AURANGABAD ELECTRICALS LTD Mar 2016 1
ABOUT BAGLA GROUP 2
3 INTRODUCTION Bagla Group was established in 1985. 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 2014-15 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 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 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 1985-1994 Notes: 1 AMML - Aurangabad Motor Manufacturers Limited 2 DSIR: Department of Scientific and Industrial Research 1995-2004 2004-2005 2006-2008 2009-2010 2011-2013 2014-2015
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 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 16949 Plant-3, Plant-6,Plant-9,Plant-N1 & GDC Certified for OHSAS & ISO 14001 ISO 9001: 2008 ISO/TS 16949: 2009 BS OHSAS 18001: 2007 ISO 14001: 2004
8 DOMESTIC & OVERSEAS CUSTOMERS Two Wheeler OEM Four Wheeler OEM Tier 1 & Non Auto
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 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
ALUMINIUM CASTING BUSINESS 11
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 FACILITIES HPDC & GDC HPDC Facilities GDC Facilities
FACILITIES: HPDC 14
15 FACILITIES: GDC GDC Machine type Mounting size (mm) No. Of machines Tilting Type 950 x 520 2 Tilting Type 900 x 450 3 Tilting Type 525 x 300 3 Tilting Type 750 x 600 4 Stationary Type 525 x 300 5 Stationary Type 700 x 600 3 Total 20 Core Machine type Mounting size (mm) No. Of machines Stationary 600 x 750 2 Stationary 600 x 400 2 Stationary 500 x 500 1 Roll Over 600 x 450 1 Roll Over 820 x 500 2 Roll Over 900 x 500 1 Roll Over 650 x 380 1 Roll Over 400 X 400 1 Swing Door 800 X 400 1 Total 12
16 FACILITIES: MACHINING, SUB-ASSEMBLY AND SURFACE TREATMENT Machining Facility Sub assembly & Painting Facility
17 FACILITIES: MACHINING Machine Plant 3 Plant 6 OBASIL Plant N1 Plant GDC Aurangabad Pune Aurangabad Pantnagar Aurangabad Total CNC Turning Centre 31 0 19 15 3 68 Turno Mill Centre 0 0 2 0 0 2 Special Purpose Machines 8 2 2 15 0 27 Vertical Machining Centre 54 1 23 14 11 103 Horizontal Machining Centre 1 2 10 0 0 13 Cylindrical Grinding SPM 7 0 0 4 0 11 Broaching Machine 1 0 1 0 0 2 Total 102 5 57 48 14 226
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 3 3 2 6 0 14 1 1 0 1 0 3 0 1 0 0 0 1 3D MODEL RPT MACHINE 0 0 0 1 0 1 Washing Machine 4 0 4 1 2 11 Leak Testing Machines 10 1 18 5 6 40 Vacuum Impregnation 0 0 2 0 0 2
FACILITIES: QA INSTRUMENTS 19
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 2 1 1 1 1 6 X-Ray Machine 0 0 1 0 1 2 Co-ordinate Measuring (3D) 2 1 2 1 1 7 Universal Load Testing 1 1 1 1 0 4 Hardness Tester 2 1 1 1 1 6 Mechanical Testing Lab 1 1 1 0 0 3 Techno Scope (porosity) 1 0 0 1 0 2 Surface Finish Tester 1 0 1 1 0 3 Full fledged Room for calibration 1 0 1 0 0 2 Optima Height Tester 0 0 1 6 0 7 Contour Tester 0 0 1 0 0 1 Profile Projector 1 0 0 0 0 1 Roundness Tester 0 0 1 0 0 1 Particle count measurement 1 0 0 0 0 1
21 PRODUCTS Cylinder Head (M/ced & sub Assy) Suspension Arm Brake Drum
PRODUCTS Bed Plate Bed Plate Oil Pan ------------------ ------------------ Support Brackets ------------------- ------------------ ------------------ ------- Gear Box Covers ------------------ -------- - ---Support Brackets ---- 22
23 PRODUCTS ---------------------------------------------------------------------------------- Pump Housings ------------------------------------------------------------------------ ----------------------------------------------------- Support Brackets ------------------------------------------------------------
24 PRODUCTS Charge Air Pipes --------------------------------------- Housings Power take off ----------------------------------------------- ------------------------------------------------------------------- Charge Air Housing -----------------------------------------------------------------
PRODUCTS 25
26 PRODUCTS Gear Housings RH Gear Housings Center Gear Housings LH
27 PRODUCTS ---------------------------------------------------------------------------- Oil & Water Pump Housings ------------------------------------------------------------------- Rear Hgs. Front Hsg Front Bracket Heat sink
28 PRODUCTS ------------------------------------------------------------------------------ Compressor Housings ------------------------------------------------------------------- ------------------------------------------------------------------------------ ECU Cover -------------------------------------------------------------------
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 PRODUCTS -------------------------- Intake Pipes ------------------------ (3.8 million pcs pa) Pulsur-180 Avenger Discover RE2S Platina CT-100 Upper Bracket Handle Holder
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 PRODUCTS Compressor Filter Housing As Cast Compressor Filter Head Machined & Painted Compressor Filter Housing Machined & Painted
ENGINEERING & TOOL ROOM 33
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 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 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
INNOVATION: CO-DESIGN, SIMULTANEOUS ENGINEERING, VA/VE 37
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 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 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 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
AE DEUTSCHLAND GmbH, GERMANY (GREENFIELD PROJECT) 42
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
HIGH TENSILE STEEL FASTENER DIVISION (BG FASTENING AND ENGINEERING INDUSTRIES PRIVATE LIMITED) 44
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 FACILITIES: FASTENER DIVISION Sr. No. Capacity Type MT / Month 1 Wire Drawing Capacity 1000 2 Forging Capacity 750 3 Heat Treatment Capacity 1000 4 Alkaline Zinc Plating Capacity 1000 5 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 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
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
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
AUTO ELECTRICALS DIVISION 50
51 FACILITIES: AUTO ELECTRICALS Description Auto Electricals Division (Plant 4) BG LI IN Electricals Open Area (Sq. Mt.) 10,000 4500 Buildup Area (Sq. Mt.) 1,500 3239 Location Aurangabad Aurangabad
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 FACILITIES AUTO ELECTRICALS Assembly Lines Online Relay Testing Facilities
PRODUCTS: AUTO ELECTRICALS Product Range: Magnetos Regulators Ignition Coils (HT Coil) Relays Flashers
CUSTOMER SUPPORT 55
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 LOGISTICS AEL Aurangabad Export Clearance at Port. Port of Mumbai Ocean Freight Local warehousing CCL at Destination Port at Destination Delivery at Customer Location
MANAGEMENT FOCUS 58
59 MANAGEMENT FOCUS Process reengineering Continuous improvement & innovation Employee development & involvement Customer satisfaction Supplier partnership Result Orientation Social responsibility
60 SHOP FLOOR MANAGEMENT Kaizens (small improvements) Focused improvements 1S - 2S Housekeeping Abnormality elimination Why why analysis
RECOGNITIONS 61
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 CONTACTS Mr. Kundan K Jha Executive Director & CEO (AEL) E-mail: kundan.jha@baglagroup.com Mobile No: +91 9372848930 Mr. Rakesh Pardeshi Sr. Manager (Business Development and Sales, AEL) E-mail: pardeshi.r@baglagroup.com Mobile No: +91 9881204950 Mr. Ajeet Kumar Sr. Manager (Business Development and Sales, AEL) E-mail: kumar.a@baglagroup.com Mobile No: +91 8380068059