Journey of Engineering Excellence - Kirloskar Introductory Presentation... · Successfully Handling Group Companies. ... Industrial & Construction Segment ... Mining Earthmoving Fluid

11-Jun-14 c:\Prsn\KOEL_Profile_FY07_updated.ppt Rajiv_NB Slide 1 of 45

Journey of Engineering Excellence

11-Jun-14 Slide 2 of 31

Cycle Works at Kirloskarwadi - 1888 – Kirloskar Brothers’ first enterprise

First Indian “Fodder Cutter” – 1901 – small shed

First Indian “Iron Plough” – 1904 – small workshop

Farm Implements – 1910 - Factory

Groundnut sheller,sugarcane crusher

Pumps – 1920- Kirloskar Brothers Ltd incorporated

Kirloskar Humble Beginning


Kirloskar Businesses At A GlanceFY10 TurnoverUSD $ 1.5 Bn

TrustReliability

Fourth Generation Of Kirloskar Successfully Handling Group Companies

Kirloskar Businesses At A GlanceKirloskar Brothers Ltd. • Centrifugal Pumps

• Hydro Turbines, Valves• Turnkey Projects• Anti Corrosion Products

Kirloskar Oil Engines Ltd. • Diesel Engines, Gensets• Bearings

Kirloskar Pneumatic Company Ltd. • Recip, Screw & CentrifugalCompressors

• Traction Gears, Gear Boxes• Refrigeration Projects• Flake Ice Plants

• Grey Iron Castings• Pig Iron

Kirloskar Ferrous Industries Ltd.

Established in 19106 Plants , 2551 employees

Incorporated in 1957 2 Plants, 847 employees

Incorporated in 1946 5 Plants, 3398 employees

Incorporated in 19922 Plants, 1329 employees

SPP, UK Acquired in Nov’03 by KBL3 Plants in UK, USA & Africa

• Fire Fighting Pumps • Water & Sewage Pumps

Kirloskar Chillers Pvt. Ltd. Incorporated in 19961 Plant, 100 employees

• Centrifugal Chillers• Screw Chillers• Reciprocating Chillers

Automotive Businesses

Kirloskar Toyoda Textile Machinery

• Spinning machines • Die Cast parts for Transmission• Forklifts

Toyota Kirloskar Motor

• Propeller shaft• Front & Rear Axle• Transmission for export

Denso Kirloskar Ind.

• Steel & Logistic Centre

• Plastic parts (Internal & External) • Steering wheel

Toyota Gosei Kirloskar Ltd.

Kirloskar Systems Ltd (Toyota Kirloskar Auto Parts)

Steel and Logistic Centre

• Radiators• Air Conditioners

• Automobiles


Kirloskar Group OverviewIndia’s Premier Engineering Group with 122 years of

experience

FY10 Sales of USD 1.5 Bn

Large and Established Distribution Network

Plants are ISO 9001, ISO 14001, ISO 18001 and TS 16949 accredited

Turnkey Project Capability Water Supply, Air Conditioning and Refrigeration, Captive/Small Power Plants

Own R&D facilities for Product Development Programs


11-Jun-14

Kirloskar Group Product Portfolio

Slide 7 of 31

Global PresenceOverseas Customers Overseas OfficesManufacturing


Kirloskar Group Financials


Kirloskar Oil Engines Limited

Vision n Values


TRANSPARENCY

KOEL

Vision

To be amongst the top ten Global Players in Off-high way engines business.

Values

Business Definition


•Farmer, Agri Marketing Societies, Stake-holders of Govt Schemes [Distribution Model]

•OEMs [Direct Supply + Distribution Model for

Bazaar Sale]

Business Definition

We are in the business of fulfilling Motive

Power needs of Customers in 3-hp to

355-hp Global Off Highway Space

• Aggressive Price-line, lower TCO & easy availability

• Tier-3 Road Map & long-term price stability [OEMs]

• Effective after-market support

Customer Needs

Customer Group

How do

we meet

the needs

• By supplying engines customized to applications needs & their end use• By collaboratively evolving future application needs • By continually mapping Product : Market needs and designing products

to fill Product Gaps

Kirloskar Oil Engines Ltd

Incorporation 1946

Plants 05

Products DDiieesseell EEnnggiinneess 3800 hp 2,400 11,000 hp

AAuuttoo CCoommppoonneennttss Bearings & Bushes

FY10 Business Highlights Value $ 480 Mn Volume 225, 000 engines 55 Mn Bearings & Bushes

Employees 3,398

Certifications ISO 9001 1992 ISO 14001 1998 Self Certification by Indian Army since

