Home / Case Studies / Auto major Lumax Industries Limited Partners Horizon for a Build-To-Suit Manufacturing Facility
Auto major Lumax Industries Limited Partners Horizon for a Build-To-Suit Manufacturing Facility
Overview
For seven decades, Lumax has always operated from their own facility, making this their first ever leased facility. The new leased facility, a build-to-suit unit, stood to serve as a manufacturing center for a range of automobile lighting systems and solutions for diverse applications. The said facility in Horizon Industrial Park at
Chakan, at its optimal capacity, can manufacture approximately 400,000 vehicle lighting sets. The auto components manufacturing facility was planned in two phases, with a critical emphasis on achieving an aggressive timeline for the dry access of Phase-I. This was essential for Lumax to initiate their fit outs, enabling trial productions and subsequent SOP (Start of Production), in line with OEM programs.
Company Overview:
The Lumax – DK Jain Group, a prominent player in the Indian Automotive Industry since 1945, has evolved into a leading manufacturer and supplier of automotive components and systems today. Specialising in automotive lighting, gear shifters, and interior systems and components, Lumax boasts a 12,000-strong workforce across 37 modern manufacturing locations in India.
The company’s manufacturing strength has been backed by one engineering centre in India and two design centres in Taiwan and Czech Republic. The Lumax Group has a turnover of over INR 6,800 crore (FY22-23), and diligently empowers the assembly lines of four-wheeler, two-wheeler and farm equipment segments for leading OEMs like Hero Motocorp, Honda Motorcycle & Scooter India, Honda Cars, Mahindra & Mahindra, Maruti Suzuki, MG Motors, Toyota, Tata Motors, Force Motors, Ashok Leyland, Daimler, TVS Motor, Royal Enfield, Yamaha, John Deere, Tafe, Escorts, and Sonalika.
Read MoreLumax’s New Manufacturing Facility: A Closer Look
Lumax had presented the following requirements to Horizon Industrial Parks for its new build-to-suit manufacturing facility at Chakan II, Pune:
- The initial requirement was for an area of 125,000 sq ft, which eventually scaled up to a chargeable area of approximately 286,000 sq ft, and was delivered in two phases.
- Phase-I development included approximately 184,000 sq ft with an open area of approximately 20,000 sq ft for parking, silos, cooling towers, water tanks, and ETPs.
- Phase-II development covered approximately 102,000 sq ft. This included space for an office mezzanine of 10,000 sq ft and a process mezzanine for HVAC and finished goods storage in an area of around 44,000 sq ft.
- The material movement from the docks to these process mezzanines would be facilitated via multiple scissor lifts installed on-site.
- The building was designed with a standard floor load of 5 MT/m2 (UDL), but in the crane traversing area of approximately 46,000 sq ft, a higher floor load of 10 MT/m2 (UDL) was provided.
- Structural provisions for the steel building and civil foundations were designed to accommodate a span of 23 x 178 m, catering to one 25-ton EOT Crane.
- Power supply infrastructure for 2500 KVA had been provided on an 11 KV transmission line, including metering kiosk and HT breaker room construction, with an option to scale up to 2500 KVA for Phase II.
- Utilities were housed along the periphery of the building with seamless connectivity to various processes that get carried out on the shop floor, including chemical storage rooms, BMC and stores with crane provisions, RM and CFS equipment storage room, granulator room, LT panel room, compressor room, HT meter room, vacuum circuit breaker (VCB) breaker and ring main unit (RMU) breaker room, medical room and creche, scrap rooms, and security office.
- Dedicated fenced premises with a security office and motorised in and out gates was provided.
- Dedicated parking areas and toilets at multiple locations within the premises were constructed as per operational needs.
Manufacturing facility developed in a strategic location in Chakan, Maharashtra
286,000 SQ FT built-to-suit facility to manufacture vehicle lighting sets
At optimal capacity, the facility can produce around 400,000 vehicle lighting sets
The crane traversing area had higher floor load of 10 MT/m2
World-class campus environment to accommodate the main factory & its auxiliary buildings.
Structural design for the 23 x 178 m steel building and foundations supports a 25-ton EOT crane
Horizon Industrial Parks’ Solution: The Key Highlights
With a clear understanding of the specifications required by Lumax, Horizon proceeded to work on delivering the bespoke manufacturing facility with the necessary infrastructure and amenities. The dry access of Phase-I was provided in April ’23 as per the agreed timeline of eight months, enabling Lumax to commence the trial production in August ’23.
Strategic and Well-Connected Location
The newly developed auto-components manufacturing facility for Lumax is strategically positioned within Horizon Industrial and Logistics Park at Chakan. The park boasts excellent connectivity to Pune Airport and a Sea Port (JNPT) via the Mumbai-Pune Expressway, ensuring efficient raw material sourcing and logistical operations. Furthermore, the plant’s proximity to end clients such as Tata Motors and Mahindra & Mahindra enhances logistics efficiency in terms of both time and delivery.
Adherence to the Stipulated Timeframe
Horizon has ensured the provision of dry access in April ’23, followed by the final handover of Phase-I in October ’23, in alignment with the agreed schedule. Concurrently, Phase-II work is actively underway on-site, adhering to the agreed schedules, and maintaining stringent HSE compliances and quality standards.
Compliance with Local Regulations
Horizon has already obtained or is in the process of securing NOCs and approvals from various governmental agencies, coordinating these efforts with Lumax’s scope of work.
Efficient Design and Layout
The build-to-suit. auto components manufacturing facility for Lumax, spanning approximately 286,000 sq ft of built-up area and an additional 20,000 sq ft of open space, has been meticulously designed by Horizon Industrial Parks to optimise efficiency. Within the park, a world-class campus environment has been created to accommodate the main factory and its auxiliary buildings. The central building will serve as the hub for the client’s primary manufacturing operations, while the peripheral utility buildings will aid in smoothening operations and material movement.
The bespoke facility will also have other efficiently designed features with functional advantages, such as the following:
- Pre-engineered building (PEB) structure with skylights, which utilises daylight and helps in saving energy.
- Louvers for air ventilation for the entire building.
- A concrete apron 26 m in width to ensure heavy-duty performance for heavy traffic loads.
- Roof insulation to minimise heat ingress.
- Crane provisions and additional floor load.
- Roof safety harness lines along the periphery of the roof and on either side of the ridge ventilator.
- Rooftop solar for energy efficiency.
ESG-Compliant Manufacturing Unit
Horizon Industrial Parks is 100% ESG-compliant. The construction materials chosen for the Lumax’s auto components manufacturing facility prioritize environmental friendliness, contributing to lower carbon emissions. The facility’s roof is engineered to support a solar panel load of up to 20 kg/sq m, allowing Lumax to harness clean and sustainable energy, reducing operational costs while promoting environmental conservation. Additionally, the implementation of a dual plumbing system with separate lines for domestic and flushing purposes ensures efficient utilization of water resources.
On a final Note
Horizon’s customised, sustainable, and state-of-the-art facility for Lumax will be a game-changer for its lighting manufacturing and production processes and sets the stage for continued growth and stronger partnerships in the coming years.
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solution for your business
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Floor 15, Tower 1, One World Center
Lower Parel, Mumbai 400 013
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