AURANGABAD ELECTRICALS LTD. Mar 2016

Transcription

1 AURANGABAD ELECTRICALS LTD Mar

2 ABOUT BAGLA GROUP 2

3 3 INTRODUCTION Bagla Group was established in It is one of the leading auto component manufacturing companies in India It has 8 manufacturing facilities across western and northern India The group sales turnover is of INR 8.7 Billion for the year Industry Presence - Automotive Manufacturing facilities / Capabilities: o Die Designing & Manufacturing Joint Ventures: o With Officine Meccaniche Rezzatesi (OMR), Italy for HPDC o High Pressure & Gravity Die Casting o Machining and Surface Treatments o With LI-IN Electricals, Taiwan for Electrical parts o Sub-Assembly o Steel Fabrication and Electro Plating o High Tensile Fasteners o Automotive electrical parts such as Ignition coil, Magneto, Starter Motor, Sensor, Flasher, Relay etc o With Fontana, Italy for High Tensile Steel Fasteners Subsidiary: o AE Deutschland GmbH, Germany: Machining of Aluminium castings Driven by 1150 qualified personnel

4 4 GROUP STRUCTURE B A G L A G R O U P Aurangabad Electricals Ltd. AE Deutschland GmbH, Germany BGFEIPL* JV With Fontana, Italy OBASIL** JV With OMR, Italy BG-LI-IN JV With LI-IN, Taiwan HPDC Machining, Painting, Sub- Assy. Design, Engg & Tool room GDC Machining, Painting, Sub-Assy. Auto Electricals Machining of Aluminium castings High Tensile Steel Fasteners HPDC Machining, Painting, Sub-Assy. Auto Electricals Note: * BG Fastening and Engineering Industries Private Limited ** OMR Bagla Automotive Systems India Limited

5 5 GROUP HISTORY Wind Power High Tensile Fasteners Solution provider across a wide range of automotive products Enters into JV with OMR Holdings Spa Establishes plant in Pantnagar for Alu. Die Casting components Investment by Blue River Capital GDC business becomes part of AEL on back of restructuring of AMML 1 R&D Centre receives recognition from DSIR 2 Formed subsidiary company AE Deutschland GmbH Die Casting BG LI-IN Electricals Limited is incorporated Shifts focus to be complete solution provider for die casting comps. Commences manufacturing of high tensile fasteners Enters JV with Fontana Finanziaria S.P.A. Auto Electricals Incorporation AEL as a auto electrical component supplier Establishes die casting unit Notes: 1 AMML - Aurangabad Motor Manufacturers Limited 2 DSIR: Department of Scientific and Industrial Research

6 6 GROUP PRESENCE Location: Pantnagar 1 HPDC Unit Location: Aurangabad 2 HPDC Units 1 GDC Unit 2 Electrical Units 1 Fastener Unit Corporate Office Location: Pune 1 HPDC Unit 08 Plants across India

7 7 QUALITY & ENVIRONMENTAL CERTIFICATIONS We commit ourselves to satisfy our customers by manufacturing products synonymous with Quality & Reliability and total dedication of all our members to achieve the goal. We adopt continual improvement philosophy in products & processes and also work towards energy conservation & environment protection & safety. All plants are certified for ISO 9001 and TS Plant-3, Plant-6,Plant-9,Plant-N1 & GDC Certified for OHSAS & ISO ISO 9001: 2008 ISO/TS 16949: 2009 BS OHSAS 18001: 2007 ISO 14001: 2004

8 8 DOMESTIC & OVERSEAS CUSTOMERS Two Wheeler OEM Four Wheeler OEM Tier 1 & Non Auto

9 GLOBAL CUSTOMERS Canada (Magna) Germany (Behr, GPM) Austria (Rotax, Scooter Tech) Netherlands (MHIL) USA (Behr, Chrysler) Italy (Aprilia, OMR, Piaggio) India (Bagla Group) Thailand (MHIL) Vietnam (Piaggio) Representatives Offices at France, Germany, UK & Italy 9

10 10 CAPABILITY OVERVIEW Design & Analysis Die Design Die Mfg M/C Unigraphics NX 8 Catia V5 R 21 VA / VE Suggestions Tool & Die Manufacturing CNC Milling CNC EDM Proe-Creo-2 NC EDM Die Mfg Engineering & Design Inputs Process Design & Development Surface Grinder Cylindrical Grinder Unigraphics NX 8 Lathe Work NC V 21 Radial Drilling Simulation Surface Treatment & Painting Manufacturing of Casting Inspection Flow 3D V10.1 Machining & Assembly Mitutoyo CMM

