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