Sona Group
Sona Group
Sona Group
Ratanmani Kukreti
2/26/2013
Contents
Company Profile Group Structure Outline Of Company Products Customers Process Chain Of Precision Parts Approach Towards Zero Breakdown Step to achieve Zero Failure Case Study - 1 (Electrical Break Down) Case Study 2 (Mechanical Break Down) Results
2/26/2013
Group Structure :
SONAGroup Group SONA
Dr. Surinder Kapur Dr. Surinder Kapur
AUTO COMPONENTS
SONA KOYO SONA KOYO STEERING STEERING SYSTEMS SYSTEMS LTD. LTD.
JSAI JSAI SFAL SFAL SONA STAMPINGS SONA STAMPINGS
SERVICE
SONA SONA eDESIGN & eDESIGN & TECH. TECH.
MOBILITY
SONA SONA MOBILITY MOBILITY SERVICES LTD SERVICES LTD (SIXT) (SIXT)
GLOBAL
SONA AUTOCOMP SONA AUTOCOMP USA USA SONA AUTOCOMP SONA AUTOCOMP EUROPE EUROPE
SONA SONA OKEGAWA OKEGAWA PRECISION PRECISION FORGING LTD. FORGING LTD. SOPL, Pune SOPL, Pune SONA BLW SONA BLW PRECISION PRECISION FORGING FORGING EUROPE & USA EUROPE & USA
FAF FAF
2/26/2013
Brief History
Sona Group is currently the largest manufacturer of steering systems and forged parts for passenger cars and utility vehicle market in India. The group turnover is over `40 Billion ($ 810 Mn) with number of employees over 3800. Sona group is diversified in auto components & services. It has 17 manufacturing plants with 4 companies overseas..
Technology Tie-Ups
1990
The Beginning
1985
Extending Partnership
1995
Global Footprint
Laurels
2010
2005
Technical Agreement with Koyo for Manual Steering Gear and Column Sona Steering enters a JV agreement with Maruti Udyog Ltd. Sona Steering Systems Ltd. commences production
Incorporation of Sona Somic Lemforder Components Ltd. Incorporation of Mahindra Sona Ltd. Mahindra Sona acquired the MSL Division of M & M
Incorporation of Sona e-Design Koyo increases stake in Sona Koyo to 20.5% Sona Cold Forgings commences productions Sona Okegawa commences production of bevel gears for domestic market & exports
New JVs JTEKT-Sona Automotive India Ltd. Sona Fuji Kiko Automotive Ltd. Sona Okegawa, Pune started commencing Production Acquisition Sona BLW Prazisionsschmiede GmbH formed
Technical Collaboration with Sona Steering Systems Ltd., a JV with Koyo for Power Maruti, lists through an Steering Gear IPO Joint Venture company formed with MMTLSona Okegawa Precision forgings Ltd.
Acquire 21% stake in Fuji Autotech France S.A.S. Merger of Sona Somic Lemforder and Sona Cold Forging Ltd.
2/26/2013
2/26/2013
The Sona Group has a strong portfolio of established businesses that includes manufacturing and IT.
Manufacturing
SONA KOYO STEERING SYSTEMS SONA OKEGAWA PRECISION FORGINGS
INFORMATION TECHNOLOGY
SONA EDESIGN AND TECHNOLOGIES
MOBILITY SERVICES
MAHINDRA SONA
Forgings,Differentials
2/26/2013
Company Profile
2/26/2013
Plant Layout
Hall 1
Hall 2
2/26/2013
Milestones
2012
OHSAS 18001Sep12
2011 2009 2008 2007
TPM Excellence in Dec 2011 TPM Re-Kickoff in Jan2009 30th Jan Acquisition of Sona BLW TPM Kickoff & Diff. Case Assembly started. New Agreement Signed with MMTL
2006
2005 2004
Commercial Production Started at Pune Plant ISO 14001:1996/EN ISO 14001in Feb ISO / TS 16949 Certified in Nov. Synchronizer Ring Production Started 20th Nov. Commercial Production & Exports to Japan Started
2003
2002
1998
1995
2/26/2013
Products
2/26/2013
10
Product Range
Differential Assembly
Bevel Gear
Speed Gear
Seat Recliner
Steering column
11
2/26/2013
Main Products
Over 250 Parts
2/26/2013
12
Key Products
Precision Forged (net shaped) Bevel Gears, Differential Case Assemblies and Synchronizer Rings for Automotive and Other applications.