11 ALUMINIUM CASTING BUSINESS 11

12 12 FACILITIES: ALUMINIUM CASTING BUSINESS Plant 3 Plant 6 Plant N1 Plant GDC OBASIL Engineering & Tool Room Description Plant 3 Plant 6 OBASIL Plant N1 Plant GDC Engineering & Tool room Open Area (Sq. Mt.) 48,969 12,000 24,417 39,000 10,500 6,375 Buildup Area (Sq. Mt.) 12,000 6,000 14,028 11,000 5,000 1,646 Location Aurangabad Pune Aurangabad Pant Nagar Aurangabad Aurangabad

13 13 FACILITIES HPDC & GDC HPDC Facilities GDC Facilities

14 FACILITIES: HPDC 14

15 15 FACILITIES: GDC GDC Machine type Mounting size (mm) No. Of machines Tilting Type 950 x Tilting Type 900 x Tilting Type 525 x Tilting Type 750 x Stationary Type 525 x Stationary Type 700 x Total 20 Core Machine type Mounting size (mm) No. Of machines Stationary 600 x Stationary 600 x Stationary 500 x Roll Over 600 x Roll Over 820 x Roll Over 900 x Roll Over 650 x Roll Over 400 X Swing Door 800 X Total 12

16 16 FACILITIES: MACHINING, SUB-ASSEMBLY AND SURFACE TREATMENT Machining Facility Sub assembly & Painting Facility

17 17 FACILITIES: MACHINING Machine Plant 3 Plant 6 OBASIL Plant N1 Plant GDC Aurangabad Pune Aurangabad Pantnagar Aurangabad Total CNC Turning Centre Turno Mill Centre Special Purpose Machines Vertical Machining Centre Horizontal Machining Centre Cylindrical Grinding SPM Broaching Machine Total

18 18 FACILITIES: SUB-ASSEMBLY AND SURFACE TREATMENT Machine / Plant Assembly Lines for various components Automated Pre Treatment & Painting Line Automated Pre Treatment & Powder coating Line Nickel Chrome Plating Plant Plant 3 Plant 6 OBASIL Plant N1 Plant GDC Total Aurangabad Pune Aurangabad Pantnagar Aurangabad D MODEL RPT MACHINE Washing Machine Leak Testing Machines Vacuum Impregnation

19 FACILITIES: QA INSTRUMENTS 19

20 20 FACILITIES: QA INSTRUMENTS MACHINE Plant 3 Plant 6 OBASIL Plant N1 Plant GDC Aurangabad Pune Aurangabad Pantnagar Aurangabad Total Spectrometer for Al Alloy and Steel material composition X-Ray Machine Co-ordinate Measuring (3D) Universal Load Testing Hardness Tester Mechanical Testing Lab Techno Scope (porosity) Surface Finish Tester Full fledged Room for calibration Optima Height Tester Contour Tester Profile Projector Roundness Tester Particle count measurement

21 21 PRODUCTS Cylinder Head (M/ced & sub Assy) Suspension Arm Brake Drum

22 PRODUCTS Bed Plate Bed Plate Oil Pan Support Brackets Gear Box Covers Support Brackets

23 23 PRODUCTS Pump Housings Support Brackets

24 24 PRODUCTS Charge Air Pipes Housings Power take off Charge Air Housing

25 PRODUCTS 25

26 26 PRODUCTS Gear Housings RH Gear Housings Center Gear Housings LH

27 27 PRODUCTS Oil & Water Pump Housings Rear Hgs. Front Hsg Front Bracket Heat sink

28 28 PRODUCTS Compressor Housings ECU Cover

29 29 PRODUCTS Front/ Rear Brake Panel (5 million pcs pa) Clutch Cover Cover Magneto (3.0 million pcs pa) Front/ Rear Brake Drum (1.5 million pcs pa) Grip Frame (0.85 mil pcs pa) Coupling (0.85 mil pcs pa) Step Holder LH/RH (3 million pcs pa) Master Cylinder (0.5 mil pcs pa) Cylinder Block (0.25 mil pcs pa)

