SANSERA ENGINEERING PVT. LTD. -...

SANSERA ENGINEERING PVT. LTD.WELCOMES

OverviewOverviewOverviewOverview

• ISO/TS 16949:2009

TUV Nord

• ISO 14001:2004

(EMS)

• ISO 50001:2011

(EnMS)

• 18001:2007

(OHSAS) TUV Nord

&

• AS 9100C-For

Aerospace

Certifications

• Machining &

Assy. of Core

Engine &

Transmission

Components

including “2Cs”

namely

Connecting Rod

& Crank Shaft

Assy.

Business Area

• Design &

Manufacturing of

CNC SPMs

• In house

capabilities

- Forging & Heat

Treatment

- CAE

- FEA Simulation

Uniqueness

• Total 10

Manufacturing

plants having

total work force

over 4600.

Plant & Workforce

Since : 1987

“Building an employee driven and

socially responsible global engineering

corporation using innovative methods

and efficient management for lasting

customer loyalty.”

MissionMissionMissionMission

Organization StructureOrganization StructureOrganization StructureOrganization Structure

Purchase

Legal

Group CEO

B. R. Preetham

Finance

Head Business

Development

J. Vidyadhar

Chairman &

Managing Director

S. Sekhar Vasan

Joint Managing

Director

F. R. Singhvi

Board of

Directors

Projects

Information

Technology

Group CFO & CS

Ramakrishnan S

AVP

Aerospace

Rakesh

Marketing

Business Dev.

Domestic

Business Dev.

Overseas

HR & IR

Plant 2

Plant 1

Plant 3

Plant 4

Plant 5

Plant 6

Plant 7

Process Eng.

Fixtures

Tools Eng.

NPD

Machine

Design

Machine

Building

CEO Forgings

Basavaraja

Head Eng..

A. Josephraj

Fitwel

Gearock

Sansera

Forging Units

Sansera

Forging Units

VP (Group) –

Operations

Praveen C

AVP

P.R.Suresh

AVP

System &

training

P.R.Suresh

Corp. Training

Corp. Quality

System

Corp. Quality

System

Corp. CSR

BangaloreBangaloreBangaloreBangaloreBangaloreBangaloreBangaloreBangalore

PunePunePunePunePunePunePunePune

ManesarManesarManesarManesarNew DelhiNew DelhiNew DelhiNew DelhiManesarManesarManesarManesarNew DelhiNew DelhiNew DelhiNew Delhi

PantanagarPantanagarPantanagarPantanagarPantanagarPantanagarPantanagarPantanagarPlant-1,BangalorePlant-1,Bangalore

Plant-2,BangalorePlant-2,Bangalore

Plant-3,BangalorePlant-3,Bangalore

Plant-7,BangalorePlant-7,Bangalore

Plant-4,ManesarPlant-4,Manesar

Plant-6,PantanagarPlant-6,Pantanagar

Plant-9,Bangalore (Aerospace)Plant-9,Bangalore (Aerospace)

Plant-5,PunePlant-5,Pune

Plant’s & Location’sPlant’s & Location’sPlant’s & Location’sPlant’s & Location’s

� Europe Representative Europe Representative Europe Representative Europe Representative : : : : Mr. Mr. Mr. Mr. DamianoDamianoDamianoDamiano PioltelliPioltelliPioltelliPioltelli

Ware Ware Ware Ware House Details :House Details :House Details :House Details :Viale degli Artigiani, 2420832 DESIO (MB) ITALIA

� USA Representative: Mr. Tushar PatelUSA Representative: Mr. Tushar PatelUSA Representative: Mr. Tushar PatelUSA Representative: Mr. Tushar Patel

Ware Ware Ware Ware House House House House Details:Details:Details:Details:International Warehousing Services15355, Oakwood DriveRomulus, MI 48174

INTERNATIONAL WAREHOUSE SERVIECS (IWS), USAINTERNATIONAL WAREHOUSE SERVIECS (IWS), USAINTERNATIONAL WAREHOUSE SERVIECS (IWS), USAINTERNATIONAL WAREHOUSE SERVIECS (IWS), USA

SST Engineering Solutions, ITALYSST Engineering Solutions, ITALYSST Engineering Solutions, ITALYSST Engineering Solutions, ITALY

Overseas Support ActivitiesOverseas Support ActivitiesOverseas Support ActivitiesOverseas Support Activities

� 3. Japan Representative : Mr3. Japan Representative : Mr3. Japan Representative : Mr3. Japan Representative : Mr. . . . YonedaYonedaYonedaYoneda

� 4. South Korea Representative: 4. South Korea Representative: 4. South Korea Representative: 4. South Korea Representative: Mr. Mr. Mr. Mr. KimKimKimKim

ROLLER TYPE SINTERED TIP TYPE

CHROME PLATED

Rocker ArmRocker ArmRocker ArmRocker Arm

SPLIT TYPE FRACTURED TYPE

INTEGRAL TYPE

Connecting RodConnecting RodConnecting RodConnecting Rod

AUTOMOTIVE GSF

TWO WHEELER GSF

Gear Shifter ForkGear Shifter ForkGear Shifter ForkGear Shifter Fork

CRANKSHAFT ASSY.

