RB GROUP

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 CONTENTS
• INTRODUCTION
• Sectors Served
• RB FORGINGS PVT LTD
• RB GEARS
• SHAKESPEAR FORGINGS LTD
• OUR PRODUCTS
• Our Clients
• Our Facilties
• Quality
• Documents
• Production
• Achievements and Awards
• Edscha points

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 Welcome To R.B.Group
• R.B. is a group of companies with manufacturing excellence
in forging, machining, gear cutting and assemblies. Our
product portfolio contains reliable and quality products for
OEM and ancillary support. R.B. group has achieved
voluminous growth and has plants in India and the United
Kingdom. Group's first company, R.B. Forging was started in
1993 and through targeted investment keeping in view the
interests of the customers, the company expanded and
built another plant under the name R.B. Gears. The group
has recently acquired a forging company in the U.K. under
the name Shakespeare Forgings.R.B. Group caters to the
needs of customers from diverse sectors like automotive,
farm and tractors, containers and commercial vehicles and
mining and railways.

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 ABOUT RB
• R. B. Forgings was formed in 1993 and has now
become an acknowledged leader in the forging
industry. It is now a leading manufacturer and
exporter of a wide range of automotive and
industrial parts. Since its inception, R.B. has
achieved voluminous growth and is a one-stop
shop for:
• Forgings
• Machining
• Gear cutting
• Assemblies
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 Sectors Served

Automotive Railway

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Tractors & Farm Equipments
 RB FORGINGS PVT LTD
With the ardor to set a mark in the engineering industry, ‘R. B. Forgings Private
Limited’ is a privately owned company that has its endeavors in the manufacturing
and exporting of all kind of forgings, fabrication machining parts and machine tools
like industrial machine tools, metal machine tools, forged machine tools, etc.
Established in the year 1993, we are a one stop solution for open and close type
forgings and precision fabrications that are in line with the latest technology.
Working under the visionary guidance of Mr. Sanjeev Garg, we have been able to
garner the certification of ISO 9002, ISO 9001:2000 and ISO/TS 16949. By
manufacturing our range in compliance with the industry accepted quality standards,
we have been able to supply our clients with an international grade range that meet
the requirements of our clients.
Our fabrication job work is carried out in a qualitative manner, with the help of our
well structured tool room and full-fledged chemical and physical labs for carrying out
different types of quality checks. The unrelenting efforts of our team have led us in
integrating top notch quality in our range, thereby helping us gain an upright position
in the market.

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 COMPANY FACT SHEET

Year of Income Tax Tax Identification

Establishment Legal Status of Firm Registration No. No. Import Export Code
1996 Private Ltd. Co. AAACR7159Q 03491004946 2201003211
registered under
Indian Companies
Act 1956

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 R.B. Gears
• RB Gears a gear manufacturing company of RB GROUP has become
a leading manufacturer and exporter of a wide range of automotive
and industrial gears and shafts. Since its inception, RB Gears has
achieved rapid growth based upon its high level of expertise, quality
and customer satisfaction.
• There is an on-going investment programme in machine tools which
already includes hobbing (0.8 – 8 module), shaving, broaching, and
crown and pinion machines.
• The plant has its own gas carburising furnaces for heat treatment of
gears.
• RB Gears has ISO 9001:2015 Certification.
• Gear Cutting
• In gear cutting, we have a complete range of Hobbing (0.5 module-
8 module), shaving, broaching, crown wheel/bevel generator and 3
Nos of gas carburizing furnaces for heat-treatment.

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 Shakespeare Forgings

• Shakespeare Forgings is based in Cradley Heath, W.