30 30 PRODUCTS Intake Pipes (3.8 million pcs pa) Pulsur-180 Avenger Discover RE2S Platina CT-100 Upper Bracket Handle Holder

31 PRODUCTS Water Pump Cover Head Cover Clutch Cover Support Command Support Assembly Suspension Arm Support Shock Absorber Assembly Head Cover Magneto Cover Support 31

32 32 PRODUCTS Compressor Filter Housing As Cast Compressor Filter Head Machined & Painted Compressor Filter Housing Machined & Painted

33 ENGINEERING & TOOL ROOM 33

34 34 CAPABILITIES: DESIGN & ENGINEERING Co-design & simultaneous engineering o o o o o Weight reduction Material substitution Improvement in mechanical properties Enhancement of performance Value Engineering: Reduction in Part count Subsequent manufacturing operations Manufacturing cycle time Robustness in manufacturing process Ease of manufacturing 3D modelling Flow, fill and solidification simulation and validation

35 35 CAPABILITIES: DESIGN & ENGINEERING Finite element analysis (S/c) Design & development of dies and core boxes Design of gating system Selection of material, heat treatment cycle Location, shape and size of rest pad, ejection pin etc. Design, development and local manufacturing (S/c) of key foundry equipment

36 36 CAPABILITIES: Objectives of R & D: Create, evaluate & validate concepts and specifications through design, simulation, manufacturing & testing of prototypes Design, development of new Product Development of new processes, technologies, methods of analysis and testing Acquire know how to manufacture light metal castings that are required for o o o Light weighting Environmental compliance Performance enhancement Improvements & innovation in design, process and product Improvement in efficiency of utilisation of resources such as equipment, energy, material etc. Reduce impact on environment due to the activities of the company Substitution of imported material, machine, tooling, technology etc. Our Engineering center has been recognised as In-house Research and Development Centre by Government of India s Department of Science & Industrial Research

37 INNOVATION: CO-DESIGN, SIMULTANEOUS ENGINEERING, VA/VE 37

38 38 INNOVATION: CO-DESIGN, SIMULTANEOUS ENGINEERING, VA/VE Before After 4 Cavity die to 12 Cavity die Before: 104 gm After: 72 gm Core weight reduction

39 39 INNOVATION: CO-DESIGN, SIMULTANEOUS ENGINEERING, VA/VE Yield Improvement Before: 35 % After: 60 % Core weight reduction Before After Core height reduced by 20 mm, 0.7 Kg sand saved

40 40 INNOVATION: PRODUCT DESIGN IMPROVEMENT (REDUCTION IN WEIGHT) Before: Weight = 2.94 Kg runner After: Weight = 2.76 Kg Die was redesigned with a weight reduction pocket to tackle the problem of solidification shrinkage.

41 41 FACILITIES: ENGINEERING AND TOOL ROOM Facility Numbers Unigraphics NX6 8 Catia V5 R17 1 Pro-E 2 Solid Edge 1 Work NC 2 Simulation Software 2 Feed Design Software 1 Vertical Machining Center 9 EDM Machine (Spark Erosion) 2 Wire cut EDM Machine 4 Die Spotting Press 1 Surface Grinding Machine 3 Cylindrical Grinding Machine 2 Coordinate Measuring Machine 1 Tempering Furnace 1

42 AE DEUTSCHLAND GmbH, GERMANY (GREENFIELD PROJECT) 42

43 43 AE DEUTSCHLAND GmbH, GERMANY The company formed & registered Land measuring 18,968 sq meters, located at Bachschleife, in the industrial area of Arnstadt, Thüringen (30 km from Erfurt) is acquired for setting up the facility Current status (Sep 2015) : Planning stage

44 HIGH TENSILE STEEL FASTENER DIVISION (BG FASTENING AND ENGINEERING INDUSTRIES PRIVATE LIMITED) 44

45 45 FACILITIES: FASTENER DIVISION (BG FASTENING AND ENGINEERING INDUSTRIES PRIVATE LIMITED) Description Fastener Division (BGFEIPL) Open Area (Sq. Mt.) 78,307 Buildup Area (Sq. Mt.) 10,683 Location (Sq. Mt.) Aurangabad

46 46 FACILITIES: FASTENER DIVISION Sr. No. Capacity Type MT / Month 1 Wire Drawing Capacity Forging Capacity Heat Treatment Capacity Alkaline Zinc Plating Capacity Dacro / Geomet Coating Capacity 50 6 Precoating / Patch Coating Capacity 50 Single roof operation for wire processing Cold forging Thread rolling Machining Heat Treatment Zinc Plating to Dacro Coating 7 Phosphating Capacity 600