2001 TS16949 2004 CE 2006 ISO 18001 2009


Kirloskar Oil Engines Ltd

Golden Peacock National Quality Award

1997, 2003 & 2004

Business Processes Oracle 12i Web enabled ERP across DemandSupply Chain

50,000 transactions/day

Economy Sectors Catered Agriculture Industry Services

2008 Market Position in India 52% share of Industrial Segment 35% share of Power Generation Segment 38% share of Bearings Segment


Location Activity

Pune Head Office

Engines (20 to 830 hp)

Bimetal Bearings

Kagal New Manufacturing Plant for Engines

& Gensets for Overseas Markets

Nasik Engines (2,400 to 11,000 hp)

Rajkot Engines (upto 25 hp)

Ahmednagar Bimetal Bearings

Multi-location Operations



Kagal Plant : Architectural Views• Plot Area : 200 Acres • Developed : 40 Acres• Plant Area : 9,450 m2 for

Gensets 34,650m2 for Engines

• CapEX : ~ $ 175 Mn • Capacity : ~ 60,000 engines

per year now

Product Range : Engines

Biggest : 11,000 hp

To

Smallest : 4 hp


11-Jun-14

Leader in supply of Diesel Engines to Market Segments such as :

Agriculture Segment [Market Share ~ 20%]

Power Generation Segment [Market Share ~ 35%]

Industrial & Construction Segment [Market Share ~ 55%]

Leader in supply of Engine Bearings to the Automotive Market Segment [Market Share ~ 38%]

Our Markets

Slide 18 of 31

11-Jun-14

Our Markets

c:\Prsn\KOEL_Profile_FY08.ppt Rajiv_NB Slide 19 of 31

Industrial Market Mix

IndustrialMarket

Construction

MaterialHandling

Mining

Earthmoving

Fluid Handling

Off_Shore

DefenceAutomotive

AgroIndustrial

IndustrialMarket

ConstructionCompactor, TM,

Compressor

MaterialHandling

Crane, FLTMining

Rigs,Mud Pumps

EarthmovingExcavator,

Dozer, Dumper

Fluid Handling

PumpsOff_Shore

Hyd Tongs,Winches

DefenceAutomotive

Zil/Ural

AgroIndustrialHarvester


11-Jun-14

Product Design

Development Time

Product Cost

From

Drawing Board

Industry

Benchmark

Jointly

Evolved

Total Capability

Slide 21 of 31

11-Jun-14

Our Customer Relationships

M&M (PTL)

JCB-India, Millers,

Voltas, Godrej,

L&T-Case,

Schwing Stetter,

L&T-Komatsu,

Greaves, Volvo

3-decades

2-decades

Armed Forces 4-decades

Slide 22 of 31

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Exc-Loaders

Compactors

Fork-lift Trucks

Excavators

Assorted

Cellular

Engineering Brand Canvas

Tr Mixers & CPs

Slide 23 of 31

11-Jun-14

Consumer Brand Canvas

Slide 24 of 31

World’s largest Genset Business; over 75,000 Gensets/year

India’s largest Engine manufacturer; over 225,000 engines/year

Over 80,000 Kirloskar Gensets keep India’s Cellular & Land Telephony network ticking on 24 x 7 basis

Over 10,000 Kirloskar Gensets deployed with Indian Armed Forces in one of the toughest terrains of the world [4250m, +550C to -300C]

Over 200 Kirloskar Gensets working on unmanned Offshore Platforms since 1985, non stop, in highly corrosive & explosive environs

