Plug and Play Automotive Component Manufacturing Facility for Yazaki India
Overview
Yazaki’s existing manufacturing facility is located towards the west corridor of Bengaluru. The company made a strategic choice to enhance its production capacity in India and set out to establish an additional state-of-the-art, manufacturing facility in a well-connected metropolitan city, closer to their existing customer base. To meet this requirement, Yazaki was in search of a reputed Grade A industrial park developer with a proven track for delivering advanced and innovative manufacturing and warehousing facilities.
Their search ended with the property at Horizon Industrial Park, Hosur. This park in Shoolagiri, near Hosur, Tamil Nadu is located along NH 44 and is well-connected to the Bengaluru city.
Company Overview:
Established in the year 1941, Yazaki Electric Wire, which began with the manufacture and sale of wire harnesses for automobiles, has expanded beyond auto parts and electric wires to encompass equipment for instrumentation, gas works, air-conditioning, and solar-heating, and agriculture products.
Yazaki is among the top 15 global auto-component companies and a global leader in Wiring Harness (W/H), boasting nearly 30% market share. The company employs over 240,000 individuals worldwide and operates in more than 46 countries across 141 regions.
Yazaki India, a fully owned subsidiary of Yazaki Corporation was established in 1997, operates 11 plants and 2 Technical Centres across 8 locations, employing nearly 12,000+ employees. The company is engaged in the manufacturing of wiring harnesses and components, including injection moulding.
Currently, Yazaki India is expanding its footprint in Wiring Harness market in India by diversifying into clusters and developing electronic products tailored for the Indian market. Additionally, the company is extending its services by producing wiring harnesses and meeting global requirements for Yazaki on an international scale.
Read MoreYazaki India’s New Manufacturing Facility: A Closer Look
Yazaki India desired a ready-built facility which could be made to fit for harness wire manufacturing with minimal customised modifications and utility enhancements such as the following:
- Yazaki was seeking a Grade A facility with a built-up area of approximately 2.5 lakh sq. ft meticulously planned to optimise operational efficiency.
- Horizon Industrial Parks was tasked to create a world-class campus environment within the park to accommodate Yazaki’s manufacturing unit.
- The facility needed to include open parking areas (spanning 21,800 sq ft holding 100 two-wheelers and 20 buses) for cars, two-wheelers, and buses.
- Their preferred design features for functional advantages, included:
- Two track sliding windows with MS grill and mesh protection on all non-docking sides.
- Enhancement of DOM, flush, and filtered water storage.
- Provision of a dedicated STP of 110KLD to manage sewage load for additional population.
- Construction of a 1.8 m height chain-link fenced premise with two security offices and separate entry and exit gates.
- Construction of a 3.70 m high scrap shed away from the main building.
- Creation of a concrete apron 16.5 m wide to ensure heavy-duty performance for heavy traffic loads.
Twelve-meter clear PEB structure with skylights to maximise daylight usage and energy savings.
Additional washroom blocks to serve a daily population of 2,000.
Roof monitor and louvers for ventilation at a rate of 4-6 ACPH for the entire building.
Handle a standard floor load of 5 MT/m2 (UDL).
Separate office entry with standard façade, canopy, and automatic sliding glass door.
Separate workers’ entry with MS railing, platform, steps, and canopy.
HORIZON INDUSTRIAL PARKS’ SOLUTION: THE KEY HIGHLIGHTS
● Strategic and Well-Connected Location
Yazaki India new manufacturing facility is strategically located in Horizon Industrial Park Shoolagiri, in Hosur, Tamil Nadu and situated along the NH 44. The park is well-connected to the city of Bengaluru and the Kempegowda International Airport, as well as the National Highway 44, National Highway 48, and National Highway 42. The facility is in the proximity of other automotive companies like Ashok Leyland, Toyota, Ola Electric, Ather Energy, TVS Motors, and Simple Energy offering Yazaki an avenue for collaborative ventures.
● Adherence to the Stipulated Timeframe
Horizon successfully provided dry access on September 15th, 2023, within 16 weeks of signing the LOI, ensuring immediate occupancy of the block/facility upon LOI signing. Following this, the final handover was completed, including all tenant improvements as per the agreed scope of work, and aligned with the agreed schedule, while maintaining stringent HSE compliances and quality standards.
● Compliance with Local Regulations
To ensure compliance with local, state, and national regulations, Horizon ensured that all the necessary standard and statutory approvals for the assembly and storage of products were sought and obtained.
● Efficient Design and Layout
Yazaki’s auto components manufacturing facility, covering over 2,54,000 sq ft of built-up area along with approximately 21,800 sq ft of open space, has been intricately crafted by Horizon Industrial Parks to enhance operational efficiency. Within the park, a premier campus environment has been curated to host the main factory alongside auxiliary structures. Serving as the nucleus, the central building is poised to facilitate Yazaki’s core manufacturing and assembly processes.
The finished facility will also have other efficiently designed features with functional advantages, such as:
- Roof safety harness lines along the periphery of the roof and on either side of the ridge ventilator.
- Rooftop solar of 500 kW capacity for energy efficiency.
- Optimised traffic flow by providing separate man-entry points and material entry points within the campus.
● ESG-Compliant Manufacturing Unit
Horizon Industrial Park, Hosur is also ESG-compliant. The materials used for the construction of Yazaki India’s facility are eco-friendly and have low embodied carbon. Use of low flow plumbing faucets, energy efficient motors and pumps, and LED lights help optimise the consumption of utilities and contributes to both economic and environmental objectives.
Yazaki will be able to utilise clean sustainable energy via the installed solar panels to bring down its operational cost and use the results to augment its existing measures towards protecting the environment. In addition, Horizon has provided dual plumbing system with separate lines for domestic and flushing system for utilising water resources efficiently.
On a final Note
Horizon’s plug and play facility with custom modifications and utility enhancements for Yazaki India will be a game-changer for its auto components manufacturing and sets the stage for continued growth and stronger partnerships in the coming years.
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Horizon Industrial Parks Pvt Ltd
Floor 15, Tower 1, One World Center
Lower Parel, Mumbai 400 013
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