Mahindra Engineering Services (MES)

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Profile

Mahindra Engineering Services (MES) is a leading engineering services provider

to the global automotive, aerospace, and manufacturing industry. We are part of the
Mahindra Group, a global manufacturing company with annual revenues in excess of
approximately USD 6 billion.

MES is headquartered in Mumbai (India), and we have our branch offices located in Pune
(India), Bangalore (India), Ohio (USA), London (UK), and Boloqna (Italy). We have
successfully established a wide customer base in the global aero and auto industry.

MES’s specialization originally lay in the automotive domain, and over the years
progressed to include Aerospace and General Engineering. Today, we offer enhanced
CAE services to all the three verticals.

Firmly anchoring the ‘design’ aspect of production, Mahindra Engineering provides

support to its clients through all the phases of product development.

Expertise

Founded in year 2003, with a highly experienced resource pool in engineering and
product development process, MES today has strength of over 1350 engineers working
on various projects in the automotive and aerospace domain from the concept to
deployment phase. To support the superior team of engineers, we are backed up with an
equally capable manufacturing setup to help in prototyping, rapid prototyping, design &
model studio, die & tool manufacturing, parts supply, and testing setup.

MES’s strategic geographical locations and various delivery models like onsite, offshore
& dual-shore models offer the advantage of 24x7 operations, leveraging time-zone
differentials, and moving from concept to product in the shortest possible time.

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It typically operates a dual-shore model with onsite coordinators at our client’s facilities,
supported by a team of engineers at our off-shore development centers in India. We can
also set up a dedicated offshore design center (ODC) in India.
Both these options result in significant savings in engineering costs for our customers.

The aerospace design group comprises of competent professionals with aerospace

background (aircraft and spacecraft) and in-depth knowledge in structural, mechanical,
thermal and acoustic design. We are able impart quality services adhering to international
standards and regulations like FAR and JAR.

Corporate History

Mahindra Engineering Services forms a part of Mahindra Group. The group for
decades is driven by the vision of delivering the very best in all its functions, the
Mahindra Group has today evolved to become one of India’s leading industrial houses,
with a turnover of approximately USD 6 billion, and employing more than 42,000 people
worldwide.

With its firm belief in innovation & technology – fortified by strong ethical groundings –
the Mahindra Group stands out as one of India’s top business houses. The Group’s
principal activities revolve around manufacturing and distribution of Automobiles and
Farm Equipments. In addition, it has a vibrant presence in IT, Financial Services,
Trading, Infrastructure, and the Auto Component Business.

Mahindra has established global manufacturing & service locations at Brisbane

(Australia), California (USA), Nanchang (China), Sharjah (UAE), Texas (USA),
Germany, UK, and South Africa. The exports of the group are spread across the world
covering USA, Malaysia, Australia, Europe, the Middle East, Africa, and the SAARC
nations.

The Mahindra Group Core Activities

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 • Automotive
• Farm equipment
• Systech
• Trade and financial service
• Information technology
• Infrastructure development

The Mahindra Group Structure

SYSTECH

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Systech is one of India’s largest conglomerates of auto components. It is equipped to give
a full service supply – right from engineering services to steel to finished products –
making Systech a one-stop-shop for its global clients.
Systech operates in the entire value-chain from Component to System supply and in
achieving this it pays meticulous attention to the services provided to its clients. On these
grounds Systech has established its fundamental principle of reserving 75% of its plant
capacities for external customers.
Amongst the resources which bolster systech is Mahindra Engineering Services (MES).
MES is celebrated as one of the few companies in the world to provide innovative design
solutions – from product concept to development.
Working in close collaboration with the other two arms of Systech – the Auto Component
Business Unit (ACBU) and the Strategic Sourcing Business Unit (SSBU) – MES
facilitates the capability of engineering, manufacturing, and a vendor support to its
clients.

Mahindra Engineering Mission

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Complete service provider in all segments committed to achieve revenues
exceeding $250million by fiscal year 2014 (Growth: 5 times in 5 years)

Mahindra Engineering Vision

We will be global leaders in providing
Innovative Engineering Solutions.