CRANKSHAFT ASSY.

Crankshaft AssemblyCrankshaft AssemblyCrankshaft AssemblyCrankshaft Assembly

INTERMEDIATE SHAFT

BALANCE SHAFT

ROCKER SHAFT

ShaftsShaftsShaftsShafts

PISTON-CONROD ASSEMBLY

ROCKER ARM ASSEMBLY

CRANKSHAFT ASSEMBLY

AssembliesAssembliesAssembliesAssemblies

BOSS HANDLE ARM SHIFTTIMING SPROCKET

ARM RELAY ADAPTER

Other ComponentsOther ComponentsOther ComponentsOther Components

CRI BODY

INTERMEDIATE RING

SUPPORT INJECTOR

Other ComponentsOther ComponentsOther ComponentsOther Components

Lever Shift

Housing Shift Lever

Housing Shift Lever

Housing Shift Lever

Shaft Control

Other ComponentsOther ComponentsOther ComponentsOther Components

SPACER , INPUT GEAR

ATTACHMENT LOWER BALL JOINT LH

ATTACHMENT LOWER BALL JOINT RH

SHAFT PROPELLER

Other ComponentsOther ComponentsOther ComponentsOther Components

VALVE BRIDGEROCKER ARM

BRACKET

ROCKER ARM ASSEMBLY

CONNECTING ROD (FRACTURED & SPLIT)

Components for HCVComponents for HCVComponents for HCVComponents for HCV

SEATING SYSTEMS

CARGO SYSTEMS

Aerospace ComponentsAerospace ComponentsAerospace ComponentsAerospace Components

Fo

rgin

g&

Ma

chin

ing

Fa

cili

ty

S.No COMPONENTSPLANT-1 PLANT-2 PLANT-3 PLANT-4 PLANT-5 PLANT-6 PLANT-7 GEAROCK FITWEL

Bangalore Bangalore Bangalore Gurgaon Pune Pantnagar Bangalore Bangalore Tumkur

1111 Adaptor

2222 Arm Shift

3333 Arm Relay

4444 Balancer Shaft

5555 Boss Handle

6666 Connecting Rod (2Wheeler)

7777 Crank Shaft Assembly

8888 CRI Body

9999 Fractured Type Connecting Rod

10101010 Gear Shifter Fork

11111111 Hydraulic Head

12121212 Intermediate Ring

13131313 Intermediate Shaft

14141414 Pad Type Rocker Arm

15151515 Rocker Shaft

16161616 Roller Type Rocker Arm

17171717 Sintered Tip Rocker Arm

18181818 Split Type Connecting Rod

19191919 Support Injector

20202020 Tensioning Bracket

21212121 Timing Sprocket

22222222 Transmission Parts

Machining Facility Forging Facility

Production FacilityProduction FacilityProduction FacilityProduction Facility

Two Wheelers

Automotive

LCV/HCV

Aerospace

Injection Systems

Domestic Customer’sDomestic Customer’sDomestic Customer’sDomestic Customer’s

Two Wheelers

Automotive

HCV

Recreation/Off road

Aerospace

Overseas Customer’sOverseas Customer’sOverseas Customer’sOverseas Customer’s

Global Customer BaseGlobal Customer BaseGlobal Customer BaseGlobal Customer Base

• Argentina*

• Algeria*

• Brazil*

• South Africa*

• Korea

• Poland

• Brazil

• Indonesia

• Thailand

• England

• Brazil

• Indonesia

• China

• Thailand

• Indonesia

• Thailand

• Indonesia• Brazil

• Argentina

• Italy

• Poland

Adaptors & Rocker

arms GSF & Rocker shaftRocker arms

Connecting rod Rocker arms & GSF Rocker arms

* One time supplies

Customer MultiCustomer MultiCustomer MultiCustomer Multi----Location SuppliesLocation SuppliesLocation SuppliesLocation Supplies

0.00

20.00

40.00

60.00

80.00

100.00

120.00

140.00

160.00

180.00

200.00

2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

Series1 25.45 32.18 37.13 38.36 47.09 65.45 81.82 88.18 103.64 136.00 151.00 189.00

