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SPM AUTOCOMP SYSTEMS PVT LTD. INDIA 3 rd November’ 2012

INTRODUCTION. SPM AUTOCOMP SYSTEMS PVT LTD. INDIA 3 rd November’ 2012. CONTENTS. SPM – AN OVERVIEW - Corporate Profile, Vision and Mission, Road Map and Customers List - Plants and their locations - Manufacturing Product Range

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SPM AUTOCOMP SYSTEMS PVT LTD. INDIA 3 rd November’ 2012

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  1. INTRODUCTION SPM AUTOCOMP SYSTEMS PVT LTD. INDIA 3rd November’ 2012

  2. CONTENTS SPM – AN OVERVIEW - Corporate Profile, Vision and Mission, Road Map and Customers List - Plants and their locations - Manufacturing Product Range - Materials and specifications - Organization Chart – Plant 2 (Ranjangaon) - Process Design and Engineering Capability - Facility of Manufacturing and Testing/Inspection Equipment - Raw Material Sources - Process/Product Capability – Cp and Cpk - Mistake Proofing and Error Proofing at manufacturing process

  3. CONTENTS ….. Continued • CASTING PROCESS • Process Flow • Casting Technology • 3. MACHINING PROCESS • Process Flow • Leak Testing • Packaging

  4. CONTENTS • 4. DEVELOPMENT PROCESS • Cross Functional Team/Multi Disciplinary Team • Project Details • Project Input – Drawing, CAD Model, customer standards • Feasibility study – Summary • Project planning Chart • Process Design – Casting • Pattern lay out • Gating System • Core Concept • Molding process • Quality Planning • PFD, PFMEA and CP – Foundry and Machining

  5. SPM – AN OVERVIEW

  6. CORPORATE PROFILE

  7. VISION & MISSION VISION To Achieve Ten percent of the World Market of Cast Exhaust Manifolds by the Year 2015. MISSION To exceed customer’s expectations by offering best service, Exhaust Manifolds and Machined Cast components of International Quality at the most competitive prices. To achieve significant continual improvement, reduction in all forms of waste and optimum use of all types of resources under safe working environment.

  8. Development Phase Consolidation Phase Growth Phase 2002 - 05 2005-09 2009-15 Sales Achieved – US $4.78 Million Sales Achieved –US $ 36.21 Million Target Sales: 10% of world market i.e. 3.6 million of Cast Exhaust Manifold No. of Customers Built – 5 Nos. No. of Customers Built – 7 Nos New Foundry for Exhaust manifold, Turbine Housing & Turbo Manifolds No. of Product developed –25 Nos. No. of Product developed – 40 Nos. Setting up of Technical Research Center Organization Recruitment Organization Stability & Development Productivity improvement 30% Yield Improvement from 37% to 45%. Internal Rejection control from 15% to 6% 74 PPM at Customer End SPM ROAD MAP TO VISION

  9. Customer Basket and Share of Business without BOP

  10. LIST OF CUSTOMERS • Maruti Suzuki India ( Ex Manifold, Maniverter ) • Suzuki Power Train ( Ex Manifold, Diff Case, Eng Bkt) • SKH-Magneti Marelli ( Catalytic cones) • Ford Motor Company ( Exhaust Manifolds) • Ford Motor Company Export ( Exhaust Manifolds) • General Motors ( Exhaust Manifolds) • Honda Siel Cars India ( Exhaust Manifold) • Ashok Leyland ( Exhaust Manifolds) • Daimler ( Exhaust Manifolds) • JCB (Exhaust Manifold & Connecting bends)

  11. LIST OF CUSTOMERS Cont… • Tata Motors ( PVBU & CVBU) : Ex Manifold,Steering Knuckles, Engine mounting Bkts • Tata Cummins : Ex Manifold • Bridgestone TVS India : Engine Mounting Bkt • Fiat India : Exhaust Manifold • Mahindra Navistar : Exhaust Manifolds • Hyundai Motors : Exhaust Manifold • Avtec Ltd : Exhaust Manifold for Daimler engines • Eicher Motors Ltd: Ex Manifold and Ex Bend. • Jaguar Land Rover & Toyota (under negotiation)

  12. PLANT LOCATIONS

  13. OVERVIEW PLANT - 2 MAIN ENTERANCE Administration Block Machine Shop Building Foundry Building

  14. SITE PLAN – Plant 2 Machine Shop Foundry

  15. Machining Facility – Plant 2 Fiat - 1.3 SDE Exhaust Manifold Line Tata Motors – Steering Knuckle Line

  16. Tata Motors – Engine Mounting Bracket Line Standard Room

  17. PRODUCT DETAILS CORE PRODUCTS : • Exhaust Manifolds • Turbine Housing • Turbo Manifold STRATEGIC PRODUCTS : • Steering Knuckle • Mounting Brackets • Case Differential

  18. Manufacturing Product Range Exhaust Manifold Catalytic Inlet Manifold Assembly Mounting Bracket Case Differential Steering Knuckle

