the issues. The productivity of this type of brick has increased by using Sacmi Press and two layers of setting pattern during firing in the Tunnel Kiln. There is no more delivery failure of this kind of product after successfully improvement of this product.

Reaping rewards
TRL Krosaki's experiment with creating wealth from wastes generated rich rewards once the process was rolled out. To date, the company has saved a significant amount of money since the problem's being solved in the last financial year.
Minimising the amount of solid wastes generated from the manufacturing process helped the company to both reduce its expenditure on storing, handling and disposing the waste, while also reducing its carbon footprint. Most importantly, the company's innovative thinking has helped it to transform a challenge into an opportunity to serve its customers better, by giving them an additional, high-quality product that they can count and rely on.
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Keep the Flame Burning, TATA Power

Project name : LDO Optimization Through Orifice Valve & Atomizer
By : Atif Eqbal
Company : Tata Power
Location : Tata Power, Jojobera, Jamshedpur
Valuable contributors : Sarthak Patnaik, Ananta Behera, Usha Agrawal, Jaigopal Soni

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"This innovation at Tata Power pertains to the optimisation of light diesel oil consumption through the application of the orifice valve and modified nozzle tip in the oil guns of steam generators," says Atif Eqbal
Oil guns using light diesel oil (LDO) are used in coal-fired boilers for initiating combustion in the boiler and are then taken over by pulverised coal for creating a stable fire ball. Oil guns are often used during monsoon for coal mill blockage, breakdowns and other emergency situations for supporting the fire ball to make the unit stable and give uninterrupted power supply to the customers.

The trigger
The trigger for this innovation came as a remark (for higher oil consumption in boiler) from a customer. Also LDO being a very costly raw material for the division and one of the most vital natural resources of the nation inspired the team to innovate the orifice valve and modified nozzle tip. This zeal to give a better performance to its customers made the team go back to the grassroots level to have better understanding of the fuel-firing system inside the boiler. After opening of LONV in the oil line, a considerable quantity of oil flowed through the pipe to the oil gun which, in turn, got atomised and created combustion inside the boiler. But in the process, a high quantity of LDO was consumed, which was to be borne by the customers.

Ideation and improvement
The Sankalp (ideation and improvement) team of Tata Power, Jojobera, during their project "optimisation of LDO" innovated the orifice valve and modified nozzle tip to be fitted in the oil gun for regulating LDO flow with better flame Intensity. It resulted in a total reduction of 73 percent of LDO consumption and an annualised saving of INR 14.3 crore / year. This innovation resulted in cost-effective generation of power supply. It would further result in preserving the nation's natural resources and decrease the company's carbon footprint.

More for less
Previously, the flame intensity obtained was 60 percent. After installation of innovations, the consumption through 1 oil gun decreased. Now the flame intensity obtained is 70 percent. The design and application of orifice valve in 120MW boiler is a unique innovation for regulating the flow of LDO. The innovation improved the performance and controlled extra cost levied upon customers. It would preserve India's vital raw materials and in the process reduce the emission of greenhouse gases.

Economic benefit
The quantum of economic benefit realized from the innovation till the time of writing this article was INR 4 crore.
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Trophy Design for Medici Hall of Fame

The Medici Group headquartered in New York, is a new type of strategy consulting firm that emphasizes execution as the best strategy. The CEO of The Medici Group, Frans Johansson, has authored two books THE MEDICI EFFECT, an international bestseller on how diversity drives innovation, and THE CLICK MOMENT, his bold new book on how to harness unpredictability to stand apart.

In The Medici Effect, author Frans Johansson explores one simple yet profound insight about innovation: in the intersection of different fields, disciplines and cultures, there’s an abundance of extraordinary new ideas to be explored. Putting together ideas from different areas — ideas that were always seen as completely apart — can easily generate an explosion of new ideas. And since the best way to have great ideas is to have lots of ideas, the best chances for innovation are at those intersections.

