PUNJAB BEVEL GEARS

INTRODUCTION
GROUP COMPANIES

SAHIBABAD UTTAR PRADESH 4 PLANTS*

LUDHIANA PUNJAB

SITARGANJ** UTTARAKHAND
**Under Commissioning

DIFFERENTIAL & TRANSMISSION GEARS and DIFFERENTIAL CAGE

FORGING MACHINING AXLE SHAFT

DIFFERENTIAL & TRANSMISSION GEARS

*There are 4 manufacturing units located within 500 metres in Sahibabad and share common resources of Metrology and Metallurgy.

INTRODUCTION..Contd.
STARTED OPERATIONS IN 1979 MANUFACTURES MORE THAN 2000 DIFFERENT TYPE OF GEARS LEADING MANUFACTURER, SUPPLIER AND EXPORTER OF AUTOMOTIVE PARTS CATERS TO INDUSTRIES LIKE COMMERCIAL VEHICLE, AGRICULTURAL TRACTORS, PASSENGER CAR, THREE WHEELER & CONSTRUCTION EQUIPMENT

INTRODUCTION..Contd.
OUR COMPETITIVENESS LIES IN THE FACT THAT WE ARE : COST COMPETITIVE,

QUALITY CONSCIOUS,
HAVING TRACK RECORD OF ON TIME DELIVERY

HAVING CAPABILITY TO DEVELOP NEW PRODUCTS IN A SHORTER PERIOD

AND

INTRODUCTION..Contd.
FINANCIALLY SOUND HAVING ASSURANCES FROM FINANCIAL INSTITUTIONS FOR SUPPORT IN THE ONGOING AND FUTURE EXPANSIONS HAVING VERY SOUND HR POLICIES WITH ALMOST NIL EMPLOYEE TURNOVER THE AVERAGE AGE OF EMPLOYEES IS 40 YEARS HAVING 100% CAPTIVE POWER BACK UP AN ISO/TS 16949: 2002 CERTIFIED COMPANY

PRODUCT RANGE
CROWN WHEEL & PINION (Gleason & Oerlikon System)
ST. BEVEL GEARS & PINIONS (Gleason Coniflex System) TRANSMISSION GEARS (Spur, Helical) DIFFERENTIAL CAGE

AXLE SHAFTS
FORGINGS MACHINED FORGINGS

TOTAL SALES (Mio Rs)

1200 1000 800 600 400 200 0 404 547 764 1116 971 FY05 FY06 FY07 FY08 FY09

TOTAL SALES (Mio $)

30 25 20 15 10 5 0 10.1 13.7 19.1 27.9 24.3 FY05 FY06 FY07 FY08 FY09

SEGMENT WISE SALES FY 09

OTHERS 6%

OEM (DOM) 32%

EXPORT 62%

OEM (DOM) EXPORT OTHERS

CAPACITY INSTALLED
Sl.No. Product Annual* New Capacity Utilization*

Capacity

under
installation

of existing
capacity 70% 70% 70% 25% 40%

1. 2. 3. 4. 5.

Crown Wheel & Pinion Straight Bevel Gears Transmission Gears Axle Shafts Forgings

420,000 Sets 720,000 Nos. 1,200,000 Nos. 60,000 Nos. 12,000 MT

120,000 sets 300,000 nos 400,000 nos 60,000 nos --

* On 2 Shift Basis

CAPABILITIES - GEARS
TYPE SPIRAL/ HYPOIDS STRAIGHT BEVEL 216(10:1) 152(1:1) 50.80 8.50 SPEED GEAR TRANS. SHAFT

MAX. SIZE (DIA) MM

MAX. FACE WIDTH/L MAX. MODULE (mm)

500
76 12.70

400
400 8.00

80
750 8.00

ACCURACY

DIN CLASS 8-9

DIN CLASS 8-9

DIN CLASS 8-9

DIN CLASS 8-9

CAPABILITIES - FORGINGS
Weight
Round Forging

0.5 Kg to 50 Kgs
Min. Dia 80 mm Max. Dia 500 mm Length 1200 mm Flange Dia 325 mm

Shaft Forgings

PLANT AREA IN SQ. FT

SAHIBABAD TOTAL AREA 500,600 LUDHIANA 152,500 SITARGANJ 183,140

COVERED AREA GENERAL OFFICE AREA

179,390

46,000

95,200

5,420

5,000

11,600

MANPOWER
Sitarganj (Planned) 100 12

Sahibabad Hourly Supervisory 435 47

Ludhiana 65 07

Manager

13

01

02

Total

495

73

114

CERTIFICATION

PUNJAB BEVEL GEARS LIMITED

( AN ISO/TS 16949: 2002 COMPANY) (Excluding Product Design)

RECOGNISED STAR EXPORT HOUSE AWARDED SILVER SHIELD FOR EXPORT PERFORMANCE DURING 2005-06 BY EEPC

CUTTING EQUIPMENT INSTALLED

CNC Turning Lathes Vertical Machining Center 22 Nos. 03 Nos.