Mahindra Engineering extents its Services to the following

CUSTOMERS

Daimler Chrysler
Nissan
Navistar
Toyota
Fiat
Seabird Aviation
Bentley
Visteon
Audi
Ford
Honda
Mazda
Volvo Construction Equipment
Thyssenkrupp Budd
Lear
MercuryMarine
Mercedez Benz

AUTOMOTIVE

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Mahindra Engineering Services has an established profile in automotive field. Our
services encompass all the facets of new product development, from initial ideas and
sketches to the series-production start-up of a complete vehicle.

Mahindra Engineering Services provide services from a mix of on-site, off-site, and
offshore services in the areas of:

• Computer Aided Design • Requirement analysis

(CAD) • Concept design
• Computer Aided • Rapid prototyping
Engineering (CAE) • Manufacturing simulation
• Knowledge Based • Tooling and parts
Engineering (KBE) • Design process
• PDM documentation
• Cad Customization • Quality/Metrics
• Advanced surfacing and • Legacy data conversion
reverse engineering

MES further gives its clients full support during the following phases of Product
Development:

• Concept Engineering • Implementation

• Design & Development • Manufacturing Support
• Validation

AEROSPACE

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Our Aerospace design group comprises of experienced Aerospace professionals (Aircraft
and Spacecraft) who have in-depth Knowledge in Aerodynamics, Structural, Mechanical,
Thermal and Acoustic Design; and can impart Quality services adhering to international
standards and regulations like FAR, CAR & EASA.

Our Aerospace Division is an AS9100 Rev.B certified design organization embodying

decades of experience in global aerospace design and development programs. We
optimally combine this experience with our thorough knowledge of aerospace regulations
and familiarity with operational environments, and leverage Mahindra Engineering's
robust customer-focused processes to provide timely, accurate, cutting-edge technical
products to our customers. We pride ourselves on offering a wide spectrum of services
ranging from conceptual design through productionizing your aerospace products, be
they components or complete vehicles. Our knowledge and familiarity with the aviation
and aerospace domains, coupled with the Mahindra Group's commitment to the
Aerospace sector, ensure that we will meet and exceed your expectations.

• Conceptual design to meet operator specifications

• Full spectrum of Computer Aided Design services
• Full spectrum of Computer Aided Engineering services
• Embedded Systems for Aerospace Applications
• Software development for Aerospace applications
• Design and development of structural test fixtures and procedures
• Design and development of production-quality tools, jigs and fixtures
• Prototyping and production planning

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GENERAL ENGINEERING

Our group of specialist engineers, who have worked for large and medium size, and light,
heavy and general engineering industries, contributes to the capabilities of MES in
assisting special product design, analysis, planning and process automation, technologies
identification and selection process, production and quality documentation, packaging
and maintenance manuals.

We bring in a rich knowledge of specialized product design and development of varied

industrial products. This cross technology group works for:

• Components and Products

• Tool Design and fabrication
• Behavior and Failure Analysis
• Engineering Software Solutions

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 CAD

CAD is used throughout the engineering process from conceptual design and layout,
through detailed engineering and analysis of components to definition of manufacturing
methods. Dominantly, the automotive and aerospace industries form the leading forces
for CAD development.

Mahindras provides complete range of CAD services specific to industries like

Aerospace, Automotive and General Engineering. The team possesses expertise in initial
feasibility study, layout preparation, detailed design and manufacturing techniques.
The added advantage of familiarity with international designs and practices makes us the
right partner when you wish to offload your jobs or need to augment your design teams.
We have numerous team members who have worked overseas for automotive and
aerospace giants and constitute a veritable knowledge base of international design
practices and work culture.

The design group primarily works on CATIA, I-DEAS, Pro/Engineer, CADDs5, PDGS,
ICEM-SURF and Unigraphics and offers a broad range of specialized services:

• Class A Surfacing
• 3D Modeling
• 2D Detailing
• Packaging Studies
• BIW/Trim Development
• CFD Model Preparation
• Reverse Engineering
• PDM Drawings

Along with the above, CAD is a vital resource for all aspects vehicle development, like:

• Chassis • Trims • Electrica

• Engine • Seatings
• BIW • HVAC

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 CAE
To reduce the development time and cost, it is becoming increasingly necessary to have reliable,
experienced and efficient CAE support system. Our CAE team strives to do exactly this!