Engines used on 85-applications spread over 9-segments

Global engine population, over 2 million engines

Power Facts


Slide 26 of 4511-Jun-14

Product Applications

Kirloskar in South Africa

Kirloskar Engines (SA) (Pty) Ltd

• Kirloskar Engines (SA) (Pty) Ltd - KESAL was established in Nov

2003, and is the sole authorized distributors of Kirloskar Diesel

Engine related products in the whole of South Africa

• Kirloskar entered South Africa in the engine business during 2003

focusing on engines for general industrial applications and Diesel

Powered Generating sets

• Already supplied more than 4,000 engines in the S.A market

• KESAL is also a Level 8 contributor to the BEE initiative

• KESAL’s spare parts stores houses all maintenance related spares

for engines, to support the product in the field

• KESAL also houses a full fledged workshop facility to service

engines, and also to support field calls / Customer complaints

• KESAL possesses adequate resources having the technical know

how to promote and support the Kirloskar Diesel Engines in South

Africa

KESAL: Workshop

KESAL: Stores

KESAL: Offices

Kirloskar in South Africa’s Mining

Industry

Kirloskar: Journey in Mining

• Kirloskar entered South Africa in the engine business in year 2003

starting with engines for general industrial applications and

Generating sets and has already sold more than 4000 engines in the

market

• In early 2005, a shortfall in the supply of engines for LHD

application was sensed, as compared to the demand from the

growing mining industry

• This triggered Kirloskar to venture into mining business sector

• The availability of correct resources having the required technical

know-how and criticality of the business sector and also a good

product were other reasons for entering this market

• Kirloskar Engines SA approached Murray & Roberts Cementation

with this mission in mind and they were kind enough to allow us to

enter this market

Kirloskar: Journey in Mining

• In July 2005, the first proto engine was supplied and mounted in a

LHD

• From then on, we have supplied and serviced more than 800 engines

in this market

• In this journey of supply of engines to mines, there have been many

learning, failures, shortfalls that have been experienced and

Kirloskar’s vision and approach towards this market is to improve

our product and encourage end users support in doing so

• We strive to supply a quality product at reasonable price and with

excellent back up service

HA694TC engine

• Kirloskar make air cooled, 6 cylinder, turbocharged engine model

HA694TC rated 105hp @ 2300rpm with peak torque of 390N-m @

1500 – 1600 rpm is now being used for re-powering LHDs (AARD

Major, GHH LF 4.2 & 4.4, Sandvik 115, Atlas Copco ST-2G)

• Currently the engines are available in U.S Tier II version and Non-

emission engines

• HA694TC engine which has been tested and tried on this application

and with emission compliance would be the right kind of

combination to explore

• Have already supplied nearly 800 engines for this application

• KESAL have started supplying US Tier II version of these engines to

GHH Mining Machines since September 2010. Even GHH Germany

is in deliberation with Kirloskar India for supplying these engines to

their German factory.

HA694TC U.S Tier II Engine

• Stanadyne Rotary FIP: Stanadyne rotary FIP is used for Tier IIengine which provides the required injection pressure and injectiontiming flexibility to meet the emission requirements. The FIP is welloptimized and matched with the engine to get the best performanceand emission output. Positive/Negative torque correction helps toachieve the required torque curve nature while dynamic timingflexibility helps in reducing the emissions.

• 5 Hole VCO injector: A 5 hole VCO injector is used withoptimized spray pattern in order to achieve the best in class fueleconomy. VCO type of construction also helps in reducing the HCemission. This plays a major role in meeting the Tier II emissionnorms.

• Cylinder head: Cylinder head is modified to suit the P type VCOinjector mounting. It also features well optimized inlet and exhaustports and valve-seat geometry to meet the air flow and swirlrequirements of Tier II emission limits.

• Piston Bowl: Tier II engine features a well optimized re-entrantcombustion bowl matched to the injector spray pattern. Combustionbowl design plays a important role in reducing the particulateemissions and meeting the fuel consumption targets.

HA694TC U.S Tier II Engine

` US Tier II

Limit

HA 694TC Engine

emission data

CO, g/kW-h 5.0 2.66

NOx+HC, g/kW-h 6.6 6.02

PM, g/kW-h 0.3 0.212

0

50

100

150

200

250

300

1200 1400 1600 1800 2000 2200

Speed , rpm

Po

we

r, h

p /

SF

C g

m/h

p.h

r

170

210

250

290

330

370

410

Torq

ue, N

m

HA694TC U.S Tier II Engine: Specifications

HA series engines: B.S II Emission comparison

HA 294, HA394 & HA494 Emission Results Emission Limits

Emission parameters (Values

in g/kW hr)

HA294

Engine rated

20.25 kW @

2300 rpm

HA394

Engine rated

34.6kW @

2300 rm

HA494

Engine rated

46.4kW @

2300 rpm

Bharat Stage II

Limits

(37<= kW < 75)

US Tier I Limits

(37<= kW < 75)

US Tier II Limits

(37<= kW < 75)

Carbon Monoxide (CO) 2.08 2.08 2.08 6.5 5.5 5

Hydro-Carbon (HC) 0.24 0.24 0.24 1.3 -7.5

(NMHC + Nox)Nitrogen Oxide (NOx) 6.99 6.99 6.99 9.2 9.2

Particulate Matter (PM) 0.34 0.34 0.34 0.85 0.8 0.4

HA694

Emission

Results

Emission Limits

Emission parameters (Values

in g/kW hr)

HA694

Engine rated

78kW @ 2300

rpm

Bharat Stage

II Limits

(75<= kW <

130)

US Tier I

Limits

(75<= kW <

130)

US Tier II Limits

(75<= kW < 130)