Gleason Crown Wheel (608/609, 606/607, No.11 & No. 22)

Gleason Pinion (No.116 & No.16) Oerlikon (SM3, S17, SKM1)

8 Sets
7 Sets 9 Nos.

CUTTING EQUIPMENT INSTALLED

Transmission Gears Hobbing 26 nos

Shaping
Shaving

26 nos
14 nos

Straight Bevel Gears

Gleason Coniflex114 Gleason Coniflex104 Coniflex WMW

02 nos 02 nos 26 nos

HEAT TREATMENT FACILITIES

Sealed Quench Furnaces Continuous Gas Carburising Furnace Gas Carburising Furnaces Rotary Hearth Furnaces Pusher Type Furnace Quench Presses Oerlikon, Klingelnberg, & Gleason Tempering Furnaces Manganese Phosphating Facilities Shot Blasting Equipments Straightening Presses

FINISHING EQUIPMENTS
Cylindrical Grinding Machines Internal Grinding Machines Spline Grinding Machine Lapping Machines Gleason (503/506/119/513/516) Oerlikon (SKL-1) Gear Testers-Gleason (502/511/17-A) -10 Nos. - 5 Nos. - 1 No. - 11 Nos. - 1 No. - 13 Nos.

METALLURGICAL LAB FACILITIES

Full range of Hardness Testers

(Rockwell, Brinell, Vickers, Micro Vickers)

Hardenability (Jominy) Apparatus Microscope with camera and image analyzer Crack detection Equipment [Magnaflux] Macro Etching Manganese Phosphating Solution Analysis Muffle Furnaces Sample Cutting / Polishing Machines

METROLOGY LAB FACILITIES

Includes: CMM with Gear Analyser

Lead and profile testers

Surface Roughness tester

Contouro Graph
Profile Projectors

Digital Temperature Calibrator

Wear Check Plug for Thread Ring Gauge Calibration

QUALITY SYSTEMS
RAW MATERIAL
Forgings are received Heat Code wise duly

Isothermally Annealed/ Normalised.

Checks before processing are: Visual Inspection for cracks and folds. Check of chemical composition by Spectro Analysis. Hardness. Jominy Hardenability.

Micro structure and Inclusions.

Grain Size and Grain flow.

QUALITY SYSTEMS.Contd.
IN-PROCESS

First off inspection

&

Patrol inspection at defined interval as per control plan

For Bevel Gears check tooth contacts in soft Gears

Before Heat Treatment inspection for all parts ensuring removal of any sharp edges and burrs.

For Bevel Gears Final Testing to ensure backlash at correct mounting distance, tooth contact, run out and marking mounting distance variations.

QUALITY SYSTEMS.Contd.
HEAT TREATMENT Batches are subjected to checks on: Effective Case Depth

Core and Surface Hardness

Microstructure- Case & Core Flatness & ovality of bore for Crown Wheels

Straightness for Shaft items

Magnetic particle inspection by Magnaflux

INVESTMENT COMMITTED
Additional Continuous Gas Carburising Furnace

Sealed Quench Furnaces

CNC Hobbers CNC Shapers CNC Shavers CNC Internal Grinder CNC External Grinders CNC Gleason/Oerlikon, Dry/Wet Cutting System for Crown Wheel & Pinion (under consideration)

CUSTOMER PROFILE DOMESTIC OEMs AUTOMOTIVE

TATA MOTORS MAHINDRA & MAHINDRA

DANA INDIA
SCOOTERS INDIA

AMERICAN AXLE & MANUFACTURING

CUSTOMER PROFILE DOMESTIC OEMs AGRICULTURE

TRACTOR & FARM EQUIPMENT INTERNATIONAL TRACTORS JOHN DEERE EQUIPMENT NEW HOLLAND TRACTORS INDO FARM EQUIPMENT STANDARD COMBINES

CUSTOMER PROFILE DOMESTIC OEMs

CONSTRUCTION EQUIPMENTS & OTHERS
JCB INDIA TELCO CONSTRUCTION EQUIPMENT ACTION CONSTRUCTION EQUIPMENT EICHER MOTORS

CUSTOMER PROFILE EXPORT OEMs

UZEL MAKINA SANAYI A.S., TURKEY MEGA MOTORS COMPANY, IRAN IRAN TRACTOR MFG COMPANY, IRAN ARVIN MERITOR, BRAZIL

CUSTOMER PROFILE - EXPORTS

We also Export our products to Importers, Gear Makers & After Markets in:

USA , U.K., France, S. Africa, Indonesia, Malaysia, Thailand, Singapore, Burma, Syria, Egypt, Turkey, Bangladesh, Sri Lanka, Iran, Dubai, Italy, Argentina, Australia, Hungary, Germany, Brazil etc.

FORGING FACILITIES AT LUDHIANA

Friction Belt Drop Hammer (1.00, 1.50, 2.00, 2.50, 3.00, 6.00, 8.00 M.T.) Up Setter - 3 Inches & 6 Inches Furnaces for Isothermal annealing & normalizing Fully equipped die making facilities Material testing facilities includes Spectro Meter & Universal Testing Machine along with Izol Impact & Charpy Testing Machines

100% back up with Captive Power

An ISO 9001: 2008 certified

FACILITIES AT SITARGANJ
Green Field Plant having shed & flooring ready Continuous gas carburising & sealed quench furnaces under commissioning at site Cutting equipments identified & under movement to site Key personnel identified Production expected to start in December 2009

Production & capacity planned

Crown Wheel & Pinion- 120,000 Sets Straight Bevel Gears - 300,000 Nos. Transmission Gears - 400,000 Nos.

PLANT ADDRESS
PUNJAB BEVEL GEARS LIMITED
B-44/1 & 52/2, Site-IV, Industrial Area, Sahibabad-201010, Ghaziabad (U.P) India Tel.: +91-120-2895386/2895320/2896075/2895344 Fax: +91-120-2896099/2896059 Email: mktg@pbgl.in Web Site: www.punjabbevelgears.com