The Medici Group has an annual event, known as the Medici Innovation Hall of Fame. The Medici Innovation Hall of Fame recognises and honors the most innovative organizations that have created a wonderful environment for innovation. You don’t have to be an Apple or a Nike to make it to the “Medici Hall of Fame” for Innovation. It’s not about one breakthrough products or services. It is about great processes that encourage employees to experiment and make mistakes! It is about having innovation as a strategic priority, managing business with a portfolio of ideas and having a culture which propagates innovation.

This year, The Medici Institute along with Harvard Business Review, Titan and MYRA School of Business, conducted the maiden award function in January 2013 at Hotel Trident, Mumbai during the mega event "Reverse Innovation Meets Medici Effect".

Titan's contribution to the event was the design and creation of the trophy, which would be awarded to ten Indian organization that have created wonderful environment for innovation.

This is the story about how the trophy was conceived and developed at the Titan Design Studio, driven by Ritika Gandhi with a team of craftsmen; with Soundarajan and Rohith K. assisting her in execution of the trophy.


The fundamentals of Medici Effect is all about using diversity which we have in abundance in India and then take that to create solutions. So getting people to this "intersention" of ideas, culture, ethnicity, religion etc is crucial for innovation. As a country rich in heritage and culture, India provides a multitude of opportunities to explore various craft skills that have evolved in various cultures over many years. The craftsmen derive their inspiration, innate wisdom and skills not from books, but from nature. Crafts reflect the immense creativity of ordinary people and their quest for self-expression and fulfillment.

Ritika says, "As of now, most of the trophies are made using acrylic, crystal and other such industrial materials, with the machining route. Breaking away from these materials and processes to using rich handcrafted techniques in making a contemporary trophy provides it uniqueness.

The trophy signifies The Medici Effect not just through its form but also through the process with which it is made."

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The form of the trophy is inspired by intersections. The elements of varying heights are symbolic of diversity. When seen from the top, the intersection between these elements creates a pure form of circle, thus signifying how coming together of diverse elements can bring about true innovation.

The elements are made using the Bidri craft of Hyderabad, which is more than 4000 years old. Bidriware is manufactures from an alloy of copper and zinc by casting. the zinc content gives the alloy a deep black colour. The craftsmen use small chisels to engrave the design over the freehand etching. Fine wire or flattened strips of pure silver are then carefully hammered into these grooves. For the final blackening process, a special variety of soil which is only available in the unlit areas of the Bidar Fort is used. The finished product appears black with brilliant silver inlay.

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The craft route not only provides uniqueness but also provides a very apt route since trophies are made in limited numbers. It also turns out to be more economical than CNC route in the long run.

With Titan, if the entire Tata group were to use handcrafted trophies and hence other groups were to follow, the corporate world would have revolutionized the craft sector in a big way!

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Skeletal EDGE - Red Dot Award

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Titan Edge from Titan Industries Limited has bagged the Best product design of the year – Watches and Jewellery at the 2013 Red Dot Design Awards for 2013. The Red Dot Design Award is an international product design prize awarded by the Design Zentrum Nordrhein Westfalen in Essen, Germany and receives more than 11,000 submissions from 61 countries.

Mahendra Chauhan, Design Manager, Titan Industries Limited, has been awarded the coveted trophy of “Best product design of the year- Watches and Jewellery”for the Skeletal EDGE that he conceptualized along with the Titan team. This year, 1,865 manufacturers, designers and architects from 54 countries were hoping to receive the coveted red dot quality seal with their products and projects. The accolade of the red dot design award, the “red dot”, is an internationally recognised quality label for excellent design.

