Client: Mahindra Defence Systems Ltd.

Project: Contribution to the Armored Light Specialist Vehicle (ALSV) for the Indian Army

Tosy Auto Products Contribution: Precision-engineered critical automotive components (e.g., specialized low, medium & high pressure fuel, oil & air hoses & pipe assemblies, custom CNC parts)

Introduction: As a DGQA-registered manufacturing leader with over 53 years of expertise, Tosy Auto Products has been a proud partner in supplying vital components to India’s defence sector. This case study highlights our collaboration on the prestigious Mahindra Armored Light Specialist Vehicle (ALSV) project, a critical asset for the Indian Army, showcasing our commitment to precision, quality, and national service.

The Challenge: Developing components for a formidable vehicle like the Mahindra ALSV presented unique and stringent demands. Defence applications require unparalleled reliability, durability under extreme operational conditions, and absolute adherence to exacting specifications. Challenges included:

• Stringent Performance Parameters: Components needed to withstand high pressures, extreme temperatures, and severe vibrations inherent in armored military vehicles.
• Specialized Material Sourcing: Identifying and procuring aerospace-grade or defence-specific raw materials with robust properties, often involving long lead times.
• Complex R&D & Prototyping: Extensive research and development was required to design components that met precise dimensional tolerances, high strength-to-weight ratios, and optimal functional performance for the ALSV’s advanced systems.
• Zero-Tolerance for Failure: Any component failure in a military vehicle can have critical consequences, demanding a “Zero Defect” manufacturing approach.

Our Process & Solution: Tosy Auto Products leveraged its deep engineering knowledge, DGQA registration, and ISO 9001:2015 certified processes to address these challenges head-on:

1. Collaborative Design & Engineering: Our R&D team worked closely with Mahindra’s engineers, translating their specific ALSV requirements into optimized designs for specialized hydraulic brake hoses, high-pressure fuel pipelines, and custom CNC machined parts.
2. Advanced Material Science: Meticulous research and rigorous testing were performed to select materials that not only met but exceeded the demanding defence standards for durability and performance in harsh environments.
3. Precision Manufacturing (Zero Defect Philosophy): Utilizing our state-of-the-art facilities in Bawana, equipped with the latest technology, we applied our Total Quality Management (TQM) and Total Productive Maintenance (TPM) systems. Every stage, from tooling and die preparation to final assembly, was subjected to stringent quality checks, ensuring components met the “Zero Defect” dictum.
4. Rigorous Testing & Validation: Prototypes underwent exhaustive in-house testing (pressure, burst, impulse, temperature cycling) followed by field trials to ensure functionality, safety, and seamless integration with the ALSV’s systems, meeting all DGQA and Mahindra’s quality authorization instructions.
5. Dedicated Project Management: A dedicated team ensured seamless communication, managed complex supply chains for specialized raw materials, and maintained strict adherence to project timelines.

The Outcome: Through this meticulous process and unwavering commitment to excellence, Tosy Auto Products successfully supplied critical components that integrated flawlessly into the Mahindra ALSV. Our contribution enhanced the vehicle’s reliability and operational efficiency, directly supporting the Indian Army’s capabilities. This project not only solidified our position as a trusted partner for defence applications but also demonstrated our ability to innovate and deliver under the most demanding specifications. Tosy Auto Products continues to be a proud contributor to the nation’s defence readiness.