Customers
Passenger car & SUV Commercial Vehicles Tractor Off Highway Equipments Farm Equipment Construction Equipments
Fiat India (SKSSL) Mahindra & Mahindra Maruti Suzuki Spicer India Ltd. Suzuki Powertrain Tata Motors Ltd. (SKSSL)
Albion Automotive American Axle Automotive Axle Axle India Axle Tech Diamler India Force Motors HV Axle Spicer India Tata Motors Volvo Eicher
Carraro India Escorts Tractors International Tractors Ltd. John Deere Mahindra & Mahindra Mahindra Swaraj New Holland India TAFE TMTL (Eicher)
Dana India Grazziano Lombardini Mahindra & Mahindra Mahindra Swaraj New Holland india TAFE TMTL (Eicher)
JCB
2/26/2013
13
Die Manufacturing
Cold Coining of the functional surface with hydraulic press lines 700 t
Design
14
Facilities
Forging Capabilities
Forging Press Capability Type
Servomotor Driven (Simplex) Friction Driven (Duplex) Friction Driven (Duplex) Servomotor Driven (Simplex) Servomotor Driven (Simplex) Servomotor Driven (Simplex)
Age
Qty. L
300 mm
1250 Ton
2 Yrs
200 mm
800 Ton
14 yrs
180 mm
220 mm
6.5 Kg
400 Ton
14 yrs
115 mm
75 mm
2 Kg
400 Ton
400 Ton
1 yrs
90 mm
70 mm
1 Kg
300 Ton
5 yrs
65 mm
30 mm
0.6 Kg
2/26/2013
15
Facilities
Machining Capabilities
Machine
Automated CNC Turning Centre CNC Turning Center Vertical Turning Lathe Angular Head Grinder Drilling & Tapping Center Broaching Centerless Grinder Honing Hobbing CNC Gear Hobbing SPM (Case Line) Shaving
Make
Mazak Takisawa, Mazak, Ace, LMW Takishawa Micromatic AMS, Fanuc Taiga, Cranebell HMT Nagel Cooper Mitsubishi Tasa Kanzaki
Age
1yr 1 Yr. to 14 yrs 1yr 7 months to 12 yrs 1Yr to 4 yrs 6 yrs to 14 yrs 1 Yr 14 yrs 22 yrs 1 yr 10 yrs 1 yr
Qty.
6 Nos. 35 Nos. 3 No. 3 Nos. 3 Nos. 2 Nos. 1 No. 1 No. 2 Nos. 1No. 4 Nos. 1 No.
2/26/2013
16
Facilities
Heat Treatment
Machine
Make
Age
Capacity
Qty.
5 yrs Sealed Quench Furnace Line Oriental Engg. Japan 6 yrs 12 yrs IPSEN India Nitriding Furnace IPSEN India 1 yrs 1 Yrs
Processes:
Case Carburizing Carbo Nitriding Hardening
2/26/2013 Sona Okegawa Precision Forgings Ltd. 17
Deform-Form Simulation
Unigraphics-NX7
ANSYS
2/26/2013
HYPERMILL
Sona Okegawa Precision Forgings Ltd.
Forging
Coining
Soft Machining
Sequential Pokayoke
Process Confirmation
Visual Inspection
Hard Machining
2/26/2013
19
CMM
Metallurgical Microscope
2/26/2013
VISION
MOTTO
Think!