  19. Manufacturing Product Range Exhaust Manifold (Honda) Split Type Manifold (Mahindra Navistar) Split Type Manifold (JCB)

  20. Ex. Manifold Ford CD (Part no. :BK3Q-9430-CD ) - EXPORT AS MACHINED AS CAST

  21. Manufacturing Product Range EXHAUST MANIFLOD GM 1 LTR. (Part no. ) 55569360 AS MACHINED AS CAST EXHAUST MANIFLOD GM 1.3 LTR. 55570416

  22. Manufacturing Product Range EXHAUST MANIFLOD GM B12D 96416307 AS MACHINED AS CAST

  23. Manufacturing Product Range Ex. Manifold Hyundai (Part no. : 2851103020) AS CAST AS MACHINED

  24. METALLURGY GRADE & SPECIFICATION New Development

  25. QMS And EMS CERTIFICATION ISO/TS 16949 And ISO-14001

  26. Organization Chart

  27. Design and Engineering Capability FOUNDRY – ENGINEERING Design Facilities • Simulation Software – ANYCAST • UG CAD & CAM - NX 7 • Auto Cad • In-house Pattern Making Facility • Video Image Analyser • Spectrometer for chemical analysis MANUFACTURING - ENGINEERING • VMC (LMW – KODI 40) • M1TR with DRO • CNC Turning Center • Surface Grinder • Radial Drilling M/c • Hydraulic Fixture for machining • Millipore tester for global cleanliness requirement • Air decay Leak Testing machines for leak proof casting

  28. FACILITY OF MANUFACTURING & TESTING/INSPECTION EQUUIPMENT FOUNDRY - PRODUCTION FOUNDRY - QUALITY

  29. Moulding Process New Moulding Line Details: Based upon athree-phase molding sequence featuring prefill, shoot, and squeeze, the HANSBERG Molding System is a consolidated, foundry-proven mold making technology which ensures the production of castings consistently complying with the strictest quality control requirements. Prefill Shoot Squeeze

  30. PHASE 1 - PREFILL Prefill ensures that clot-free sand always fill deep pockets and cavities, even when the pattern contour is most intricate, as is the case with this knuckle arm mold Outstanding casting skin quality

  31. PHASE 2 - SHOOT Distance to edge 25 mm or Less Excellent mold surface hardness with homogeneous distribution from mold center to flask edges Mold hardness 87-92° Draft Angle 0.5 Deg. Shooting is instrumental to achieving high compaction in deep cavities where squeezing alone can not always reach

  32. PHASE 3 - SQUEEZE Uniform compaction throughout the mold depth Outstanding mold rigidity is always achieved Strictly controlled compression force per mold surface unit Minimum casting mass variation Minimum usage of sand

  33. FLASK DESIGN Pin / bushingassembly (right). Each flask is fitted with one round and one elongated bushing. Poka-Yoke: Automated sensors to ensure the dimensional accuracies of pins & bushes. Nodular iron flask pair(above). Note the double-wall design combining high rigidity with lightness.

  34. Flask rigidity is of paramount importance in high-pressure molding. Wall deformation should not exceed 0.25 mm under a load of 4 kgf/cm2.

  35. SPECIAL FEATURES Flask cleaning unit (left). Automatic Box Cleaning as compared to Manual Cleaning in the Present Line Automatic sprue cutting unit (right). OnlineAutomatic Sprue Cutting as compared to Manual cutting in Present Line, avoiding variation in pouring cup size

  36. CASTINGS DIMENSIONAL ACCURACY Complying with the strictest quality control requirements: automotive safety part casting Diameter variation is < +/- 0.5 mm Mass variation <  0.2 kg on 50 kg casting

  37. FACILITY OF MANUFACTURING & TESTING/INSPECTION EQUUIPMENT MACHINE SHOP - PRODUCTION MACHINE SHOP - QUALITY

  38. Raw Material Sources

  39. Process Capability of Existing Product - Foundry

  40. Process Capability of Existing Product - Machining

  41. Process Capability of Existing Product - Machining

  42. List of Poke Yoke

  43. Poke Yoke Implementation

  44. Poke Yoke Implementation

  45. Poke Yoke Implementation

  46. Poke Yoke Implementation

  47. Poke Yoke Implementation

  48. SPM – THE COMPLETE SOLUTION • Productivity • Value Engineering • In Process Inspection • Process Improvement Cost Quality Focus Area Delivery Development • On time • Design Capability • First Time Right

  49. CASTING TECHNOLOGY &PROCESS

  50. Casting Technology HIGH PRESSURE MOLDING PROCESS We, at SPM have opted for High pressure molding process with green sand having a composition of Silica sand with 98% minimum silica content, sodium based Bentonite for better swelling and binding property, Lustrous carbon for providing a reducing atmosphere in the mold cavity. Water is added to get the optimum properties in the sand mix like compactibility, green compressive strength, Loss on ignition, dry strength, and also better collapsibility for easy separation of casting from sand at the time of knock out. This sand is reusable by remixing small quantities of Bentonite and other additives for replenishing the lost properties due to molten liquid metal casting process.

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