The objective of our CAE team is to check and prove functional requirements of parts and
systems virtually, prior to even first prototypes, in shortest possible time, carrying out all
required simulations. They use various sophisticated software which perform computations on
latest high end servers. Our team continuously enhances its skills and knowledge, which helps in
carrying out efficient and reliable analysis for different types of projects involving vehicle safety,
fluid dynamics, design optimization, operational stability, durability and rigidity.

Types Of Analysis

Safety Analysis

This analysis is carried out to assess the vehicle design against safety regulations. Compute
cluster available with us is capable of providing shorter turn around times for full vehicle crash
simulations.

Durability Analysis

Durability analysis is carried out to predict fatigue hot spots and fatigue life. The analysis is
helpful in understanding the root cause of fatigue problems and to assess different design
options.

Ride and Handling Simulation

Multi body dynamic simulations are carried out to ascertain performance for ride and handling of
full vehicle models taking into account flexibility of components.

CFD Analysis

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In this type of analysis, flow simulations for external flows around the vehicle, under hood flows,
HVAC flows, coolant jacket flows for engines, fuel injector flows are carried out. 1D simulation
also can be carried out for quicker and accurate flow simulations for pipe flows.

Optimization

Shape and size optimization is carried out to reduce the material contents of solid shaped or sheet
metal components for various objectives related to rigidity and/or NVH performance.

NVH analysis

NVH analysis can be carried out to get full insight into the acoustic problems. It is possible to
accurately and quickly predict effect of design changes. Also reduce noise levels before
prototype is made and tested.

CAE Software Customization

User interface tuning to maximize the software performance and incorporating very useful
macros can be undertaken.

FEA and Experimental Correlation

The results obtained through simulation can be validated by actual testing in lab. Changes in FE
models can be carried out to make it behave like a physical model. Proposals for changes in
design made after this are very accurate.

Heat Transfer and Thermo structural Analysis

Heat transfer analysis can be carried out to predict temperature distribution in components for
service conditions. The results can be further utilized to carry out structural and fatigue
calculations for additional service loads.

Moldflow Analysis

Injection molding simulation can be undertaken to ascertain flow inside the component to
identify critical areas. Changes in molding parameters and injection locations can be carried out
before mold is manufactured.

Stamping Simulation (Sheet Metal Forming)

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Stamping process simulation can be carried out to ascertain problems which may arise during
actual forming process of sheet metal panels. Modifications to process parameters and die design
can be suggested to ensure fault free stamping operations.

Softwares:

1.Pre-processing
Hypermesh, Optistruct, Patran. Ideas, Gambit, ICEM CFD, T-Grid, Ansa, Hyperform

2.Solver
LSDYNA, ANSYS, Nastran, ABAQUS, Sysnoise, Falancs, Fluent, Optistruct, Virtual Lab

3.Post-processing
Hypermesh, Hyperview, Patran, LS Post, Hyperform

4.Multi Body Dynamics

ADAMS

5.Engine Simulation
GT Power, Excite

6.Mathematical modelling
Matlab, Simulink

7.Computing Server

- 8 CPU Opteron Cluster (2 units)

- 2 CPU Opteron Machines (4 units)
- 2 CPU HP UNIX machines (2 units)
- 6 CPU Altix Cluster (1 unit)
- 10 CPU IBM E326 Series Cluster (1 unit)

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 Engineering services

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Engineering services represent one of the largest sections of the industrial world, with an
estimated 750 billion $ worth of value addition per year. These services comprise a vast
swatch of design & support services essential for the functioning of practically every
industry, spread across the entire spectrum of engineering.

Engineering services are those service functions that deal with or related to core
engineering processes.
Examples are:
- CAD / CAM (computer aided manufacturing / design)
- Auto design
- Failure analysis of structural steel

The distinction that needs to be drawn here is between engineering functions and
engineering service functions. An engineering function could be auto engine manufacturing.
A related engineering service function would be designing the engine. It is similar to the
distinction between manufacturing and manufacturing support services. A significant
portion of these services also are being outsourced and there is potential for more
outsourcing in this field.

Engineering services delivery revolves around technical skills, domain expertise and good
engineering judgment. Engineering design work centers on product IPs of manufacturing
companies. Most of the services outsourced are related to design services around patented
products, design specifications or customized interiors of a total engineering solution.