When the Titan Edge was launched back in 2002 , it was the first time ever that an Indian watch company pushed the boundaries to design and manufacture indigenously the slimmest watch, thereby gaining an entry into the Guinness Book of World Records.
Ten years later, the new generation Edge 2012, is lighter than ever before at 36 grams, by using a skeletal structure encased in titanium- a new age material used in aircraft and spacecraft.
The new EDGE is the slimmest and lightest watch in the universe.
Its form and proportions are very contemporary. The watches have sapphire crested top and bottom, unique construction houses 1.15mm movement between 2 layers of sapphire which reduces overall thickness of watch to 4mm only.
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Tanishq Mia (2011)

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In November 2011, Tanishq announced the launch of its first ever co-creation activity ‘My Expression’. The activity was an open-for-all contest aimed to identify and reward the best creative minds across the country. Interested participants were required to submit an idea for Mia – the new Working Women’s line and the top 10 finalists had a chance to win Rs1,00,000 each. The selected idea was used in the next collection for Mia. Points were awarded for originality and innovativeness of the idea, degree of detail in idea submission, the fit with the brand and ease of manufacturability. Once the ideas were collected, public voted for their favourite ideas through an online poll system, and the top ideas made it to the Jury Selection round, at the end of which the top 10 won the cash prize of Rs1,00,000 each. A 3-member jury comprising eminent personalities including Revathi Kant, GM – Design, Innovation and Development, Tanishq, Anaita Shroff Adajania, Fashion Director, Vogue India and Shimul Mehta Vyas, Mentor, Textile Apparel and Accessory Design, National Institute of Design (NID) evaluated the designs and ideas to shortlist top 10 winners. Announcing the launch, Mr. Sandeep Kulhalli, Vice President, retail and marketing, Tanishq, said, “My Expression is the first of its kind initiative in the Indian jewellery industry. We are excited about the contest as it is interactive platform to engage with our customers and fans.” He further added, “Through this engagement, we can also secure useful insights on Tanishq’s jewellery collection, alongside find intelligent, creative and smart young designers with great ideas. We look forward to active participation and indulgence from our fans and help make co-creation a success.”

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Stones in Wax Casting (2006)

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The Mould setting idea was invented by the Jewellery manufacturing team to increase productivity & quality and as well as reduce the lead time & Manufacturing cost.

Traditionally, jewellery manufacturing consists of two stages i.e Upstream and Downstream stages with the upstream is done through “Investment Casting route” and the Downstream consists of manual Processes. The upstream processes are mostly done through machines while the three downstream processes; Bench Working, Stone setting and Polishing are manual operations. The complexity of stone setting is higher than the other two operations and hence is the bottleneck operation for jewellery manufacturing. Developing this skill needs high level of training for a minimum of 1 year training and 1 year hands-on-experience. The capacity of the plant is restricted by the capacity of stone setting.

This innovation of mould setting was conceived in-house and was taken up for trials using internal resources without any external technical inputs. Through this process, the manual stone setting is eliminated and the stones are set in the rubber mould in the upstream stage itself. This de-skills the setting process and any person can do the setting with very little inputs and there is no specialized skill required for this purpose. By this, the bottleneck is eliminated and the capacity of the plant could be enhanced to the tune of 163% directly without any additional resource.
This has also resulted in reduction in employee fatigue and increased the employee motivation levels.

Mould setting process :
1. Instead of Silver master, Mould will be cut with finished proto product (with stones)
2. Stones will be kept in the rubber mould itself instead of setting in the Gold metal
3. Wax pieces will be moved to Casting after Tree making
4. After Casting, the semi finished products will be finished and polished.

The following problems were identified in Conventional process :
1. Downstream activity requires high skill – Manual Intervention
2. Stone setting requires the highest skill, and is a bottle neck operation in the flow
3. Capacity is restricted
4. Longer lead time
5. Variation in quality levels
6. Low employee morale due to monotonous / high skill job

Advantages of the Mould setting :
1. Stone setting process de-skilled by this invention.
2. No capacity constraint
3. Lead time reduced from four weeks to three weeks
4. Laymen can do this job where in the conventional process, high skilled technician required
5. Quality of the product will be increased when compared to the manual stone setting
6. Less Manufacturing cost
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Virtual Stone Setting (2007)

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Conventional prototype making process
In the convention proto making process, the design will be made in CAD (Computer Aided Design). CAD input file will be given to CAM (Computer Aided Machine) where we get the Resin master which is replica of the original design.
Resin master will be converted as a Silver master through investment casting process. Then the Rubber mould will be cut using the Silver master. We can take “n” number of wax pieces using the Rubber mould. A wax tree will be made using the wax pieces. The wax tree will be converted to Gold tree through investment casting process. The separated cast pieces will be moved to Downstream department where we get the final jewellery product. Diamonds will be set manually. The stone setting operation is the most critical and complex process in the jewellery manufacturing . This 100% manual depended process is taking 65% of the production lead time. After setting the stones in the product, polishing will be done and now the final product is ready.

