Presentation by Surinder Kapur September 14th, · PDF filesona autocomp usacomponents sona koyo steering systems ltd. mahindra sona ltd. sona somic lemforder ltd. sona okegawa precision

Presentation by Surinder Kapur

September 14th, 2012

The Sona Group

• 25 years ago the Sona Group started with :

» 25 employees

» 1 million € Sales

» 1 company in India

The Sona Group

• Today » 6000 Employees (4500 in India and 1500 outside India)

» Global Sales revenue cumulatively of € 680 million

» 8 manufacturing companies in India, 18 Plants.

» 1 overseas company with 3 plants in Germany and 1 plant in the US

» All Indian companies are with ISO 14000 and TS 16949 certification and practicing Japanese TQM and TPM methods.

» Sona Koyo is Deming Prize Winner and TPM Excellence Award winner

Sona

Autocomp

USA

SONA KOYO

STEERING

SYSTEMS

LTD.

MAHINDRA

SONA LTD.

SONA SOMIC

LEMFORDER

COMPONENTS

LTD.

SONA

OKEGAWA

PRECISION

FORGING LTD.

SONA

E-DESIGN &

Technology

Auto Components Services

Sona Holding

Support

Sona

Autocomp

France

JTEKT SONA

AUTOMOTIVE

INDIA LTD.

Fuji Autotech

Europe

.

SONA FUJI

KIKO INDIA

LTD.

Koyo- Sona

Electronics

Ltd.

SONA

MOBILITY

SERVICE

(SIXT)

SONA BLW

PRECISION

FORGING

GROUP

Germany

+

SONA

Plant Selma

USA

Sona

Stampings

PVT. LTD.

Structure

Sona BLW Precision Forge

1 plant in

North Carolina, USA

Fuji Autotech

Brazil

Sona BLW

Präzisionsschmiede

3 Plants in Germany

Sona Group India

18 Plants Fuji Koyo Czech

(FKC)

Fuji Autotech

France

Minority Stake Sona Group

Companies

Fuji Autotech

Sweden

Service Co

Global Footprint

Sona Marketing Offices

•USA

•Europe

•Japan

Chennai

• Sona Somic Lemforder

• Sona Koyo Steering Systems

• JSAI

DELHI

GURGAON

BAWAL DARUHERA

NASIK

PUNE

CHENNAI

Pantnagar


Pune

• Sona Okegawa Precision Forgings

Nasik

• Mahindra Sona

Bawal

• JSAI

• SFAL

Gurgaon


• Sona Okegawa Precision Forgings


• Sona Stampings

Daruhera

• Sona Koyo Steering Systems (3 Plants)

SANAND

Sanand


PANTNAGAR

Sona

Koyo

Sona

Somic

Sona

Okegawa

Mahindra

Sona

Cold

Forging

Production 1987 1995 1998 1980 1997

TS16949

ISO 14001

TPM

Excellence

Award

Deming CERTIFICATIONS

Presence in India

Sona Group is India’s largest manufacturer of Steering Systems

R&P Power Diff case Assembly Propeller Shaft CEPS Steering U Joints

Columns & shafts

Market Leaders in India

http://images.google.com/imgres?imgurl=http://philip9876.files.wordpress.com/2008/03/tatalogo.jpg&imgrefurl=http://philip9876.wordpress.com/2008/03/26/tata-buys-jaguar-land-rover/&h=193&w=268&sz=30&hl=en&start=1&tbnid=KkRu5J40wdsaTM:&tbnh=81&tbnw=113&prev=/images?q=tata+motors+logo&gbv=2&hl=en&sa=G

http://www.carraro.com/default.asp

http://images.google.com/imgres?imgurl=http://upload.wikimedia.org/wikinews/en/thumb/b/b8/Ford_Motor_Company_logo.png/320px-Ford_Motor_Company_logo.png&imgrefurl=http://en.wikinews.org/wiki/Ford_Motor_Company_cutting_30,000_jobs_by_2012&h=125&w=320&sz=44&hl=en&start=10&um=1&tbnid=Mlia8b19rju67M:&tbnh=46&tbnw=118&prev=/images?q=force+motor+company+logo&um=1&hl=en&sa=G

http://images.google.com/imgres?imgurl=http://blog.wired.com/cars/images/2007/03/30/toyota_logo_2005.jpg&imgrefurl=http://blog.wired.com/cars/2007/03/index.html&h=301&w=350&sz=14&hl=en&start=7&um=1&tbnid=Z7mfeoRPIPZdeM:&tbnh=103&tbnw=120&prev=/images?q=automotive+axles+logo&um=1&hl=en&sa=G