Total Turnover

in M

illi

on

US

D

# Projected

#

Sansera GrowthSansera GrowthSansera GrowthSansera Growth

0

5

10

15

20

25

30

35

40

45

50

2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

Series1 1.82 2.55 2.85 3.82 4.73 5.45 9.09 11.64 22.73 36.73 37.46 45.69

Export Turnover

in M

illi

on

US

D

# Projected

#

Sansera GrowthSansera GrowthSansera GrowthSansera Growth

Business Distribution FY16Business Distribution FY16Business Distribution FY16Business Distribution FY16

16

2021

2223

2527

29

0

5

10

15

20

25

30

35

2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16

810

11

1416

18

21

30

0

5

10

15

20

25

30

35

2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16

Total Customers & Product Families YOY Total Customers & Product Families YOY Total Customers & Product Families YOY Total Customers & Product Families YOY

Tota

l P

rod

uct

Fa

mil

ies

(YO

Y)

� Started in 2000.

� TS 16949 Company wholly owned by Sansera.

� Facilities equipped with Drop Hammers (0.75-1 ton), Hydraulic Hammers (1-1.6 ton),

Presses varying from 1600 to 2000 ton.

� Other facilities like Shot peening, Shot blasting, Controlled Cooling.

Gearock Forge Gearock Forge Gearock Forge Gearock Forge ---- BangaloreBangaloreBangaloreBangalore

� Started in 1987.

� TS 16949 Company.

� Facilities equipped with Drop Hammers, from 250 to 1000 kg. Presses varying from

250 to 1600 ton.

Fitwel Forge Fitwel Forge Fitwel Forge Fitwel Forge ---- TumkurTumkurTumkurTumkur

PRODUCT PROCESS

TOOLS FIXTURESDesign

Design CapabilitiesDesign CapabilitiesDesign CapabilitiesDesign Capabilities

� UNIGRAPHICSUNIGRAPHICSUNIGRAPHICSUNIGRAPHICS - 3D Modelling & Toolpath generation

18 Workstation

� CATIA & ProCATIA & ProCATIA & ProCATIA & Pro----E E E E – Modelling Software

each 1 Workstation

� INVENTOR fINVENTOR fINVENTOR fINVENTOR for or or or MACHINE MACHINE MACHINE MACHINE DESIGN DESIGN DESIGN DESIGN - 9 Workstation

� AUTOCAD / INVENTORAUTOCAD / INVENTORAUTOCAD / INVENTORAUTOCAD / INVENTOR- 40 Workstation

� NX NASTRAN FOR ‘FEM’ ANALYSISNX NASTRAN FOR ‘FEM’ ANALYSISNX NASTRAN FOR ‘FEM’ ANALYSISNX NASTRAN FOR ‘FEM’ ANALYSIS -1 Workstation

� ‘Q FORM’ & ‘FORGE Q FORM’ & ‘FORGE Q FORM’ & ‘FORGE Q FORM’ & ‘FORGE –––– Nxt’ Nxt’ Nxt’ Nxt’ for Forging process

simulation & analysis 1 Workstation

� “VERACAD” VERACAD” VERACAD” VERACAD” – For Pre-forming tool design.

� “WRENCHWRENCHWRENCHWRENCH---- Enterprise “ Enterprise “ Enterprise “ Enterprise “ - PDLM SOFTWARE FOR

Management of Product Development, Documents &

Data Control

Design ResourcesDesign ResourcesDesign ResourcesDesign Resources

Static AnalysisStatic AnalysisStatic AnalysisStatic Analysis

� Value engineering suggestions.

� Manufacturing feasibility study & suggestion.

� Alternative cost reduction proposals.

Leading to maturity of design with minimal iterations

CUSTOMER Part Name Status

Customer 1 - USA Crank Shaft

Material : Low carbon to medium carbon

Heat treatment: Case carburizing to Induction hardening

Cost saving : 37%

Customer 2 - India Rocker Arm Shape optimization: Forging die life increased by 30%

Example

Concurrent EngineeringConcurrent EngineeringConcurrent EngineeringConcurrent Engineering

� DIGITAL SERVO TECHNOLOGY.

� CONTROL SYSTEMS FROM FANUC / SIEMENS

� IN-HOUSE SOFTWARE.

� SMALL FOOT PRINT & LOWER POWER.

� REAL TIME PRODUCTION MONITORING.GANTRY SYSTEM

VERTICAL HONING MACHINE 8-STATION MACHINE

Machine BuildingMachine BuildingMachine BuildingMachine Building

Metrology

Metallurgy

Metallurgy & MetrologyMetallurgy & MetrologyMetallurgy & MetrologyMetallurgy & Metrology

� Residual stress measurement.

� Large and heavy samples are measured with high accuracy.