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Rapid prototype making process
In the innovative proto making process is deskilling the complex operation, ie. Stone setting through placing the virtual stones in the CAD stage itself instead of setting the stones in metal. CAD input file will be given to CAM (Computer Aided Machine) where we get the Resin master which is replica of the original design.
Rubber mould will be cut using the Resin master and the implication of the stones will be formed in the Rubber. Stones will be placed in the Rubber mould itself, where the exact cavity is available. We get the wax pieces with stones placed. A wax tree will be made using these wax pieces. The wax tree will be converted to Gold tree through investment casting process. The separated cast pieces will be moved to Downstream department where we get the final jewellery product. Only finishing operations will be carried out there and the final product is ready. The stone setting operation has been completely eliminated through innovative process.
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Automation of Diamond Bagging (2010)

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Diamond bagging is the process where the diamonds are grouped on the basis of their size. The diamonds are counted and then bagged, according to product requirements for any given pattern of jewellery. This is a skillful task where the probability of errors creeping in is ever present. Manual bagging leads to inaccuracies in the counting, sorting and bagging of the stones. Any increase in demand means putting more skilled people on the job, the nature of the job results in employees suffering from back pain, eye strain and fatigue.
Way back in 2007, a dedicated team was formed to build a machine to automate the diamond bagging. The idea was to build a machine that could pick and bag single diamonds. Initially, pins were used in the machine to pick up the diamonds, where the pin wears out frequently. Then vibratory bowls were used instead of pins and a sensor for counting the diamonds, chutes for holding the diamonds, pallets were used for bagging.
This machine can bag 16000nos/day as against the requirement of 40000nos/day, and the rest was bagged manually. The appropriate diamonds (for e.g. VVS1, VS1, SI2, SI2GH, and SI3) are loaded in the servo chute and according to the requirement, the diamonds in the upper chute will be transferred to the lower chute through linear vibrator and the sensor will ensure the number of diamonds in the lower chute. The robot will pick the diamonds from the lower chute and it will place in weighing balance and the diamonds are loaded to the pallet for bagging and finally the label is manually pasted on the bag.
Another machine was built with capacity of 24000nos/day to avoid manual bagging completely. The number of chutes was increased to meet the requirement and also an additional weighing balance was introduced to reduce the idle time of the machine. In this machine, the pallet was replaced by blister packing, since the pallet has to be cleaned every time before loading, to avoid the mixing of various qualities of diamonds. The collection of diamonds from the pallet is a tedious job and this is made easy in blister packing. An ink jet printer is to be incorporated in place of label printer which will print the bagging details on the blister packing instantaneously.
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Tanishq Karat Meter (1998)

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Why a Karat Meter?
Since ancient times jewellery made of gold enjoyed a Unique place in the creation but unfortunately there was no equipment through which its purity could be checked; hence it was solely trust or word of mouth that would certify the purity of the gold. Hence, often people use to get cheated by their jeweler who use to mix up other metals and alloys with the gold which would eventually negotiate the excellence of this precious metal. As a result hardly ever people use to get pure gold in return of their money that they paid to buy gold thinking it to be pure.
Years passed, technology enhanced and finally an instrument was invented which could check the karatage of the gold. Karat meter was the name given to this dream instrument. Barely some of us would have ever heard of such instrument as very few jewelers have this instrument in their stores to satisfy their customers, because numerous jewelers believe that keeping such instrument would prevent them from malfunctioning thus will also cut off large part of their profit, As a result even now people don’t get the purity for what they pay.

