Tenneco is set to support CV OEMs with the most modern exhaust solutions so that they can stay ahead of the tightening emission norms.
Daimler India Commercial Vehicle’s new 3134 deep mining tipper and 3143 coal tipper are equipped with a Tenneco exhaust system. Even the BharatBenz 4940 long-haul tractor is said to have been equipped with a Tenneco exhaust. Supporting Daimler India Commercial Vehicle’s (DICV) ambitious Thunderbolt program, which culminated in the introduction of the tippers mentioned above, and which will replace the Mercedes-Benz Actros in the Indian market, Tenneco, it is clear, is working with global commercial vehicle manufacturers on what are termed as global initiatives. The 3143 is destined for export, and is powered by the OM457 400-series Mercedes-Benz engine. The Tenneco exhaust system is coupled to this power plant, which ironically, is also powering the Mercedes-Benz O500 luxury coach.
Hi-tech solutions for higher needs
Developments like these assume much significance. They are happening at a time when the government and judiciary are looking up to the next phase of emission reforms in response to curb the rising pollution levels. With the next phase of emission reforms expected sooner than later, developments like the Thunderbolt programme reflect on how OEMs are infusing new technologies with the support of their suppliers to produce ‘greener’ automobiles, and commercial vehicles in particular. It was in 2010 that the government announced the enforcement of Bharat Stage IV (BS IV) emission standards in 13 cities. Its nationwide implementation is yet to take place. As the nation gears up to look beyond BS IV emission norms, and perhaps jump to BS VI by 2020, the role of suppliers is set to be crucial. Especially those that are into the manufacture of systems that are in close proximity to the emission curbing units on an automobile.
Exhaust systems for example. From the BharatBenz 3143 (Thunderbolt) it will be clear that a move to high-tech products is already underway. Tenneco, it is no secret, is geared up to expand its portfolio for the CV industry. “A fully indigenous BS IV aftertreatment system, completely designed and developed in India, including the software, controls, sensors, calibration and adaptation of dozing technologies for a local OEM is currently at the certification level,” says Pankaj Kapoor, Deputy Managing Director, Tenneco Automotive India. Claiming to be a leader in developing Clean Air systems globally, BS IV emission standards, and the related automotive technologies, are not new to Tenneco. Kapoor adds, “A typical Euro IV exhaust system for commercial vehicles incorporates a Selective Catalytic Reduction (SCR) system. It is coupled with decomp reactors and urea dozing for which you need electronic sensors and controls. It turns into a complete exhaust system, which is quite complex and has in it mechanical parts, electronic parts, electrical parts and a software as well.”
Euro IV solutions for export programs; BS IV solutions for local needs
Prime supplier of Euro III emission compliant exhaust solutions, which involves a muffler with pipes attached to the catalytic converter, to almost all the major OEMs in India, Tenneco is also honouring contracts for three global commercial vehicle manufacturers for Euro IV emission compliant (SCR-based) exhaust solutions. One of these manufacturers is DICV. “We are ready for the launch of SCR system by the end of this year,” states Kapoor. “Mass production will start for the systems when the implementation of BS IV emission norms will happen,” he adds. Headquartered at Illinois, USA, Tenneco has been working on the challenges the Indian duty cycles have of offer. This includes the need to adapt as well as develop products and solutions that will address the needs of the local market. Kapoor avers, “Tenneco’s product development cycle in India incorporates the voice of customers, duty cycles and largely prevalent overloading problems as well. A lot of application engineering is done while following our TDPC process and to support this, our engineers work closely with OEMs to understand their development cycles and tweak products accordingly.”