Midlands, U.K. The company performs coining, piercing,
machining, N.D.T. and assembly operations on parts
produced by its sister companies in the RB Group.
• It also acts as a warehousing and logistics centre for the
Group’s European and N. American activities.
• Shakespeare Forgings can act either as a facilitator between
the customer and its sister companies in India or as the
contractual partner with the customer, guaranteeing the
quality and supply from its sister companies in India.
• Shakespeare Forgings is an engineering plant which is able
to add value to parts produced by it’s sister companies in
India.
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 Gear Cutting

• With an aim to provide value-added services to our

customers and to stay in line with their requirements,
R.B. Forgings has persuaded forward integration and has
installed a gear cutting division in the name of "R.B.
Gears Pvt. Ltd". We have added machines like Hobbing,
Shaving, Shaping and Grinding of reputed make to
manufacture and supply complete gears. Through this,
R. B. Forgings has derived strategic advantage vis-a-vis
its competition as the company is a one stop for
forgings, machining as well as gears with the highest
quality standard.
Our gear division has the infrastructure to manufacture
a wide range of gears, shafts, and machined parts. We
have a strong technical team to develop and
manufacture the parts.We always incline towards a
flexible approach that allows us to adopt to dynamic
changes of automotive industry into our mainstream
business.
Our range of Gear cutting is mentioned below:
• Module: 1 to 7 mm
• Diameter: 20 to 320 mm
• Job Length: up to 1000 mm
• Hobbing Length: up to 200 mm
• Broaching Capacity (40 Ton): 200 mm Dia, 2 mt Length
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 Crown Pinion
• With a mission to upgrade our infrastructure, the company continues
to invest in high-end technologies and is always inclined towards a
flexible approach that allows it to adopt to dynamic changes of
automotive industry into its mainstream business. R.B. Forgings
recently augmented its manufacturing capabilities and has installed
state of the art crown and pinion cutting division.
• We have installed modern machines along with an in-house facility for
material heat treatment. We implement modern management systems
inspired from export experience, in line with European standards of quality
and productivity. With in-house forging, machining, gear cutting and heat
treatment, we can provide our costumers good combination of technology,
quality, price competitiveness and delivery.

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 Shafts And Pinions
By using cutting edge technology and premium grade raw material, we are
instrumental in designing and supplying a comprehensive assortment of shafts
and pinions. This range is subject to customization at numerous specifications
and is offered to our clients at market leading prices.

Automotive Shafts
We bring forth for our clients, a superior quality range of automotive and tractor
shafts that cater to the needs of several industry verticals. Customized in
accordance to the clients’ requirements, these automotive shafts and tractor shafts
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offered at the most competitive prices. 12
 Automotive Pinions

We offer wide variety of precision

engineered automotive or tractor pinions
that are specially designed for automotive
and tractor applications.

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 Automotive Hinges
• Our comprehensive assortment of forged fittings includes a technically
upgraded gamut of forged automotive door hinges that are customized
according to the required dimensions provided by our customers.
Available in a variety of shapes and metals, these door hinges are easy to
install and use.

Container Hinges
Available with us is a durable and avenge-free range of hinges that are made
using high-quality brass, aluminium and stainless steel. These hinges are
provided with heavier gauzes with standard hole placement and smooth finishes
so that they are apt for usage in connection with different solid objects that allow
them the least angle of rotation.
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 Towing Parts & Assemblies
• We aim to provide our customers with high quality towing truck supplies. Our wide range of
products includes straps, wire rope assemblies, safety gears, LED lights, The parts can be
customized as per OEM requirement. Our fast and reliable export services ensure that these
products get delivered on time to our customers.

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 Forged & Machined Parts

• We specialize in designing a tough and high performing range of precision

machine parts that are extensively used in diverse industries and sectors.
Known for their simplicity in operations and user-friendliness, these
machine parts are available for our clients at market leading prices.

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 Precision Machine Parts
• We specialize in the engineering and machining of a
sophisticated range of precision machine parts that are
precision made at our machining centers. Offered in
numerous specifications to choose from, these parts can be
structured as per customers' specifications.