About the Karat Meter
The Karat meter is a scientific device launched by India based TATA Group which uses  X-rays to give an exact reading of the purity of gold. Due to its very high precision, X-ray analysis has been adopted by international agencies in India as part of the certification process used to hallmark gold. It is an accurate, non-destructive means of testing the purityof gold and other related elements.
Karat meter is technically called X-Ray Fluorescence (XRF) Spectrometer. Tanishq named it as karat meter for easy understanding to customers.
The analysis of gold in gold jewelry alloys has been performed during the last thirty centuries by the cupellation or fire assay method. Although it is the most accurate technique it is also destructive. The touch stone method has been there for centuries but is not an accurate method of testing gold. Its accuracy is dependent on composition and colour of alloy, quality of touch stone, strength of touch acid, lighting conditions and operator skill. The test is not suitable for very high karat gold or hard white gold.

Segment
Jewellery Tanishq targets the mid-premium segment in retail of jewellery business. (premium segment by ZOYA, mass segment by GOLDPLUS+) Cater with ‘superior craftsmanship, design expertise, product innovation, and guaranteed quality’. Gold jewellery in 22k pure gold, Also make platinum jewellery, with diamond and other precious stones. Innovated karat meter, the only non-destructive method to check purity of metal and jewellery. To promote glamour value of metals (gold) besides its status as a secure source of investment.
Tanishq took the challenge not only to educate people about what all things should be well thought-out before planning the purchase of gold stuff but also to create openness on how jewelers exploit innocent people by selling ornaments made up of impure gold. 
Tanishq planned a campaign in all the regions in india . During this period Tanishq selected various location where people came to the Tanishq van and got free ‘gold purity check’ done on karat meter and also received a certificate that mentioned the karatage of the jewelry checked and if they found their jewellery to be less than 22k (i.e. up to 19.9k of purity) they could also exchange it for Tanishq’s certified jewellery at any of its outlet. To add more Tanishq offered that jewellery up to 19.9k would be valued at 22k in exchange of any Tanishq Product. Almost all Tanishq showrooms across the country use the globally acclaimed device called Karat meter for measuring gold purity. Karat meter uses X-rays to give an exact reading of the purity of gold in just 60 seconds, giving the consumer an unmatched benefit when buying or selling gold. This system is designed to give an accurate and quick reading of karatage of gold jewellery. It is in fact the most scientifically proven, non-destructive means of testing the purity of gold

What are the benefits of using a Tanishq Karat Meter?

  • It offers non-contact and non-destructive testing. Sample material is not consumed.

  • It is extremely fast. Measurement takes only Seconds, and results are obtained immediately.

  • It can identify all elements in the sample and their respective weight percentages (composition)

  • The results are operator independent, so different people using the system will get the same results.


X-ray assay is NIST (National Institute of Standards Technology) traceable and confirms with ASTM B568 and ISO 3497.
The Karat Meter is recognized by World Gold Council for testing of gold .
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Titan EDGE (2002)

This collection made ripples in international markets. The watch boasts of housing a 1.15mm thin movement in a case that is no thicker than 3.5mm. These watches are also 30m water resistant. The styling and design are contemporary, and the collection was the winner of the 2003- Business World - NID Design Excellence Award - Best Lifestyle Product.

Comment by Michael Foley - Designer for Titan EDGE

"The most delightful part of the whole experience was being able to extract as much out of the design to make it absolutely timeless and minimalistic. ‘Detail that echoes purity’ was the overriding principle. I also really liked the collaborative spirit and openness at Titan, which led to the manifestation of Edge."

How 11 Indians pulled off the impossible :
Making breakthrough Innovation Happen


Author - Porus Munshi

Ratan Tata's view about this book :

"This book... distinguishes itself by its detailed focus on the thought processes which inspired the breakthroughs. This innovative approach in storytelling enhances the book's inspiration quotient for the reader and challenges her or him to set out on a similar journey."

Excerpts from the book :

Gandhi's biggest concern was not expelling the British. That could be done. But if it was done without an enslaved people first feeling and seeing themselves as equal to any ruler, one set of rulers would only be replace by another, and inequality with its inherent exploitation and arrogance would continue. The challenge for him was to get the people of India to move from a state of defence to positive irreverence. In a sense, Gandhi's challenge is as relevant today.