47 47 PRODUCTS: FASTENER DIVISION (BOLTS) Types : Engine Studs, Con rod bolts, Axles, Flange bolts, Socket head bolts Size Range : M6 to M16 Length : Upto 300mm Grade : 6.8, 8.8, 9.8, 10.9, 12.9 Thread Type : Metric

48 PRODUCTS: FASTENER DIVISION (NUTS) Types :Nylock, Domed, Wheel and Serrated Flange Nuts Size Range : M6 to M16 Grade : 4, 6, 8, 10 Thread Type : Metric 48

49 PRODUCTS: FASTENER DIVISION (SPECIAL FASTENERS) Size Range : M6 to M16 Length : Upto 300mm Grade : 6.8, 8.8, 9.8, 10.9, 12.9 Thread Type : Metric 49

50 AUTO ELECTRICALS DIVISION 50

51 51 FACILITIES: AUTO ELECTRICALS Description Auto Electricals Division (Plant 4) BG LI IN Electricals Open Area (Sq. Mt.) 10, Buildup Area (Sq. Mt.) 1, Location Aurangabad Aurangabad

52 52 FACILITIES AUTO ELECTRICALS Production : Conveyorised, Temperature & Dust Control environment CNC multi spindle & twister for secondary coil winding. Vacuum potting machine from Huebers, Germany. On-line burning & Open voltage circuit tester Testing in actual operating condition with Magneto Performance Test Machine (Chuyi, Taiwan) Capacity to produce 16 Million Relays Per Annum In-house Research and Development Centre recognised by Government of India s Department of Science & Industrial Research Quality Control : Endurance testing for HT coil, Jig for life cycle test Vibration testing, Hot water & Salt spray test chamber Hot & cold chamber X-ray testing machine

53 53 FACILITIES AUTO ELECTRICALS Assembly Lines Online Relay Testing Facilities

54 PRODUCTS: AUTO ELECTRICALS Product Range: Magnetos Regulators Ignition Coils (HT Coil) Relays Flashers

55 CUSTOMER SUPPORT 55

56 56 CUSTOMER SUPPORT Conference call E - Mail Internet portal Periodic visits Local office NPD Status update Schedule visibility Delivery performance Stock monitoring Quality status

57 57 LOGISTICS AEL Aurangabad Export Clearance at Port. Port of Mumbai Ocean Freight Local warehousing CCL at Destination Port at Destination Delivery at Customer Location

58 MANAGEMENT FOCUS 58

59 59 MANAGEMENT FOCUS Process reengineering Continuous improvement & innovation Employee development & involvement Customer satisfaction Supplier partnership Result Orientation Social responsibility

60 60 SHOP FLOOR MANAGEMENT Kaizens (small improvements) Focused improvements 1S - 2S Housekeeping Abnormality elimination Why why analysis

61 RECOGNITIONS 61

62 62 AWARDS BAL Q - Gold Award - AEL Plant N1 General Motor "Best Quality Supply Award - OBASIL Excellent performance award at QCFI Convention in Sept 2014 Plant 9 Appreciation award in state level Kaizen competition by QCFI Plant 9 Suzuki Motor Best Supply Performance Award. BG LI-IN Electricals Silver Award at Quality Circle Forum of India - AEL Plant 9 BAL TPM Award - AEL Plant N1 BAL Q - Gold Award - AEL Plant 3 BAL TPM Award - AEL GDC division BAL Q - Gold Award - AEL GDC division Tata Toyo Best Supplier AEL GDC division Atlas Copco Best New Supplier AEL GDC division BAVA Kaizen Competition (2nd Runner-up Award) BAL "Q - Silver Award"- AEL Plant 3 BAL "Q - Silver Award"- AEL Plant 4

63 63 CONTACTS Mr. Kundan K Jha Executive Director & CEO (AEL) kundan.jha@baglagroup.com Mobile No: Mr. Rakesh Pardeshi Sr. Manager (Business Development and Sales, AEL) pardeshi.r@baglagroup.com Mobile No: Mr. Ajeet Kumar Sr. Manager (Business Development and Sales, AEL) kumar.a@baglagroup.com Mobile No: