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PUNJAB BEVEL GEARS WELCOMES.

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Presentation on theme: "PUNJAB BEVEL GEARS WELCOMES."— Presentation transcript:

1 PUNJAB BEVEL GEARS WELCOMES

2 INTRODUCTION Sahibabad Sitarganj Sahibabad

3 INTRODUCTION GROUP COMPANIES SAHIBABAD UTTAR PRADESH 4 PLANTS*
LUDHIANA PUNJAB 2 PLANTS SITARGANJ UTTARAKHAND 3 PLANTS Differential & Transmission Gears and Shafts Forging Machining Axle Shaft Differential & Transmission Gears, Differential cage and Drive line parts *There are 4 manufacturing units all located within 500 metres in Sahibabad.

4 INTRODUCTION Started operations in 1979 Manufactures more than 2000 different type of gears Leading manufacturer, supplier and exporter of automotive and tractor parts Caters to industries like commercial vehicles, agricultural tractors, passenger cars, three wheelers & construction equipments

5 INTRODUCTION Our competitiveness lies in the fact that we are: Cost Competitive, Quality Conscious, Having track record of on time delivery Having 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 2014 Having assurances from financial institutions for support in the on going and future expansions Having very sound HR policies with almost nil employee turnover The average age of employees is 40 years Having 100% captive power back up at all plants An ISO/TS 16949: 2009 Certified Company

7 PRODUCT RANGE Crown Wheel & Pinion (Face Mill, Face Mill Completing
and Face Hob in both Dry and Wet cutting) ST. Bevel Gear & Pinions (Gleason Coniflex System) Transmission Gears(Spur,Helical) Differential Cages Axle Shafts Forgings/Machined Forgings Drive Line Parts

8 (Face Mill and Face Hob Wet Cutting process)
PRODUCT RANGE Crown Wheel & Pinion (Face Mill and Face Hob Wet Cutting process) Crown Teeth Cutting Pinion Teeth Cutting Crown & Pinion Testing

9 PRODUCT RANGE St. Bevel Gears & Pinions (Gleason Coniflex System)
Teeth Cutting Gear & Pinion Testing Teeth Cutting

10 PRODUCT RANGE Transmission Gears and Shafts (Spur, Helical)
CNC Blanking CNC Hobbing Spline Hobbing Stack Hobbing

11 PRODUCT RANGE Transmission Gears and Shafts (Products)

12 PRODUCT RANGE Differential Cages CNC Machining CMM

13 PRODUCT RANGE Axle Shafts

14 GROUP TURN OVER (Mio Rs)

15 GROUP TURN OVER (Mio $)

16 SEGMENT WISE SALES FY13-14

17 CAPACITY INSTALLED Sl.No. Product Annual* Utilization Capacity of
Crown Wheel & Pinion ,000 Sets 60% Straight Bevel Gears ,500,000 Nos. 80% 3. Transmission Gears ,600,000 Nos. 60% 4. Axle Shafts ,000 Nos. 25% 5. Forgings ,000 MT 70% Differential Cage ,000 Nos. 40% Drive Line Parts ,000 Nos. --- * On 2 Shift Basis

18 CLASS 6-7 in Dry Cutting & 8-9 in Conventional
CAPABILITIES - GEARS TYPE SPIRAL/ HYPOIDS STRAIGHT BEVEL SPEED GEAR TRANS. SHAFT MAX. SIZE (DIA) MM 600 216(10:1) 152(1:1) 400 80 MAX. FACE WIDTH/L 70 50.80 135mm Shaving 1000mm MAX. MODULE (mm) 13.00 8.50 8.00 ACCURACY DIN CLASS 6-7 in Dry Cutting & 8-9 in Conventional CLASS 8-9

19 CAPABILITIES - FORGINGS
Weight Kg to 50 Kgs Round Forging Min. Dia 80 mm Max. Dia 500 mm Shaft Forgings Length mm Flange Dia 325 mm

20 PLANT AREA IN SQ. FT Sahibabad Ludhiana Sitarganj Total Area 500,600
152,500 183,140 Covered Area 179,390 46,000 95,200 General Office Area 5,420 5,000 11,600

21 MANPOWER Sahibabad Ludhiana Sitarganj Hourly 335 165 100 Supervisory
47 07 12 Manager 13 01 02 Total 395 173 114

22 CERTIFICATION / AWARD QUALITY SYSTEMS:
Plants at Sahibabad and Sitarganj are ISO/TS 16949: 2009 certified Forging plant at Ludhiana is ISO 9001: 2008 certified Differential gear plant is ISO 9001, ISO & ISO certified EXPORT PROMOTION: Recognized star export house Awarded 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 2010 Best supplier award for consistent delivery performance through pull system-KANBAN by TAFE in 2013 Supplier recognition award by American Axle in 2010 Direct on line supplier award by TAFE & International Tractors Limited

24 CUTTING EQUIPMENT INSTALLED AT SAHIBABAD/LUDHIANA
CNC Turning Lathes Nos. Vertical Machining Center 10 Nos. Gleason Crown Wheel Sets (608/609, 606/607, No. 22, No.11 & No.112) Gleason Pinion Sets (No.116) Oerlikon Nos. (SM3, S17, SKM1)

25 CUTTING EQUIPMENT INSTALLED
AT SAHIBABAD Transmission Gears Hobbers nos CNC Hobbers nos CNC Shaper 1 no. Shapers nos Shavers nos Shobbers 1 no Straight Bevel Gears Gleason Coniflex nos Gleason Coniflex nos Coniflex WMW nos

26 HEAT TREATMENT FACILITIES
Sealed Quench Furnace Sealed Quench Furnace Continuous Gas Carburising Furnace

27 HEAT TREATMENT FACILITIES
Sealed Quench Furnaces Continuous Gas Carburizing Furnace Rotary Hearth Furnaces Induction Hardening / Softening Quench Presses – Gleason Tempering Furnaces Manganese Phosphating Facilities Shot Peening Equipment Shot Blasting Equipments Straightening Presses

28 FINISHING EQUIPMENTS Cylindrical Grinding Machines -15 Nos.
CNC Internal Grinder No. CNC Lathe for Hard Nos. Internal Grinding Machines Nos. Spline Grinding Machines Nos. Lapping Machine Gleason Nos. (503/506/119/516) Gear Testers-Gleason Nos. (502/511/17-A)

29 METALLURGICAL LAB FACILITIES
Full range of Hardness Testers ( Rockwell, Brinell, Micro Vickers) Hardenability (Jominy) Apparatus Microscope with camera and image analyzer Magnetic Particle Inspection Macro Etching Muffle Furnaces Manganese Phosphating Solution Analyzer

30 METROLOGY LAB FACILITIES
CMM with Gear Analyzer Lead and Profile Testers Surface Roughness Tester Contouro Graph Profile Projectors Gear Roll Testers Digital Temperature Calibrator dB Meter

31 QUALITY SYSTEMS RAW MATERIAL Visual Inspection for cracks and folds.
 Forgings are received Heat Code wise duly Isothermally 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 at correct mounting distance, tooth contact, run out and marking mounting distance variations.  

33 QUALITY SYSTEMS HEAT TREATMENT Batches are subjected to checks on:
Effective Case Depth Core and Surface Hardness Microstructure- Case & Core Flatness & ovality of bore for Crown Wheels Straightness for Shaft items Magnetic particle inspection

34 TRACEABILITY RAW MATERIAL TRACEABILITY
- Unique TR No. Identifying steel mill, grade & forge shop punched on parts wherever possible HEAT TREATMENT TRACEABILITY - Unique charge No. identifying furnace, month & process parameters punched on parts wherever possible CWP SET TRACEABILITY - Unique set no. etched on both the members LOGO MARKING - Customer / PBG logo punched / Laser marked / Bar Code as per customer requirements

35 INVESTMENT COMMITTED Additional Continuous Gas Carburizing Furnace Additional Sealed Quench Furnaces Shaving Cutter Sharpening- Gleason Additional CNC Hobbers Additional CNC Shapers CNC Shavers Additional CNC Internal Grinder CNC External Grinders Additional Vertical Machining Center

36 CUSTOMER PROFILE–DOMESTIC OEMs
AUTOMOTIVE Tata Motors Mahindra & Mahindra American Axle & Manufacturing Scooters India

37 CUSTOMER PROFILE–DOMESTIC OEMs AGRICULTURE
Tractors and Farm Equipment International Tractors John Deere Equipment Dana India Indo Farm Equipment Sicma India

38 CUSTOMER PROFILE–EXPORT OEMs
Meritor, Brazil Dana, USA Hema Endustri A.S.,Turkey Mega Motors Company, Iran Iran Tractor Mfg Company, Iran

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 Yard Friction Belt Drop Hammer Up Setter Annealing 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 Inches Furnaces for Isothermal annealing & normalizing Fully equipped die making facilities Material testing facilities includes Spectro Meter & Universal Testing Machine along with Izol Impact & Charpy Testing Machines 100% back up with Captive Power An ISO 9001: 2008 certified

42 FACILITIES AT SITARGANJ
Latest Generation Gleason Phoenix CNC Dry/Wet Cutting System

43 FACILITIES AT SITARGANJ
Pinion Teeth Cutting Line Crown Teeth Cutting Line Lapping & Testing Line Metallurgical Lab Sealed Quench Furnace Phosphating Plant Annealing Furnace Forging Press Forging Press

44 FACILITIES AT SITARGANJ
Green Field Plant Production started from March 2010. Equipment at the Plant: Gleason Phoenix CNC Cutting(600 HC) No. Gleason Phoenix CNC Cutting(275 HC) No. CNC Blade Profile Grinder No. CNC Cutter Build Machine No. CNC Gear Measuring Machine No. Gleason Pinion Generator(No.116) sets Gleason Crown Wheel(606/607, No.22) sets Hobber nos. Shaper nos. Shaver nos. Milling nos. External Grinder nos. Internal Grinder nos. CNC Lathe nos.

45 FACILITIES AT SITARGANJ
Gleason Lapper(503, 506, 514) nos. Oerlikon Lapper SKL no. Gleason Tester(511, 512, 17A) nos. Continuous Gas Carburising Furnace no. Sealed Quench Furnace no. Gas Carburising Furnace nos. Rotary Furnace no. Gleason Quenching Press (537) nos. Shot Blasting Equipment no. Fully Equipped Metrology and Metallurgical Laboratory 100% captive power back up

46 PLANT ADDRESS PUNJAB BEVEL GEARS LIMITED
Unit-I &Address for communications: B-44/1 & 52/2, Site-IV, Industrial Area, Sahibabad , Ghaziabad (U.P) INDIA Tel.: , Fax: / URL: Unit-II : B-174, Phase –I, Eldeco Sidcul Industrial Park, Sitarganj , Udhamsingh Nagar , (Uttarakhand), INDIA Unit-III: V&PO: Bhama Kalan, Kohara-Machiwara Road, Ludhiana (Punjab), INDIA

47 THANK YOU


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