Automotive and Industrial Gear Manufacturing

Presentation By :
Arvind Bhardwaj : Roll No 04
Shrikant Desai : Roll No 09
Naresh Joshi : Roll No 20
Rahul Wankhede : Roll No 54
 FACTORY LOCATIONS
• THANE – GEAR MANUFACTURING PLANT
• DEWAS (M.P) – 02 UNITS (GEAR MANUF. PLANT)
• PITAMPUR – ISEZ UNIT (GEAR BOX PLANT)
• GURGAON – OUTSOURCING UNITS (ALL GEARS)
Process Flow of Gear manufacturing

Blanking - Heat Packing &

Outsourced Treatment Dispatch

RQC Hard`Gear
Finishing

Soft Gear
FQC Customer
Cutting

OEM After Market Exports

 Types of gears manufactured :-
DIFFERENTIAL GEARS:
 Spiral Bevel (including Crown wheel & Pinion)
 Hypoid
 Straight Bevel
TRANSMISSION:
 Spur gears
 Helical gears
 Cluster gears and Shafts
DRIVE LINE AGGREGATES:
 Agri gear box
 Snow blower gear box
 Industrial gear box
 Parallel shaft
 Transmission & Axle Assembly
Crown Wheel & Pinions Straight Bevels Transmission &
Engine Gears

Gearboxes & Diff. Outsourced parts

assemblies
Receipt Quality Control(RQC) -Section

 The function of the RQC is to inspect the

quality parameters required in the blanks for
the gear cutting process.
 The blanks obtained from the vendors are
accompanied by a dimensional report.
 These blanks are sample checked again if
they are of right dimensions and are then
sent in.
 If the blanks are found to be defective they
 HOBBING SHAPPING HEAT
GEAR CUTTING TRETMENT

SPECIAL
GRINDING
INSPECTION HANDLING PACKING
RACKS
 COST EFFECTIVENESS
• Vendor Selection for Forgings and Blanks / Transportation up to Factory .
• Rejection and transportation cost will be bear by Vendors.
• In line process and placing of machines to increase production / Reduce Wastage
and Continuous process without breaks.
• Mass Productions.
• Proper Handling Equipment to avoid accidents and damages to the products.
• Inspection of Finish Goods to avoid rejections.
• Vendor Selections for Packaging Materials.
• Proper Labeling and Marking to avoid confusions and proper identification of the
customers.
• Consolidation of Material to Distribution Centers.
• Consolidation of Export Cargo coming from different location.
• FCL Movements to avoid extra cost to the customer at Destination ports.
Techniques implemented to reduce the
Warehouse and Distribution cost
1. Reduce square footage and optimize space

2. Racking

3. Reduce Labour

4. Inventory Control techniques

5. Reduce Vendor Cost

6. Reduce time wasted traveling

7. Move orders to zone

8. Batch orders and sort

Techniques implemented to reduce the
Warehouse and Distribution cost

Optimization in distribution with approach to reduce cost.

1. Sustainability in packaging.

2. Optimizing In-Plant Logistics.

3. Developing Multimodal Logistics

 Air on the Move

Storage space utilization of < 25% & 75% of

SPACE is taken up by AIR,
To Reduce the empty cost we implemented
the Double deck truck to enable vertical space
utilization
 In Plant Logistics
Overcoming Human limitation

Pulley system to minimize human

effort – No ELECTRICITY IS
USED 30% reduction in manual
handing
 In Plant Logistics

Zero manual – “Zero Energy” transfer system

Utilization of gravity racks for flowing downwards bins with

“0” Manual Interventions
ORIGINAL EQUIPMENT AFTER SALE SERVICE PARTS

EXPORTS
ar OEM CUSTOMERS
EXPORT CUSTOMERS
AFTER SALE SERVICE MARKETS