Growing and achieving high profitability. Supplying to major global OEMs directly or indirectly. At least 50% of sales overseas, Be #1 in every business line
2/26/2013
2/26/2013
22
2/26/2013
23
TPM Policy To enhance the operational efficiency and equipments by achieving Zero breakdowns and Zero defects Optimization of process and resources Create Visual Factory
Planned Maintenance Pillar Data collection of all the break down, break down matrix, why-why analysis and implementing PM,CBM and TBM activities Optimization of process and resources by eliminating minor stoppage and re-storing optimal condition Expose losses and problems
Trained ,Skilled and Motivated Motivations by autonomous maintenance employees for the first time right job and Implementing MP Kaizen To achieve a safe and green factory through Zero accidents and Zero Pollutions
2/26/2013
By eliminating un-safe conditions, arresting air, oil and water leakage and conservation of natural resources
24
2/26/2013
25
ENHANCING DESIGN ( Uncontrolled Stresses & Insufficient Stress) Problem Discussion with DM team Problem Analysis
DO FMEA
NO
Countermeasures
Countermeasures
NO
Implementation of Countermeasures
Implementation of Countermeasures
IF OK
Horizontal Deployment
IF OK
Horizontal Deployment
2/26/2013
26
Activity :
Activity
Maintaining Basic Condition
Step-2
Step-3
Step-4
Step-5
2/26/2013
27
Jishu- Hozen
Initial Cleaning
Keikaku - Hozen
Analysis of Present Status
2/26/2013
28
Jishu- Hozen
Counter Measure Against SOC & HTA
Keikaku - Hozen
Restoration and Improvement of the Deteriorated Equipment
2/26/2013
29
Keikaku - Hozen
Tentative Standard Maintenance Procedure
2/26/2013
30
2/26/2013
31
2/26/2013
32
CASE STUDY
2/26/2013
33
Equipment
Induction Heater
Forging Press
2/26/2013
34
Failure Analysis :- Analysis by Branch wise Stratification of Mechanical & Electrical Failure ( Nos./Branch) 400 Ton press
2/26/2013
35
Total 17 Phenomenon
2/26/2013
36
S.NO.
Phenomenon
Induction Heater Trip Converter Failure LMD Wheel Not Working Temp Problem Starting Failure Bus Bar Clamping Problem Over Frequency Alarm
F08
F09
F10
F11
F12
2/26/2013
38
Answer
Dc Voltage Is Not Converted In To Ac Single Phase Inverter Circuit does Not perform Thyrister Blow off Not Known
Action
Check Inverter Section Check Protection Circuit Replace Thyrister
Answer
Action
Reset Induction Heater
Dc Voltage Is Not Converted In To AC Why-2 Single Phase Inverter Circuit does Why-3 not perform Why-4 Thyristor Blow off
Answer
Action
Stop Induction Heater and reset
Action
Check Inverter Section Replace Thyrister Provide More Cooling
Why -1 Converter Failure Dc Voltage Is Not Converted In To Ac Why-2 Single Phase Thyrister Failure Why-3 Thyrister Failure
Insufficient Cooling Water Pressure (1kg/Cm2) & Flow (11 Lpm) Is Less At Heat Increase Water Why-4 Insufficient Cooling Exchanger Inlet Pr. & Flow Water Pressure (1kg/Cm2) & Flow (11 Lpm) Is Less At Increase Pump Why-5 Heat Exchanger Inlet Pump Efficiency Is Low Efficiency
Every Individual part of the induction Heater was replaced with New part including PCB cards, But Problem could not be solved
2/26/2013
39
Why- Induction Heater Not Working ? Why- Convertor Failure Caption Illuminate ?
Why- Over Voltage, Over Frequency & Starting Failure LED "Glow " inspite of all the parameter within range ? Why- Temperature drop in Billet when 41 & above Diameter is heated ?
4. Brain Storming
Dept. Manufacturer Manufacturer Project Design Project Design Maintenance Maintenance Maintenance
40
Case Study- No. 1 5. Design Change for Electrical & Electronic Circuit
12 PCB cards are attached to one Mother board with interlocking to each other
2/26/2013
41
Case Study- No. 1 6. Outcome One Single Card was developed 7. Result For Induction Heater
2/26/2013
42
2/26/2013
43
Stirrer
Tank
2/26/2013
Pump
S.NO.