Aiming at high level of localisation
Operating in India under two business units – Clean Air (CA) and Ride Performance (RP), Tenneco products in India have a local content of up to 80 per cent. This enables the company to better serve the local requirements, especially in terms of costs. According to Kapoor, his company is planning to hike the local content to 84 per cent in the next few years. The significance of cost reduction, it is clear, is high. For Tenneco has to balance between fulfilling the OEM’s requirement for the local market as well as the export markets. For example, Tenneco has been meeting the Euro V needs for Mahindra’s LCV export portfolio with Diesel Particulate Filters (DPF). Kapoor explains that it is important to understand the adaptability and design of the customer and his requirements to enhance performance while packaging the products. When it comes to the RP business vertical, Tenneco has developed various components like cabin dampers, axle dampers, steering dampers and lateral dampers ranging from 35mm dia. to 45mm dia. for commercial vehicles. These are capable enough to meet future regulatory requirements according to Kapoor. He adds, “We try to localise most of the products in RP. We have localised the piston rods; we have also developed localised sintered metal parts for Ashok Leyland M&HCVs at our Puducherry plant.” Over the past few years, Tenneco has been consistently working to achieve higher level of localisation as far as its current as well as upcoming products are concerned. With an average localisation level of 88 per cent, it is aiming at a level of 95 per cent in the next few years. Especially in the area of heavy duty trucks. It is in the area of heavy duty trucks that Tenneco has developed the blow-off design axle dampers to improve durability and offer high damping forces to enhance control at lower speed.
Addressing the needs through six manufacturing plants
Tenneco operates six plants in India. Each business vertical has three plants. Under the CA business vertical, the Chakan plant is serving the needs of Tata Motors and Mahindra LCVs and M&HCVs. This plant also serves the needs of other global OEMs. The Chennai plant would supply SCR systems to DICV for its Bharat Benz BS IV (Euro IV) needs in India. The youngest plant at Sanand is awaiting start of production (SOP) and will serve passenger vehicle manufacturers like Ford, which has set up a plant at the same location. At the RP end, the company has a plant at Bawal, Hosur (to develop shock absorbers and struts) and Puducherry (to manufacture sintered metal parts for inter-company use). Under the RP business vertical, the company would serve the needs of Tata Motors and Ashok Leyland along with other global OEMs from its Hosur facility.
Engineering prowess
Tenneco has 15 engineering centres worldwide. According to Kapoor, these work in close cooperation, and are virtually connected, be it the core engineering centres in USA and Europe or application engineering centres like the one at Hosur. Highlighting the cost requirements and environmental regulations in India, Kapoor opines that India is a very segmented market, and despite having relationship with global OEMs at the international level, it is important to provide them with local content at the local level with more or less the same amount of robustness. While doing this, states Kapoor, it is essential to be competitive. He adds that India will be the centre of excellence for shock absorbers worldwide. This again is based on the lower costs the product can be had at in India. Under the RP business vertical, Tenneco, in 2013, introduced a mobile workshop called the ‘ride tuning’ bus. It caters to both, commercial vehicles as well as passenger vehicles, and includes electromagnetic testing to facilitate precise work. Also installed in the bus are damper testing machines, special assemblies and gas fitting tools, which suit Tenneco’s designs and validations in a vehicle. “Apart from assembling and testing the shock absorbers at the premises of the customer, we have a complete library of ‘valve’ in our bus to suit the Indian terrain” says Kapoor.
Expecting CV business to grow
Over 65 per cent of the company’s revenues in India come from the RP business vertical. This also includes 10 per cent revenue earnings from the aftermarket part of the business. The CA business vertical contributes the remaining 35 per cent. The CV product portfolio in particular forms a smaller, 5 per cent chunk of the business Tenneco conducts in India. This is however expected to grow. Says Kapoor, “We expect the commercial vehicle business to grow substantially with the advent of BS IV emission norms and contribute 20 to 25 per cent in the next two-to-four years. According to Kapoor, much of this will come from the CA business vertical. Not worried about the talk off skipping one emission level to jump to the other, Kapoor concludes, “Euro IV products can be easily upgraded to Euro V. For Euro VI, apart from SCR you need DPFs. So as a global technology supplier we have products at the Euro VI level. We have no issues in getting them to India.”