Sona Group is Worlds largest Precision Forged Bevel Gears Manufacturer

Bevel Gears Synchronizer Rings Speed Gears Axle Stubs Hatebur Flanges

Output Shaft

World’s Largest Precision Gear

Manufacturer

http://www.zercustoms.com/news/images/Daimler-logo-b.jpg

http://longron.com/BMW.htm

http://longron.com/vw_logo_barra_www.jpg

http://www.digital-humans.org/Caterpillar-logo.jpg

Steering column

Rear axle

Steering Gear

Propeller shaft

Clutch

Assembly

Control arm

Bevel Gear

Seat Recliner

Product Portfolio

Global Customers

http://www.zercustoms.com/news/images/Daimler-logo-b.jpg

http://longron.com/vw_logo_barra_www.jpg

http://longron.com/BMW.htm

http://www.cars-directory.net/articles/scania/Scania-Logo-logo.jpg

http://www.digital-humans.org/Caterpillar-logo.jpg

http://images.google.co.in/imgres?imgurl=http://www.sophus3.com/images/Renault-logo.jpg&imgrefurl=http://www.sophus3.com/clients.htm&h=416&w=300&sz=15&hl=en&start=8&tbnid=sdupOxEGSiRCwM:&tbnh=125&tbnw=90&prev=/images?q=renault+logo&gbv=2&hl=en&sa=G

http://thegarageblog.com/garage/wp-content/uploads/gm-logo.jpg

http://www.impressivepowerboats.com/images/ZF Logo.jpg

http://images.google.co.in/imgres?imgurl=http://www.jimsoffroad.com/DANA LOGO.jpg&imgrefurl=http://www.jimsoffroad.com/vendors.htm&h=600&w=900&sz=38&hl=en&start=1&tbnid=WnwDvIixIFXwJM:&tbnh=97&tbnw=146&prev=/images?q=dana+logo&gbv=2&hl=en&sa=G

http://images.google.co.in/imgres?imgurl=http://www.automotive-rheinland.de/content/image/BPW_Logo.jpg&imgrefurl=http://www.automotive-rheinland.de/goto/BPW_Bergische_Achsen_Kommanditgesellschaft_51.html&h=472&w=472&sz=46&hl=en&start=4&tbnid=mpgAqu1l1o2g2M:&tbnh=129&tbnw=129&prev=/images?q=bpw+logo&gbv=2&hl=en&sa=G

http://images.google.co.in/imgres?imgurl=http://www.underconsideration.com/brandnew/archives/chrysler_detail.gif&imgrefurl=http://www.underconsideration.com/brandnew/archives/chrysler_gets_heavy.php&h=413&w=470&sz=97&hl=en&start=4&tbnid=BpaKPzZCMZeKfM:&tbnh=113&tbnw=129&prev=/images?q=chrysler+logo&gbv=2&hl=en&sa=G

http://images.google.co.in/imgres?imgurl=http://www.linamar.com/_layouts/images/linamar/linamar_logo.jpg&imgrefurl=http://www.linamar.com/sitemap&h=43&w=166&sz=19&hl=en&start=1&tbnid=6VvPtbs4EOyMOM:&tbnh=26&tbnw=99&prev=/images?q=linamar+logo&gbv=2&hl=en&sa=G

http://images.google.co.in/imgres?imgurl=http://www.pissedconsumer.com/images/categories/honda_logo.jpg&imgrefurl=http://www.pissedconsumer.com/consumer-reviews/honda-american-honda-motor-co..html&h=304&w=450&sz=17&hl=en&start=1&tbnid=BiS1wJoORhVu_M:&tbnh=86&tbnw=127&prev=/images?q=honda+logo&gbv=2&hl=en&sa=G

http://images.google.co.in/imgres?imgurl=http://i7.ebayimg.com/01/i/000/93/19/3963_1_sbl.JPG&imgrefurl=http://stores.ebay.co.uk/1st-Tools-Direct&h=344&w=400&sz=16&hl=en&start=2&tbnid=AcpdiBkautr-gM:&tbnh=107&tbnw=124&prev=/images?q=JCB+logo&gbv=2&hl=en&sa=G

http://images.google.co.in/imgres?imgurl=http://www.friesenusa.com/images/JohnDeereLogoV.jpg&imgrefurl=http://www.friesenusa.com/seed_tenders.htm&h=450&w=600&sz=28&hl=en&start=1&tbnid=uf1TXtz44JbXzM:&tbnh=101&tbnw=135&prev=/images?q=john+deere+logo&gbv=2&hl=en&sa=G