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 Auto parts

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 AUTO PARTS

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 OUR CLIENTS

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 OUR QUALITY

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 QUALITY POLICY
• We at RB Forgings Pvt Ltd. are committed to
improve our Processes and capabilities on
continuous basis and thus give our Customers
complete satisfaction by providing of best in
Product Quality, deliveries and Prices. We will
continually evaluate and improve our
products/services through the Quality
management System (IATF)

Managing Director

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 QUALITY OBJECTIVES

• To meet or exceed Customer Delivery expectations on at least 95% of the orders

• To Reduce the Internal rejections not to exceed 2 % of the orders
• To reduce Customer rejects to a maximum 1% of the Orders
• Compliance with statutory and regulatory requirements
• This Objective is measured by zero actions that lead to violations or findings from
regulatory inspections.
• To maintain The IATF 16949:2016 Standard requirements through the cycle of certification.
• This Objective is measured by no major non conformance findings on surveillance audits
• To adhere 100% timeline for new product development.
• To Adhere Equipment Calibration (In-house) schedule by 100%
• 100%Adherence to Maintenance Schedules (Preventive) and at least 100% adherence
Predictive maintenance for critical machines
• To Adhere To Tool Planning’s and Tool Development schedule (100%)
• 100% Adherence to Training program /Schedule for workers and staff
• To Increase Continual Improvement projects/ kaizen’s by 5% for 2019-20

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 Monitoring of Quality Objectives
Who will be When it will be How will the results
Ref. QUALITY Objective What will be done? What resources will be required?
responsible? completed? be evaluated?
RB/OB/01 To meet or exceed Customer Order vs Supply to be Variation in data (order vs Supply) Operations Monthly Monthly data
Delivery expectations on at monitored regularly analysis
least 95% of the orders
RB/OB/02 To Reduce the Internal In process Quality improvement CAPA implemented and Monitoring Quality Monthly Monthly data
rejections not to exceed 2 % of analysis
the orders
RB/OB/03 To reduce Customer rejects to a PDI Quality Improvement Monitoring of Customer Quality Monthly Monthly data
maximum 1% of the Orders complaints/feedback and CAPA analysis
Implemented

RB/OB/04 Compliance with statutory and This Objective is measured by Legal Register maintained Admin Yearly Compliance record
regulatory requirements zero actions that lead to
violations or findings from
regulatory inspections.

RB/OB/05 To maintain The IATF 16949:2016 This Objective is measured by no Internal Audits and MRM to be adhered System Controller Monthly Audit Reports And
Standard requirements through the major non conformance findings on regularly Minutes of meeting
cycle of certification. surveillance audits Record

RB/OB/06 To adhere 100% timeline for new NPD Timelines to be adhered MOM for New Developments Plan vs NPD Team Monthly Monthly Review
product development. Actual

RB/OB/07 To Adhere Equipment Calibration Calibration Schedule to Be Calibration plan vs actual data (delays QUALITY Monthly Monthly Review
(In-house) schedule by 100% adhered to be informed )

RB/OB/08 100%Adherence to Maintenance Maintenance (preventive and Maintenance plan vs actual data (delays Maintenance Monthly Monthly Review
Schedules (Preventive) and at least Predictive to be informed )
100% adherence Predictive
maintenance for critical machines

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RB/OB/09 100% Adherence to Training Training Schedule and OJT Training Schedule to Be adhered HR/Training Monthly 25
Monthly Review
program /Schedule for workers and Trainings (changes need to be informed and
staff
 Overall Process Sequence & Interaction

System
Customer RESOURCE Management Material MANUFACTURING QA
METALLURGY/LAB Documentation
requirements MANAGEMENT Responsibilty management
and Coordination

Marketing
Buisness planning FG Stores, Logistics Customer
(customer Enquiry Personnel and Skills Incomming RM Forging Internal QMS Audits
and Objectives and Dispatch Complaints/CAPA
review) Inspection

Customer Specific Equipment and Management Reciept and Internal Process

Standard room MSA and SPC In Process
requirements maintainence review Logistics Stores and Product Audits
Inhouse Calibration

Facilties and
New Product Manufacturing Non Continual Final and
Infrastructure Outsourced Consumable Stores
Devolpment confirmity improvements PDI/Dispatch
management Calibration