That is the mindset that Titan Watch Industries' then Managing Director Xerxes Desai faced, when in 1994, he set his team an orbit shifting challenge : "Create the slimmest water-resistant watch in the world!"

This meant that the watch would need to be a maximum of 3.5mm thick - as thick as the edge of a floppy disk - and water-resistant to boot. When they went to the masters of watch making, the Swiss, to look for help and insights, the Swiss said it was impossible. It couldn't be done. A watch could either be ultra-slim or water-resistant. It couldn't be both.

The Titan team, however, took on the challenge and said that if the Swiss couldn't do it, they would, and they did.

It took them four years, but they did the impossible and they did it through radical feats of engineering that challenged almost every parameter of watch making. The slimmest water-resistant watch in the world was conceptualised, designed, developed and manufactured not in Switzerland or Japan, but right here in India by a company just a little over a decade old then. The ëdge"as it was called, was production ready by 1998 and was finally launched in the market in 2000. In a very quiet, low-key manner, an Indian company had created an engineering breakthrough and nailed history to its doorstep.

Today, the Edge is a success story for Titan and is sold globally as the world's slimmest water-resistant watch. The single brand contributes to around 6 percent of Titan Watches turnover. But more than the revenue impact, the true impact of the Edge is that it gave Titan the confidence that it could make truly global innovative products.

The Challenges :

Developing the Edge wasn't easy since engineering was a huge challenge. But the greater challenges were internal. As B.V Nagaraj, then head of Product Engineering put it, the top challenge was to instil in people the self belief that they could do it. In something truly radical, the greatest challenge always lies in creating self-belief in the team. At Titan, the first reaction of many in the organisation was "if the Swiss can't do it, how can we?" That is perhaps the biggest illogical conclusion you may have heard, if somebody else hasn't done it, it always means that no one is ever going to do it. And if somebody does it, it won't be us. It'll be some other team somewhere else.

It was this mindset of deference to the developed world that key players - Dwarkanath, then Chief Technology Officer, Subramanya Bhatt, then Head of Movement R&D, B.V Nagaraj and of course Xerxes Desai - had to tackle and it proved to be their greatest challenge when it came to energising the team.

Finally, after four years of hard work and breaking boundaries, the watch was ready. The prototypes were sent to Chronofiable SA, Switzerland, a world-renowned independent Horological Testing Agency. There, the watches were subjected to a series of stringent tests like high and low temperature tests, exposure to vibrations, shock tests, drop tests etc all spread over a span of eight weeks. After these tests, Titan Edge was certified as not just reliable, but also water-resistant upto thirty meters.

They were also tested at Titan internally, and what's interesting is the way Dwarkanath tested it. He said "Sure the agencies test thoroughly, but somehow they can never replicate actual life conditions." So he threw the Edge against a wall, and onto the floor at different angles to check if it stays safe. He chucked it into a swimming pool and it was expected to work. Finally, he tied it to the shock absorbers of his car and made several trips on the terrible roads between Bangalore and Hosur, covering 200km in all. The Edge passed these tests too.

The team had done the impossible. They had created the world's slimmest water-resistant watch. A team that believed it didn't have the competency suddenly discovered talents they had no idea they had!

Thank you Seenivasan K (Movement Manufacturing) for using OCR on the book and sharing this article!

About the author :

Porus Munshi is an Associate at Erehwon Innovation Consulting, a company dedicated to fuelling innovation in India. He is a postgraduate in psychology and was the author of a widely read column for the Hindu Businessline titled ‘Work and You’. Human performance, impossible dreams and causes, and taking on challenges fascinate him. In his work with clients across industries, Munshi is known as someone who releases and unblocks the innate potential of people, so that they begin to conceptualize, innovate and achieve what they previously believed to be impossible. He triggers and facilitates innovation missions and works with top leadership teams, helping them make mindset shifts.
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Tata Ace - Small is big (2005)

If the invention of the wheel can be credited with changing the course of mankind, the addition of a wheel has been equally successful in transforming futures. Just ask the team at Tata Motors. The Nano may well be redefining Tata Motors’ identity now, but to understand how the company’s present route was charted, drive back to mid-2005, and the launch of a mini-truck called Ace.

