3 INTRODUCTION GROUP COMPANIES SAHIBABAD UTTAR PRADESH 4 PLANTS* LUDHIANAPUNJAB2 PLANTSSITARGANJUTTARAKHAND3 PLANTSDifferential &TransmissionGears and ShaftsForgingMachiningAxle ShaftDifferential &TransmissionGears, Differential cageand Drive line parts*There are 4 manufacturing units all located within 500 metres in Sahibabad.
4 INTRODUCTIONStarted operations in 1979Manufactures more than 2000 different type of gearsLeading manufacturer, supplier and exporter of automotive and tractor partsCaters to industries like commercial vehicles, agricultural tractors, passenger cars, three wheelers & construction equipments
5 INTRODUCTIONOur competitiveness lies in the fact that we are:Cost Competitive,Quality Conscious,Having track record of on time deliveryHaving capability to develop new products in a comparatively shorter period
6 INTRODUCTION Financially sound having credit rating of ‘care BBB-’ (Triple B Minus) For long term bank facilities for 2014Having assurances from financial institutions for support in the on going and future expansionsHaving very sound HR policies with almost nil employee turnoverThe average age of employees is 40 yearsHaving 100% captive power back up at all plantsAn ISO/TS 16949: 2009 Certified Company
7 PRODUCT RANGE Crown Wheel & Pinion (Face Mill, Face Mill Completing and Face Hob in both Dry andWet cutting)ST. Bevel Gear & Pinions(Gleason Coniflex System)Transmission Gears(Spur,Helical)Differential CagesAxle ShaftsForgings/Machined ForgingsDrive Line Parts
8 (Face Mill and Face Hob Wet Cutting process) PRODUCT RANGECrown Wheel & Pinion(Face Mill and Face Hob Wet Cutting process)Crown Teeth CuttingPinion Teeth CuttingCrown & Pinion Testing
9 PRODUCT RANGE St. Bevel Gears & Pinions (Gleason Coniflex System) Teeth CuttingGear & Pinion TestingTeeth Cutting
10 PRODUCT RANGE Transmission Gears and Shafts (Spur, Helical) CNC BlankingCNC HobbingSpline HobbingStack Hobbing
11 PRODUCT RANGETransmission Gears and Shafts(Products)
22 CERTIFICATION / AWARD QUALITY SYSTEMS: Plants at Sahibabad and Sitarganj are ISO/TS 16949: 2009 certifiedForging plant at Ludhiana is ISO 9001: 2008 certifiedDifferential gear plant is ISO 9001, ISO & ISO certifiedEXPORT PROMOTION:Recognized star export houseAwarded silver shield for export performance during ,, , , & by Engineering Export Promotion Council, India
23 CERTIFICATION / AWARD CUSTOMER AWARDS: Best supplier award for new product development by TAFE in 2010Best supplier award for consistent delivery performance through pull system-KANBAN by TAFE in 2013Supplier recognition award by American Axle in 2010Direct on line supplier award by TAFE & International Tractors Limited
29 METALLURGICAL LAB FACILITIES Full range of Hardness Testers( Rockwell, Brinell, Micro Vickers)Hardenability (Jominy) ApparatusMicroscope with camera and image analyzerMagnetic Particle InspectionMacro EtchingMuffle FurnacesManganese Phosphating Solution Analyzer
30 METROLOGY LAB FACILITIES CMM with Gear AnalyzerLead and Profile TestersSurface Roughness TesterContouro GraphProfile ProjectorsGear Roll TestersDigital Temperature CalibratordB Meter
31 QUALITY SYSTEMS RAW MATERIAL Visual Inspection for cracks and folds. Forgings are received Heat Code wise dulyIsothermally Annealed/ Normalised from approved Forge shops.Checks carried out before processing are: Visual Inspection for cracks and folds. Check of chemical composition by Spectro Analysis at forging plant. Hardness. Jominy Hardenability. Micro structure and Inclusions. Grain Size.Inclusion Rating.Macro etching/Grain flow.
32 QUALITY SYSTEMS IN-PROCESS First off inspection as per control plan. Patrol inspection at defined interval as per control plan.For Bevel Gears check tooth contacts in soft Gears.Before Heat Treatment inspection for all parts.ensuring removal of any sharp edges and burrs.For Bevel Gears Final Testing to ensure backlash atcorrect mounting distance, tooth contact, run out andmarking mounting distance variations.
33 QUALITY SYSTEMS HEAT TREATMENT Batches are subjected to checks on: Effective Case DepthCore and Surface HardnessMicrostructure- Case & CoreFlatness & ovality of bore for Crown WheelsStraightness for Shaft itemsMagnetic particle inspection
34 TRACEABILITY RAW MATERIAL TRACEABILITY - Unique TR No. Identifying steel mill, grade & forgeshop punched on parts wherever possibleHEAT TREATMENT TRACEABILITY- Unique charge No. identifying furnace, month &process parameters punched on parts wherever possibleCWP SET TRACEABILITY- Unique set no. etched on both the membersLOGO MARKING- Customer / PBG logo punched / Laser marked / Bar Code asper customer requirements
39 CUSTOMER PROFILE-EXPORTS We also Export our products to Importers, Gear Makers & After Markets in:USA , U.K., France, S. Africa, Indonesia, Malaysia, Thailand, Singapore, Myanmar, Syria, Egypt, Turkey, Bangladesh, Sri Lanka, Iran, Dubai, Italy, Argentina, Australia, Hungary, Germany, Brazil.
40 FORGING FACILITIES AT LUDHIANA Steel YardFriction Belt Drop HammerUp SetterAnnealing Furnace
41 FORGING FACILITIES AT LUDHIANA Friction Belt Drop Hammer (1.00, 1.50, 2.00, 2.50, 3.00, 6.00, 8.00 M.T. and a 25T Counter Blow hammer)Up Setter - 3 Inches & 7 InchesFurnaces for Isothermal annealing & normalizingFully equipped die making facilitiesMaterial testing facilities includes Spectro Meter & Universal Testing Machine along with Izol Impact & Charpy Testing Machines100% back up with Captive PowerAn ISO 9001: 2008 certified
42 FACILITIES AT SITARGANJ Latest GenerationGleason PhoenixCNC Dry/WetCuttingSystem