India Customers

http://www.carbodydesign.com/archive/2006/10/29-a-new-logo-for-fiat/Fiat-Logo-2000.jpg


http://images.google.co.in/imgres?imgurl=http://www.sophus3.com/images/Renault-logo.jpg&imgrefurl=http://www.sophus3.com/clients.htm&h=416&w=300&sz=15&hl=en&start=8&tbnid=sdupOxEGSiRCwM:&tbnh=125&tbnw=90&prev=/images?q=renault+logo&gbv=2&hl=en&sa=G

http://thegarageblog.com/garage/wp-content/uploads/gm-logo.jpg

http://images.google.co.in/imgres?imgurl=http://www.jimsoffroad.com/DANA LOGO.jpg&imgrefurl=http://www.jimsoffroad.com/vendors.htm&h=600&w=900&sz=38&hl=en&start=1&tbnid=WnwDvIixIFXwJM:&tbnh=97&tbnw=146&prev=/images?q=dana+logo&gbv=2&hl=en&sa=G


http://images.google.com/imgres?imgurl=http://www.moneycontrol.com/news_image_files/Eicher_logo.jpg&imgrefurl=http://indiaearnings.moneycontrol.com/sub_india/news.php?category=14&sc_did=EM&h=120&w=120&sz=5&hl=en&start=4&um=1&tbnid=GFPyMQzwoe9GfM:&tbnh=88&tbnw=88&prev=/images?q=eicher+motor+logo&um=1&hl=en&sa=N

http://images.google.com/imgres?imgurl=http://blog.wired.com/cars/images/2007/03/30/toyota_logo_2005.jpg&imgrefurl=http://blog.wired.com/cars/2007/03/index.html&h=301&w=350&sz=14&hl=en&start=7&um=1&tbnid=Z7mfeoRPIPZdeM:&tbnh=103&tbnw=120&prev=/images?q=automotive+axles+logo&um=1&hl=en&sa=G

http://images.google.com/imgres?imgurl=http://www.waynesfarmmachinery.com/images/TafeLogo.gif&imgrefurl=http://www.waynesfarmmachinery.com/tafe.asp&h=146&w=413&sz=4&hl=en&start=1&um=1&tbnid=iKGHtMCyjMpCbM:&tbnh=44&tbnw=125&prev=/images?q=TAFE+logo&um=1&hl=en&sa=G

http://images.google.co.in/imgres?imgurl=http://www.pissedconsumer.com/images/categories/honda_logo.jpg&imgrefurl=http://www.pissedconsumer.com/consumer-reviews/honda-american-honda-motor-co..html&h=304&w=450&sz=17&hl=en&start=1&tbnid=BiS1wJoORhVu_M:&tbnh=86&tbnw=127&prev=/images?q=honda+logo&gbv=2&hl=en&sa=G

http://www.swarajenterprise.com/images/ptl_logo.gif

http://images.google.com/imgres?imgurl=http://www.cyberautocop.com/gifs/hindustan-logo.gif&imgrefurl=http://www.cyberautocop.com/automobile-manufacturers.html&h=40&w=58&sz=1&hl=en&start=5&um=1&tbnid=DbutfAfyoAMGNM:&tbnh=40&tbnw=58&prev=/images?q=hindustan+motor+logo&um=1&hl=en&sa=X

http://images.google.co.in/imgres?imgurl=http://i7.ebayimg.com/01/i/000/93/19/3963_1_sbl.JPG&imgrefurl=http://stores.ebay.co.uk/1st-Tools-Direct&h=344&w=400&sz=16&hl=en&start=2&tbnid=AcpdiBkautr-gM:&tbnh=107&tbnw=124&prev=/images?q=JCB+logo&gbv=2&hl=en&sa=G


http://images.google.com/imgres?imgurl=http://upload.wikimedia.org/wikinews/en/thumb/b/b8/Ford_Motor_Company_logo.png/320px-Ford_Motor_Company_logo.png&imgrefurl=http://en.wikinews.org/wiki/Ford_Motor_Company_cutting_30,000_jobs_by_2012&h=125&w=320&sz=44&hl=en&start=10&um=1&tbnid=Mlia8b19rju67M:&tbnh=46&tbnw=118&prev=/images?q=force+motor+company+logo&um=1&hl=en&sa=G

http://images.google.co.in/imgres?imgurl=http://www.friesenusa.com/images/JohnDeereLogoV.jpg&imgrefurl=http://www.friesenusa.com/seed_tenders.htm&h=450&w=600&sz=28&hl=en&start=1&tbnid=uf1TXtz44JbXzM:&tbnh=101&tbnw=135&prev=/images?q=john+deere+logo&gbv=2&hl=en&sa=G

http://images.google.co.in/imgres?imgurl=http://www.thelightisgreen.com/Hyundai Logo 01_1.jpg&imgrefurl=http://www.thelightisgreen.com/2008/07/hyundai-up-in-u.html&usg=__j29LX2qI5mIgXsiud6KH2DFOLEY=&h=827&w=1034&sz=55&hl=en&start=8&um=1&tbnid=iVGSkQAwWsdANM:&tbnh=120&tbnw=150&prev=/images?q=Hyundai&hl=en&sa=N&um=1

12

Sona Koyo Steering

System Ltd

Sona Okegawa Precision

Forgings Ltd

Sona Somic Lemforder

Components Ltd

Sona e-Design &

Technologies Ltd

S MIC

Mahindra Sona Ltd.