Residual Stress Measurement SystemResidual Stress Measurement SystemResidual Stress Measurement SystemResidual Stress Measurement System

Heat Treatment Induction Hardening

Die Milling

FacilitiesFacilitiesFacilitiesFacilities

Automated 2500T Forging PressAutomated 2500T Forging PressAutomated 2500T Forging PressAutomated 2500T Forging Press

@ For smaller wt. conrod’s this can be lesser

Description Make TonnageMax wt. of forging

(Con Rod)Max size. Wt. tolerance Status Capacity

Detail Kurimoto2500

Tonne 2 kg

Length 300mm

CD+/- 12 gm

@ In production since

2013

1.8 Mio pcs

/year

New Plant Location New Plant Location New Plant Location New Plant Location –––– Bidadi, BangaloreBidadi, BangaloreBidadi, BangaloreBidadi, Bangalore

Description Details Remarks

Land Area 60,787 Sq.m 15 Acers

Planned Built up 27,000 Sq.m

Machine Shop 13,500 Sq.m

Forging Shop 10,800 Sq.m

Admin & Canteen 21,000 Sq.m 3 Floors

Total Production capacity 72 Million 72 Million 72 Million 72 Million for Year Ending FY 15

37373737

13131313

7777

3333

7777

2222 3333

0

5

10

15

20

25

30

35

40

Rocker Arm Gear Shifter Fork

(2W)

Connecting Rod

(2W)

Crankshaft Assy. Connecting Rod

(4W)

Gear Shifter Fork

(4W)

Others

Pcs

In

Millio

ns

Pcs

In

Millio

ns

Pcs

In

Millio

ns

Pcs

In

Millio

ns

Production CapacityProduction CapacityProduction CapacityProduction Capacity

QC & Kaizen Projects

Number of Continuous Improvement Projects

985 ProjectsImplemented

81

155

277

492537

985

0

200

400

600

800

1000

1200

2010-11 2011-12 2012-13 2013-14 2014-15 2015-16

95%

5%

QC & KAIZENS

* 2015-16

KAIZEN QCC

Total Employee InvolvementTotal Employee InvolvementTotal Employee InvolvementTotal Employee Involvement

School building – Govt. Primary School,

Doddakallasandra, Kanakapura road

,B’lore.

� Scholarships to rural students

� Creation of educational facilities in semi – urban and rural areas

� Constructed school buildings at Doddakallasandra & Neralur

� Conducted Blood donation camps

�Adopted Govt. School at Doddakallasandra

� Conducted HIV awareness program.

� Employment to visually challenged people

� Tree Planting during World Environment Day

�Donation for building for a Govt. School at Bommasandra.

�Adopted & Co-Managing Govt.Industrial Training Institute near Pune.

� Over 200 Sansera Employees have volunteered for CSR Activities and are currently involved with three local bodies around

Bommasandra Industrial area in educating, awareness and implementing garbage segregation and Recycling;Tree Planting & Water Re

harvesting.

School building Vivekananda Primary

School, Neraluru, Anekal Taluk, BangalorePhysically & Visually challenged

employees at job

Corporate Social ResponsibilityCorporate Social ResponsibilityCorporate Social ResponsibilityCorporate Social Responsibility

Overall Excellence Award

Maruti Suzuki India Ltd.-2011Grand Award for QCDDM

Honda Motorcycles and Scooters - 2009

Supplier Award For Quality Received from Honda

Motorcycles and Scooters India Pvt Ltd. - 2004 Vendor Performance

Maruti Suzuki India Ltd- 2005

Best Machining award from

Yamaha Motors Pvt. Ltd-2001

Award for New Product Development Support

Bajaj Auto- 2005

Customer Recognition’sCustomer Recognition’sCustomer Recognition’sCustomer Recognition’s

Best Collaboration Award from

Ducati Motor Holding - 2014

Quality & Service Award from

Ducati Motor Holding Spa. Italy- 2011

Customer Recognition’sCustomer Recognition’sCustomer Recognition’sCustomer Recognition’s

Perfect Quality Award from Fiat- 2013

Customer Recognition’sCustomer Recognition’sCustomer Recognition’sCustomer Recognition’s

Sliver Award for part Development from India Yamaha Motors-2013

Customer Recognition’sCustomer Recognition’sCustomer Recognition’sCustomer Recognition’s

Quality Excellence Award from

General motors- 2013Quality Excellence Award from

General motors- 2014

Supplier Quality Excellence Award

from General Motors - 2015

Customer Recognition’sCustomer Recognition’sCustomer Recognition’sCustomer Recognition’s

Competitiveness Award from General Motors - 2015

Customer Recognition’sCustomer Recognition’sCustomer Recognition’sCustomer Recognition’s

Samman Patra Award -2007

Star Export House Certification-2011

Government Recognition’sGovernment Recognition’sGovernment Recognition’sGovernment Recognition’s

Prashamsa Suraksha from National safety

Council -2013

Safety Recognition’sSafety Recognition’sSafety Recognition’sSafety Recognition’s