Customer Order CAPA /System Non

Purchasing
review confirmity Followup

Tool Room) Risk Mitigation Plan

APQP/PPAP Vendor Selection
monitoring

Supplier
Devolpment and Maintainence (
Performance PM/BD/PRM/TPM
Heat Treatment and
monitoring Normalizing

Training

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 ORGANIZATION CHART
DESIGN ENGINEER
DESIGN
INCHARGE/TOOL ROOM
I/C
DIE &TOOL ROOM STANDARD ROOM ASST

PRESS SHOP
FORGE SHOP INCHARGE BAR CUTTING SHOP MAINTAINENCE
SUPERVISOR )

VP OPERATIONS NORMALIZATION /HEAT NORMALIZING

LABORTARY INCHARGE) ASSISTANT LAB)
TREATMEN) SUPERVISOR ()

IN PROCESS QUALITY
QUALITY INCHARGE

Final Quality ()

MANAGING DIRECTOR ( Internal ( QMS, Process

System Controller
and product) Auditors (

ACCOUNTS ()
GROUP COMMERCIAL
HEAD

OFFICE ASSISTANT
ADMIN EXECUTIVE (Sanjna)

Operartions Director

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 QUALITY MANUAL
• C:\Users\Ankur\Downloads\Latest Quality
MANUAL.docx

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 AWARDS AND RECOGINATION
Best Development Performance Award
R.B. Forgings Pvt. Ltd. won the Swaraj
Supplier Performance Award for Best
Development in the year 2010-11

Excellence in Quality Award

R.B. Forgings Pvt. Ltd. wins the Excellence in
Quality Award by Department of Industry and
Commerce, Government of Punjab.

R.B. Forgings Pvt. Ltd. won the Quality Systems Appreciation

1/26/2020 Award on behalf of Mohali Industries Association for the 29
year
2006.
 R.B. Forgings Pvt. Ltd. won the Swaraj Supplier
Performance Award in Best SCM Performance for the year
2009-10.

Best SCM Performance Award

R.B. Forgings Pvt. Ltd. awarded with Swaraj Supplier
Performance Award for Best SCM Performance on the Supplier
Meet, 29th September, 2010.

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 OUR FACILITY

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 OUR FACILITY

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 Forging
Our forging section is equipped with a forging press
and drop hammers of different capacities and has
its own tool rooms with high-speed CNC millings to
provide all solutions at one shop.

•Forgings Press: 1, Capacity 2500 Ton.

•Drop Hammers: 5, Capacity 0.75 to 3 Tons.
•Capacity to Forge Parts: 0.25 kg to 35 kg.

Also, there has been a continuous investment in

modern support equipment including induction billet
heaters, production hardening and tempering
facilities, shot blasting, coining and crack detecting
equipment.

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 Quality Improvement Project

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QUALITY TRANSFORMATION INTIATIVE
• Trainings at Each Level
• 5s Implementation
• Employee motivation and appraisals.
• Deployment of Quality tools for problem
solving.
• To reduce energy/ fuel costs by going for
automation.
• Up gradation of plant and machinery
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 Quality Control & Assurance:
• R.B. Forgings has a fully integrated Quality Assurance
System with in—house standards room and a metallurgical
Laboratory. Forging is practiced with PPAP and TQM
techniques. The laboratory is well equipped and is able to
satisfy the most demanding customer specifications.
The laboratory houses a spectrometer for chemical analysis
as well as for normal metallurgical facilities expected of a
quality forge, i.e magna flux crack detecting, hardness
testers and microscopy. Our qualified personnel ensures
that the written procedures from the Quality Assurance
Manual are adhered to throughout the Company.