Engineering work is unique in the sense that it is generally not considered a commodity;
rather it is considered a value-added service. It is not something that can be automated as

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there are always different factors and emerging technologies. The engineer is in contact with
the client at all steps. The user may also be brought in the process. This is an iterative
process. Constant reevaluation of the process and the progress is required. This leads to
modifications. Upon completion, the engineer may be involved in the operation, the sales, or
may teach the use of the product.

I. Idea Phase - Identification of a problem or an idea (new building, product)

II. Design Phase - The engineer analyzes the idea or problem. Designs solution under
guiding factors listed below.

III. Test Phase - The engineer applies the design to a model to test. This would occur
more frequently with products as opposed to construction.

IV. Manufacturing or Construction Phase - The engineer supervises the

manufacturing processes (for electrical and mechanical engineers), construction (mainly for
civil engineers), or improvements made to a plant, operating system. Modifications made
during this process.

V. Product Completion or Production—Engineer or manufacturer may simply

hand product over to the client (i.e. electrical device), may sell the product (i.e. scientific
instrument), may actually operate the product (power plant), or may teach the operation to
the user (i.e. office building).

Standards play a large role in engineering work as much of engineering results in the design
of products. Standards serve to facilitate the reproduction and ensure compatibility between
products. This could be in the form of standard software formats to guidelines for fitting
screws or pipes.

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IT is linked to the entire value chain but engineering sits at the heart of it.
Some companies such as Toyota are built around engineering
% of respondents considering their function as core / strategic (Billing Association of Humanist
survey):

BAH survey

Engineering 95%
Finance 80%
S&M 70%
Manufacture 60%
IT 30%

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Engineering services outsourcing (ESO) is the next logical step for India, moving from low-
end BPO work to high-end ESO. Mahindra Engineering Services (MES) is a leading
engineering services provider to the global automotive, aerospace, and manufacturing
industry.

The current automotive marketplace is an innovative and dynamic one with companies
vying with one another to create and bring about breakthroughs in design and technology.
Mahindra engineering prides itself on not only keeping up with the latest trends but also
anticipating customer requirements well in advance, taking the concept of innovation and
preparation to the next level. Combating pricing pressures, product differentiation and the
other hindrances to new product development, we offer strategic automotive engineering
services.

The solutions for the automotive domain help international automotive companies become
successful by reducing costs and maximizing productivity. We help them in various areas of
the product development process such as ideation, optimization, testing, research and
development, pre-production prototyping, production control and post-production lifecycle
management and support.

We help our customers with 2D and 3D drawings with special reference to the automotive
sector. Our solutions reflect the highest levels of automotive and mechanical engineering,
coupled with cutting-edge technology. We provide solutions that touch every aspect of the
automotive domain such as procurement and logistics, manufacturing, product development,
marketing and sales, etc.

The mission is to provide robust, high-quality engineering expertise to enable our customers
in the automotive domain to produce high-performance automobiles that will move up the
value chain. The automotive experts at Outsource2india offer services that are designed to
provide automotive manufacturers the best-in-class design solutions. They are entitled to

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continuous training in all the leading automotive technologies. The team comprises of
skilled automotive and mechanical engineers who are experienced to provide you with the
design required at the manufacturing stage. Our automotive engineers have the knowledge
of widely used design and manufacturing standards used across the industry. This helps us in
delivering solutions right from the concept stage to the implementation stage.

Automotive Solutions

Providing an entire range of services in all fields of automotive manufacturing and design,
they:
• Efficiently manage business complexities
• Offer advanced product portfolio management services
• Help companies manage change in a dynamic global environment

An Overview of the Services / Solutions available

Product Development and Engineering

We provide a wide spectrum of integrated services that not only are affordable but also
enable you to meet your business needs. We help our customers design, visualize and
simulate complex automotive product and process designs, besides supporting integrated 3D
modeling and electrical design processes.

Key services and solutions used by the regular customers include:

• Finite Element Analysis (FEA) services

• CAD Services like modeling, conversion and migration
• Plastic molding solutions
• Reverse engineering solutions
• Jigs and fixtures design solutions

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Enterprise IT Services
We enable automotive manufacturers and their suppliers to effectively tackle and meet
economic and competitive pressures with our PLM solutions. Some of our service
capabilities are vehicle styling, digital prototyping, concept design and ergonomics.