The ingenuity was in its simplicity: Ace was the first small goods-carrier on four wheels, in a market dominated by three-wheeled commercial vehicles. In 2009-10, just four years after its launch, sales of the Ace crossed the 100,000-mark—the only goods commercial vehicle in the country to reach that milestone.

The achievement is especially significant considering the Ace’s genesis. The project was started in the backdrop of Tata Motors’ jaw-dropping Rs 500 crore loss in 2000-01. “That is when we took stock of the customer segments and our own product portfolio. We wanted to reduce our dependence on the goods-cargo heavy commercial vehicle business,” says Prakash Telang, MD, Tata Motors’ Indian operations. Still, the move to a four-wheeled light commercial vehicle was a radical decision. While most competitors were focusing on medium-sized trucks, Tata Motors was considering a compact four-wheeler in the lowest-tonnage segment of the market: a mini-truck.

Last-Mile Distribution

The business opportunity was sound, even if untested (three-wheeled goods carriers were the standard product in the segment). When a country is in the early stages of road development, medium trucks operate as a point-to-point workhorses. But as a country begins to evolve, as the transportation network assumes a hub-and-spoke model, in cities, sales of medium trucks start to shrink. “You then have large trucks that are carriers from hub to hub. We saw the opportunity in retail distribution with smaller vehicles—for the last-mile distribution,” says Telang. By opting to develop a small truck in 2001, Tata Motors was betting on a stable revenue contributor as long as infrastructure projects were on track.
Other domestic players, notably Eicher Motors, Piaggio Vehicles India, Force Motors and the Mahindras, were also working on the four-wheeled variant in early 2000. A year before the Ace, Piaggio Vehicles had a ready variant in Europe that it wanted to localise for India. “We tried to introduce the concept of a quadricycle in this country in 2004,” recalls Ravi Chopra, Chairman and MD of Piaggio Vehicles in India. “This was a three-wheeled vehicle with a fourth wheel (at the back). All the testing procedures, emission norms, rules and regulations for the quadricycle are as they are for three-wheelers. We wanted to introduce that in India,” he explains.

For government approvals, there was no opposition to a Piaggio quadricycle in the commercial (goods carrier) configuration, but there was opposition to it in the passenger segment over safety norms: the domestic industry wanted the gross vehicle weight to exceed 600 kg, the global standard. This eroded its production volumes on the Piaggio quadricycle platform, which was meant for sub-600 kg vehicles. “Our idea of a four-wheeled vehicle had to be postponed,” Chopra rues. Around the same time, Force Motors, too, had displayed its mini-truck at an auto expo. It was their market to lose.

Within Tata Motors, the New Product Innovation (NPI) team tackled the same challenge differently. For long, Tata Motors had been the incumbent in the medium and heavy commercial vehicles (M&HCV) market with more than 70% share. So, the brief to the NPI team was: miniaturise an HCV. The man to head the Ace project was a 30-year-old divisional manager called Girish Wagh. Eight years on, he would head Tata Motors’ small-car project.

Frugal Engineering

With the engineering of Ace, Tata Motors demonstrated how to keep a project’s overall cost tight, and its final price competitive. To achieve this, the automaker had to get a stranglehold on the budgets of each component. “The Nano team that was doing its costing decided that all single components would have a target base-cost to reach the golden mark of Rs 1 lakh,” says Telang. “So, we had to have a tighter budget each for axles, engines, tyres—and then work towards that. Ace was also such a tightly costed project,” he explains.