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 EDSCHA POINTS

C:\Users\Ankur\Downloads\Edscha PA_Actions_RB Forging Stand

16.05.2019.xlsx

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 Point 1
IATF 16949 Certificate Scanned
IATF Manual
IATF INTERNAL AUDIT SUMMARY ( Last 2019)
IATF INTERNAL AUDIT SCHEDULE and PROCESS
PRODUCT AUDIT PLAN AND RECORDS

Auditee – Gurcharan Singh (1.2)

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 Point No 1.3
• QUALITY POLICY
• QUALITY PROCEDURES
• QUALITY OBJECTIVES MONITORING SHEET
(2019)

• Auditee – Gurcharan Singh

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 Point No 1.4 and 1.5
• Management representative
• List of Internal Auditors (
Process/Product/QMS/Supplier Audits )
• Management Review Meeting
agenda/Procedure
• Management review Meeting log/record
(2019) with Status PPT
Auditee: Gurcharan Singh
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 Point No 1.6
• Risk monitoring Plan with mitigation and
action points Sheet
• Kaizen Summary - Presentation
• Corrective action – Example

• Auditee – Quality/MR

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 Point no 1.7
• Customer Complaints ( 2019) Status
• CAPA – 8D and Closure
• Performance and Delivery review (OCT- DEC 19)
• CSR Score / Customer Satisfaction Index Data
Analysis

Auditee- Gurcharan /Harinder

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 Point no 1.8
• ZERO DEFECT POLICY RB
• INHOUSE REJECTION AND REWORK ANALYSIS (
Top 3 )Pareto (Last QTR) Both units

• Auditee – Quality

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 Point No 2.1
• APQP- Procedure
• APQP SAMPLE FILE ( EDSCHA) with checklist
• FEASIBILTY REPORT
• TIMING CHART/GATEWAY REPORT
• CFT FORMATION
• PFD
• PFMEA FOR PROTOTYPE
• CONTROL PLAN PROTOTYPE
• BOM
• PSW STATUS/Order Status Record
• PFMEA FOR PRODUCTION
• CONTROL PLAN
• Process Sheet/SOP/WI
• Quality Plan
• Packaging Instruction
• Dispatch monitoring
•
• Auditee- Development team ( Mr. Deshraj/Amit/Rajkumar)

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 Point no 2.2
• APQP PLANS ( Timeline plan vs actual )
• Production Plan Last QTR ( Plan vs Actual
Status)
• Dispatch Plan last Qtr ( Plan Vs Actual)
• In case of Deviation CAPA In variation of
Production /Dispatch /Development

• Auditee- Devolpment/Production/Dispatch
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 Point no 2.6 and 2.7
• Change Management procedure
• Change Management ( document master List
/issue No and revision no Updation log)
• ECN Change record ( history Log)
• Escalation matrix

• Auditee- Devolpment/MR/Quality

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 Point no 3.1 and 3.2
• CUSTOMER SPECIFIC REQUIREMENT SHEET
• CSR matrix with Symbols for Critical points
used in Drawings
• Review of Critical Points in process audits
covering CSR ( Example EDSCHA)

• Auditee- Development /Quality

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 POINT NO 3.3 and 3.4
• EDSCHA SPECIFIC REQUIREMENTS
• SAMPLE APQP FILE
• CFT TEAM SHEET

• Auditee- Development

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 POINT NO 4.1 and 4.2
• FMEA Procedure/WI
• FMEA SAMPLE EDSCHA
• Training Need evaluation during FMEA –
Training identification format and Training
Schedule

• Auditee- Devolpment /Quality/MR

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 Point No 4.3 , 4.4 & 4.5
• Control Plan Edscha example
• Control Plan Adherence ( Process Audit )
• Process and Product audit schedule

• Auditee- Devolpment /MR

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 Point no 4.6 & 4.7
• Results of performance test eg run rate
• Production handover template
• Customer drawing Index – Balloned drawing
example

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 Point No 5.1,5.2&5.3
• Purchase /vendor development/ vendor rating
procedure/formats
• Approved Supplier List with Certification
status ( ISO/IATF)
• Vendor/supplier/provider rating ( LAST 3
MONTHS 2019)

• Auditee- Kiran/VK CHAHUAN

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 Point No 5.4,5.5 and 5.6
• Supplier agreement ( PO with specific terms
related to EDSCHA/Customers)
• CSR for quality parameters shared with vendor
• Incoming acceptance record
• Storage condition monitoring ( FIFO and
Handling )
Auditee- Purchase/Store/Quality