Overseas Technology Partnerships

http://images.google.co.in/imgres?imgurl=http://www.livermoreperformance.com/images/Products/koyo/koyo_logo_2in.gif&imgrefurl=https://www.lpiracing.com/store/pc/viewPrd.asp?idcategory=9151&idproduct=22870&usg=__W8C_aIDuXHV5rZSJ4h74MYjr3PE=&h=67&w=144&sz=7&hl=en&start=12&um=1&tbnid=ah_Tl8VudSwIyM:&tbnh=44&tbnw=94&prev=/images?q=logo+of+koyo+electronics+japan&gbv=2&ndsp=20&um=1&hl=en&sa=N

Sales Profile F 2011

Sona BLW

(Okgwa)

6.0%

Others

2.0%

Sona Somic

6.0%

Sona BLW (Ger.)

39.5%

JTEKT Sona

7.0%

Mahindra Sona

7.0%

Sona Koyo

28.0%

Sona BLW (USA)

4.5%

Group Turnover – € 680 million

Sona Okegawa

Group 50%

INDIA

56%

Respect for the Individual

Service to the Customer

Excellence in the pursuit of our Goals

MOTTO

Think!

Create a Company That India is Proud of

To Make Sona A Partner Of Choice’ to Global Customers

MISSION

An organization of energized and involved employees.

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

VISION

Sona Vision 2020

The German Adventure Acquisation of ThyssenKrupp

Forging Company

Why the Acquisition

• Globalization

• Technology Leadership

• World No.1

17

1951 Fabrication of first forged differential gears world- Wide in BLW; Daimler -Benz is first customer for these parts.

1953

Straight bevel gear patent

1965 Start-up of the First automatic multi-stage Forging press “Hatebur” at Remscheid plant

1979/80 Remscheid produces first precision forged differential gears BLW files Production process And design of “Back Tapered coupling Teeth” as patent

1986/89 Wanheim plant is integrated into The Thyssen Business unit “Forming technologies” Acquires BLW And establishes The business Segment “gear parts”

1996 Business unit “forming Technologies” Acquires US- Precision forge SMB from Saurer AG (later renamed TK PF Inc.) and Integrated it into The business Segment “gear parts”

2002 Business Segment “gear Parts” is separated From the forming group and named ThyssenKrupp Prazision. (Plants Remscheid Munich, Wanheim And Selma (US)

Today Successful worldwide producer of precision forged power train parts e.g bevel -,speed gears and axle drive components

2008

Sona Okegawa acquired Thyssenkrupp Technologies and Sona BLW formed

1998

Start of Sona Okegawa Precision Forgings Ltd- Indian Operations

History- Sona Precision Forging Group

Remscheid Duisburg

Selma, USA

Munich Remscheid Duisburg Selma Gurgaon Pune

Foundation 1925 1773 1911 1996 1997 2005

ISO/TS16949

DIN EN ISO 14001

TPM Excellence Practicing Practicing Practicing Practicing Practicing

Munich

Locations- Sona Precision Forging Group

Post Acquisition Challenges

• Financial Crisis – Oct 2008

• Creating a ‘Mittelstand’ company with a ‘big

group’ mentality management

• Inefficient processes – low OEE, high Scrap

• Dealing with German Unions and high labour

cost

Competitiveness Strategy –

next 3 years, 2010 - 2013

Our Vision – Be Globally Competitive

To be globally competitive Precision Forge

Take an Active Part in our Customers‘ Globalization Strategies

To Offer World Class Supply and quality

Strategy developed with Employees

Improve

Productivity

Reduce

Scrap

Introduce

New Products

CAPEX

Education/Training

How ?

Introduce New Prod.

Strategy of HOW to become Globally

Competitive – 3 years

From Now to 2020

Become the #1 Global Independent Precision forging Group with sales of $1 billion .

Mission 2020 - Sona Precision Forging Group

No. 1 Precision Forging Company

Globally $ 1 billion

Globalization –

follow the customer

Strategic

Development Partner

Operational

Excellence R&D and Innovation

Geographical strategy Quality strategy Synergy strategy

Respect for the Individual Service to the Customer Excellence in the

pursuit of our goals

Governance excellence HR Excellence

2020

Documents

Presentation by Surinder Kapur September 14th, · PDF filesona autocomp usacomponents sona koyo steering systems ltd. mahindra sona ltd. sona somic lemforder ltd. sona okegawa precision