Carbon Monoxide (CO) 2.87 5 5.5 5

Hydro-Carbon (HC) 0.2 1.3 - 6.6

(NMHC + Nox)Nitrogen Oxide (NOx) 9.17 9.2 9.2

Particulate Matter (PM) 0.512 0.7 0.8 0.3

• De-rated for Underground Application (27 kW @ 2300Rpm)

• Centa-Flex Flywheel

• SAE 3 / 4 Bell Housing

• Std Double Drive Belts

• Cast Iron Sump

• Hydraulic Oil-Cooler

• Exhaust Centre / Rear Discharge

• Intake Facing Cooling-Fan

• Mechanical Shut Down

HA394 Engine Scope

• De-rated for Underground Application (36.1 kW @ 2300Rpm)




• Cast Iron Sump




• Mechanical Shut-Down

HA494 Engine Scope





• Cast Iron Sump





HA594 Engine Scope



• SAE 3 Bell Housing


• Cast Iron Sump





HA694 Engine Scope

• Spares for 100/120 air-cooledengines.

• More than 5 decades of expertiseand excellence in the manufacturingof engines.

• Spares for over 2 million worldwideengine population

• Spares manufactured to OEMspecifications.

• Air-cooled spare parts compatiblewith certain Deutz models.

• Quality manufacturing processesemployed for manufacturingengines are utilized for themanufacture of spares.

Why Kirloskar ?

• Six decades of engineering & knowledge experience in engine &

Genset manufacturing

• Quality product at competitive price

• Immaculate back-up service

• Proficiency built in the entire value chain

• A strong base of partner suppliers

• Robust Financials

• Aggressive plans for investment & expansion

.

• Reduced replacement cost on new and rebuilt engines

• New Engine Availability to the Equivalent of the current Fleet

• In-house manufacturing of Quality Spare Parts at competitive

prices

• Management Familiar with Mining Industry (39 Years

Experience)

• HA Series engines are all supplied standard with double groove

pulleys with a 13mm pitch and cast iron front covers proving

them to be more reliable in their harsh environment

• Majority of Spare Parts Interchangeable within HA Series and

current Locomotive and Mining fleet

• Enable End User to Achieve a Quality Standard

Advantage Kirloskar!!!

Customer References

• 912 Diesels Scott Lane (021) 982 4891

• Amgen Power Allan Latta (011) 421 8453

• Barberton Mines Dario Negri (013) 712 9060

• Benhaus NW Wessie v d Westhuiszen (014) 592 6677

• Braybar Pumps Des Shepherd (011) 421 6773

• B+S Platinum Mine Tony Fourie (014) 572 1720

• BRPM mine Marius Barnard (083) 579 3094

• City Hire Services Vee Naidoo (011) 420 2737

• Diesel Electric Services Kevin Donaldson (011) 493 7079

• Diesel Generator Services Nick Smit (021) 981 4801

• Dosco GPM Ken Barnard (011) 452 5843

• DPA Diesel Services Frank Testa (011) 493 6046

• Dura Piling Piet Smit (011) 494 4058

• Dwarsriver Mine Rian Burger (013) 230 5300

• Engine Applications Derek Palmer (011) 825 1560

• Engine Control Systems Rudi De Beer (011) 391 1443

• Fourways Motor Engineering Fritz Pretorius (018) 786 1995

• Genset Marketing Piet Wessels (018) 469 4117

• Hal Core Drilling Kobus Halliday (012) 252 3836

Customer References

• Hydrostatic Trans Engineering John Venton (018) 784 4301

• Ian Dickie & Co - JHB Joe Knighton (011) 609 4130

- Cape Town Ian Fraser (021) 534 3431

• JIC Mining Services Kiewiet Bender (018) 462 4554

• Kirsons Trading Anil Sur (011) 666 4705

• Lynx Power Technologies Al Gardner (011) 869 3314

• Mogwele Hannes Groblar (013) 712 3075

• Mill Trader NW Andre Verster (014) 572 3526

• Murray & Roberts Cementation Billy Owen (014) 536 5400

Gert Richter (014) 572 1370

Jose Mendez (011) 201 5000

• Rovic Engineering Victor Havenga (018) 293 3574

• Super Rock Drills Ge Jooste (012) 803 7925

• Thor Drill Rigs Rudi Greyling (012) 736 2345

• Wrenn Power Niel Owen (011) 614 7045

Slide 51 of 4511-Jun-14

Thank You…

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Journey of Engineering Excellence - Kirloskar Introductory Presentation... · Successfully Handling Group Companies. ... Industrial & Construction Segment ... Mining Earthmoving Fluid