F08
F09
F10
F11
F12
2/26/2013
45
ANSWER
DIE LUBE VALVE REMAIN OPEN
ACTION
CLOSE DIE LUBE VALVE ALLOW DIAPHRAGM TO SETTLE PROPERLY CLEAN DIAPHRAGM OF VALVE ELIMINATE SHARP BENDS
ACTION
MAKE FAULT DIAGNOSYS EASY
WHY-2
FAULT DIAGNOSIS IS TIME CONSUMING FIVE TIMERS , CONTACTORS AND RELAYS ARE INTER CONNECTED WITH TOO MANY WIRES
FIVE TIMERS , CONTACTORS AND RELAYS ARE INTER REDUCE THE CONNECTED WITH TOO MANY WIRE WIRES CONVERT RELAY ELECTRICAL CIRCUIT IS MADE LOGIC TO PROGRAMME WITH RELAY LOGIC LOGIC
DIE LUBE SEDIMENTS WHY- VALVE DIAPHRAGM RAISED ACCUMULATE IN DIAPHRAGM 3 FROM ITS SEATING SEAT DIE LUBE SEDIMENTS WHYSHARP BEND IN DIE LUBE ACCUMULATE IN 4 TRANSFER PIPE LINE DIAPHRAGM SEAT WHY- SHARP BEND IN DIE LUBE 5 TRANSFER PIPE LINE
WHY-3
DIE LUBE TANK TOO FAR FROM BRING TANK NEAR THE PRESS TO THE PRESS
WHY- DIE LUBE VALVE DOES NOT REMOVE 2 OPEN VALVE OUTLET GETS CLOGGED CLOGGING DIE LUBE SEDIMENTS WHY- VALVE OUTLET ORIFICE ACCUMULATE AT THE OUTLET 3 GETS CLOGGED ORIFICE OF VALVE CLEAN VALVE DIE LUBE SEDIMENTS WHY- ACCUMULATE AT THE 4 OUTLET ORIFICE OF VALVE WHY5 ORIFICE SIZE IN 1MM INCREASE ORIFICE SIZE CHANGE DESIGN
2/26/2013
46
WHY PHENOMENON
ANSWER
ACTION
1 MM ORIFICE
2/26/2013
DIE LUBE FLOWING WHY - CONTINUOSLY DIE LUBE VALVE REMAIN CLOSE DIE 1 FROM NOZZLE OPEN LUBE VALVE ALLOW DIAPHRAGM VALVE DIAPHRAGM DIE LUBE VALVE RAISED FROM ITS TO SETTLE WHY-2 REMAIN OPEN SEATING PROPERLY VALVE DIAPHRAGM DIE LUBE SEDIMENTS CLEAN RAISED FROM ITS ACCUMULATE IN DIAPHRAGM WHY-3 SEATING DIAPHRAGM SEAT OF VALVE DIE LUBE SEDIMENTS CLEAN PILOT ACCUMULATE IN PILOT PRESSURE RESSURE WHY-4 DIAPHRAGM SEAT ORIFICE IS CLOGGED ORIFICE DIE LUBE SEDIMENTS ACCUMULATE IN ORIFICE SIZE IN ONLY INCREASE WHY-5 PILOT ORIFICE 1MM ORIFICE SIZE ORIFICE SIZE IS CHANGE WHY-6 1MM STANDARD DESIGN DESIGN
47
2/26/2013
48
2/26/2013
49
2/26/2013
50
2/26/2013
51
2/26/2013
52
2/26/2013
53
Background :
2/26/2013
54
Distribution of Kaizen to achieve Zero Break Down Zero Break Down Machine Category Criteria for Zero B/D
Zero B/D for last > 10 to 12 Month (<5 Hrs./ month) Zero B/D for last 7 to 9 Month (<5 Hrs./ month) Zero B/D for last 4 to 6 Month (<5 Hrs./ month) Zero B/D for last 2 to 3 Month (<5 Hrs./ month) Zero B/D for last 1 to 2 Month (<2 Hrs./ month)
No of Machine
Platinum
18
Diamond
16
Gold
33
Silver
51
Bronze
72
2/26/2013
55
Thank You
2/26/2013
56