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 Point no 6.1,6.2
• Development to production handover record
• Production schedule
• SOP Example
• WI
• Process sheet/Logs maintained by Production
• List of Material handling equipment
• Traceability requirements/Job Card/Bin
Cards/heat/batch codes
• Auditee Devolpment/production/Quality
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 Point No6.3
• Skill matrix Updated
• Training Records ( On Job Training)
• Role and responsibility / KRA Document
• Core tools training ( List of personnel)
• Material Flow ( Reject /rework/on hold )

• Auditee: HR/Quality/MR

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 Point No 6.4 and 6.5
• List of Plant/Machinery/Equipments ( both Units) with
Critical machines/equipment identified with CP/CPK and
SPC Monitoring plan ( both Units)
• Display of WI/SOP on work stations
• Display of Daily Monitoring trends/SPC for critical
parameters /machinery
• List of critical spares / Status
• Preventive and predictive mtc Schedule
• MTTR of last QTR ( 2019) and MTBF last QTR ( 2019),
Lesson learned /CAPA related To Maintenance
• Maintaince target/Internal KPI- monitoring
• Auditee- Daljit Singh/Manjeet

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 Point No 6.6
• EDSHA PORTAL TO BE USED FOR
COMMUNICATING DEVOLPMENT/QUALITY
ISSUEs ( Login Required?)
• Communication record ( edscha example)

• Auditee - Devolpment

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 Point No 7.1, 7.2
• Contingency Plan record /verification
• Training on Contingency plan
• Mock Drill records For contingency

• Auditee – Admin/Production /Plant head

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 Point No 7.4 and 7.5
• Complaint /CAPA Status report with evidence
• 8d, Root cause analysis /5 Why /Fish Bone etc
• Problem Solving examples

• Auditee: MR/Quality

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 Point No 8.1, 8.2, 8.3 and 8.4
• Critical points Identification in
development/Production as per VDA 6.1
• Procedure/WI for Identification and process
control
• EDSCHA critical points Review sheet with
ballooned drawings and process sheet
• Critical part Points archiving period is 3 years
only at present
• Auditee: Devolpment
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 Point no 9.1, 9.2
• List of chemicals / Oils/ hazardous material/Gases
at RB ( both units) with MSDS Display at Storage
location and Availability of antidote/PPE/Fire
Extinguisher
• Leakage prevention ( oil/Chemical ) tray
mechanism
• List of PPE Available Stock/Usage Instruction
• Display of Safety Instructions at points of usage

• Auditee- Store/Admin/HR/maintainence

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 Point No 9.3, 9.4& 9.5
NO accident/incident related to Environment
reported at RB.
Reach regulation not applicable at RB as no
chemicals are being used which falls under EU
directive

RB Have IMDS registration ( No?)

ISO 14001 Roadmap

Auditee: Plant Head/Dir OPT

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 Point no 10.1, 10.2
• EMS POLICY/Roadmap for 14001
• Certificate Global Norms

• Auditee: Plant head

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Point No 10.3, 10.4, 10.5,10.6 10.7, 10.8, 10.9, 10.10, 10.11, 10.12

• No child Employee Policy

• No Discrimination Policy ( HR Policies)
• Anti Bribery policy
• Whistle Blower Policy
• Proper Facility ( Lux level, Noise Monitoring,
Ergonomic Monitoring Records)
• Air monitoring, Water testing records / Clean
water tank status
• Data Protection Policy
• Auditee : HR/Admin/Management
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 Point no 10.13, 10,14, 10.15,10.16

• Occupational Health and Safety Policy

/Roadmap OHSMS Certification
• Supplier Development Plan For EHS
• CAPA on Incidents/Accidents/near miss For
EHS Requirements /First Aid Log/Mock drill
records

• Auditee: production/Plant head

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Trainings at Plant Level

5s, 7QC tools, SOP’s, Motivation

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 5s Pledge Signing

5 s Implementation the first step

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 THANK YOU

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