Procurement and Logistics

Global automobile enterprises need to manage their supply chain costs and need to re-
evaluate and re-define the complete global supply chain network. Our capabilities in the
Supply Chain Management (SCM) and Supplier Relationship Management (SRM) space lie
in the areas of enterprise applications, process optimization, business intelligence and
information management.

Process Optimization
Process optimization services include planning and forecasting to optimize a process. Some
factors to be considered during process optimization are procurement management, supplier
evaluation and performance monitoring and other data analytics. We are cognizant of these
factors which are essential for the success of a project and aim at delivering the same to our
customers.

Information Management
Demand / supply levels in the automotive sector keep fluctuating depending upon the global
requirements and conditions. We offer a wide range of services including enterprise data
warehousing, data migration and master data management. These services help our
customers achieve optimum inventory levels and develop a comprehensive supply chain
mechanism.

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Manufacturing and Quality
Consistency benchmarks in quality and processes are essential for an automotive
organization to survive and succeed in the current scenario. We help companies incur lesser
costs in manufacturing and develop strong expertise in the various spheres of manufacturing
and quality control.

Automotive Electronics
The teams of experts from the automotive domain, who help our customers, overcome the
major obstacles such as technology constraints, resource crunches or restrained budgets.
Thee provide faster time-to-market solutions, frameworks and possess the ability to integrate
products across technologies and platforms.

Aerospace and Aviation

The aerospace industry is slated to become one of the fastest growing industries in the
world. Unfortunately, it is also experiencing numerous multi-faceted challenges such as
increasing operating costs and reduction in revenue-per-person in the passenger segment.
Stiff competition among major players in the aviation industry has now shifted the focus to
innovation, cost effectiveness and outsourcing.

Outsourcing in the aviation industry has come a long way from the low-end projects
undertaken in the early 1990s, which involved the basic use of computer-aided design
(CAD) and computer-aided manufacturing (CAM). At the turn of the millennium, the global
aerospace and aviation industry began to realize that outsourcing to countries like India held
many advantages.

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Services That are Currently Outsourced to India

While outsourcing to India has become a notable trend, the number of activities being
outsourced is growing by the day. The domain expertise in the aerospace and aviation
industry includes concept, design and analysis for a wide range of aircrafts. They provide
the following services in the aerospace and aviation industry:

• Linear and non-linear FE modeling • Rigid and flexible body dynamics

and analysis simulations
• 2D drafting and 2D design services
• 3D modeling
• CAD conversion services
• CAD migration services
• Drawing conversions
• Legacy data conversion
• Research and analysis outsourcing
• Casting services and design
• Sheet metal design services
• Embedded software development
• Offshore technical support services
• Surfacing services
• Software development and testing
• Research and development
• Mechanical designing
• MRO value chain automation
• Business transition system
• Safety critical systems development
• On-board / Non-critical systems
development
• Process definition
• CNC / CMM Programming
• Production management
• Prototyping
• Tooling design
• Structural analysis of aircraft
structures (ribs, spars)

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Areas Covered in the Aviation Industry

Mahindra engineering has a large number of skilled engineers who work on different
aircrafts such as Light Passenger Aircraft, Jet Trainers and Helicopters, besides others. They
are also positioned to effectively serve the aerospace industry in the areas of:

• Product design and development

• Embedded systems
• Product Life Cycle (PLC) management
• IT solutions
• Full Life Cycle safety / mission-critical software solutions
• Onboard software and hardware development
• Testing and integration
• Verification and validation

Tools and Technologies Used

• MOKA
• ICAD Frameworks
• CAT Script
• VB Script
• C++
• Scripting for all major CAD / CAE tools

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Advantages of Outsourcing Mechanical Engineering
Services to India

By outsourcing the mechanical engineering services to India, the customers / clients

would enjoy the following benefits:
• Access to a large pool of highly-trained engineers
• Time-zone advantage
• Reduction in development costs
• Improved operating efficiency
• Boost in innovation
• High speed development
• Reduced time to market
• Cost competitiveness

Based on a domain expertise spanning almost a decade, our mechanical engineers

offer modular service concepts, ranging from conceptual design to detailed design
and analysis.
Thus, in the years to come, India seems to be a bright beacon for attracting a growing
clientele in the aerospace and aviation industry.

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