The Nano, manufactured at the Pantnagar plant in Uttarakhand, shares more than just the production facility with the Ace. “When Girish moved from here to the Nano project, there was automatically a transfer of learnings,” recalls Telang. The engine development of Ace is a classic instance of the frugal manufacturing that Tata Motors followed. The Tata Indica had a 1.4 litre, four-cylinder engine. “We cracked an ingenious way to convert two cylinders out of this into an engine for the Ace. That proved very handy for us,” he adds.

The decision to go small was critical, and was driven by the nature of the truck market. First, it meant fleet operators’ credit-payback burden with Ace was reduced compared to the credit burden of a medium or large truck. During a cyclical downturn, sales of mini-trucks would thus be largely unaffected. If medium and heavy truck buyers were discouraged by an economic slowdown, the mini-truck buyers would still be relatively comfortable.This was evident in fiscal year 2009, after the financial meltdown. Even as the M&HCV market in India shrank 33% compared to the previous year, Ace in the light-CV segment fell by just 12%. “The moment liquidity conditions improved, the Ace market returned faster,” Telang points out. The Ace today accounts for nearly 70% of the segment, which it virtually created. In terms of competition, Mahindra & Mahindra’s Maxximo and Gio are the only light commercial vehicles.

When the mini-truck project began, internal resources were scarce. Tata Motors’ priority in 2000-01 was to capture market with the Indica, its indigenously developed hatchback. The Indica was a Rs 1,700-crore project. But with the Rs 500-crore loss straining the company’s balance-sheet, the mini-truck’s budget would be a small fraction of that. As it turned out, Tata Motors spent about Rs 200 crore on the Ace, over five years. Compare this with the Rs 2,000-crore Nano project.

“We’d set up facilities within existing premises in Pune. We had to watch out for risk. That was a challenge for the team,” Telang recalls. The Tata Ace was launched in May 2005 with an initial production capacity of 30,000 units a year. The company opened over 300 exclusive sales outlets for the Tata Ace. The response was a pleasant surprise. Within a year, Tata Motors had sufficient demand to double output. Shortly thereafter, in August 2007, it set up a dedicated facility in Pantnagar.

By capturing the small-vehicle share in India, Tata Motors has cracked the mass market. In that sense, the Ace has been a prelude to the Nano.

Path To Profit

While a low-cost vehicle keeps revenue ticking, industry analysts have been quick to question profitability. It is a question that the Nano faces after the 2008 showdown in Singur, and even as its 225,000-unit facility gets up and running in Sanand, Gujarat. In the case of Tata Ace, its profitability rose because of its brand extensions.

The Tata Ace portfolio now comprises the Ace, the Ace HT, the Ace Ex and the Super Ace (a 1-tonne vehicle). In June 2007, Tata Motors launched Tata Magic, developed on the Ace platform, as a four-wheeler for public transportation. Magic has been working, especially in semi-urban and rural areas. With sales of nearly 49,000 units in 2009-10, it clocked a growth of 71% over the previous year. In all, Tata Ace and Tata Magic crossed 150,000 units in 2009-10. The profits vary across product lines, even as the company gets to enjoy economies of scale. In the case of the Nano, Tata Motors seeks to do much the same across variants.

Now, Tata Motors is also looking to lead in clean technologies. There are 15 prototypes of the electric Ace being tested in Europe for foreign markets. In India, the CNG variant has caught on in Delhi. “CNG is a better alternative as a fossil fuel, especially when electricity generation in India is largely coal-based. There is no point cutting greenhouse gases in cities when our electricity comes from coal mines,” Telang asserts.
When the mini-truck first hit the domestic market in fiscal 2006, 70% of the segment was in the cities. The rural-urban market break-up for the Ace is now at 50-50. And Tata Motors seeks to make it 70-30 in favour of rural markets on the back of the government’s progressive policies.
More than anything, the shift from a three-wheeled commercial vehicle to a compact four-wheeler sub-1 ton category truck has been a branding success. It had unexpected results. “We found that Ace gave a sense of respectability to the owner of the product,” Telang smiles. “In the south, one customer said, ‘I started getting offers for my wedding once I began driving the Ace’.” Clearly, the wheel of fortune didn’t turn for Tata Motors alone.
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