Sona Group

Moving Towards Zero Breakdown
Ratanmani Kukreti
2/26/2013
Sona Okegawa Precision Forgings Ltd.
Contents
Company Profile Group Structure Outline Of Company Products Customers Process Chain Of Precision Parts Approach Towards Zero Breakdown Step to achieve Zero Failure Case Study - 1 (Electrical Break Down) Case Study 2 (Mechanical Break Down) Results
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Group Structure :
SONAGroup Group SONA
Dr. Surinder Kapur Dr. Surinder Kapur
AUTO COMPONENTS
SONA KOYO SONA KOYO STEERING STEERING SYSTEMS SYSTEMS LTD. LTD.
JSAI JSAI SFAL SFAL SONA STAMPINGS SONA STAMPINGS
SERVICE
SONA SONA eDESIGN & eDESIGN & TECH. TECH.
MOBILITY
SONA SONA MOBILITY MOBILITY SERVICES LTD SERVICES LTD (SIXT) (SIXT)
GLOBAL
SONA AUTOCOMP SONA AUTOCOMP USA USA SONA AUTOCOMP SONA AUTOCOMP EUROPE EUROPE
SONA SONA OKEGAWA OKEGAWA PRECISION PRECISION FORGING LTD. FORGING LTD. SOPL, Pune SOPL, Pune SONA BLW SONA BLW PRECISION PRECISION FORGING FORGING EUROPE & USA EUROPE & USA
MAHINDRA MAHINDRA SONA LTD. SONA LTD.
KOYO SONA KOYO SONA ELECTRONICS LTD. ELECTRONICS LTD.
FAF FAF
GROUP SHARED SERVICES

CONTROLLER CONTROLLER LEGAL LEGAL IT IT FINANCE FINANCE CORP. AFFAIRS CORP. AFFAIRS
FUJI AUTOTECH FUJI AUTOTECH EUROPE EUROPE
FAB FAB FKC FKC FAAB FAAB
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Brief History
Sona Group is currently the largest manufacturer of steering systems and forged parts for passenger cars and utility vehicle market in India. The group turnover is over `40 Billion ($ 810 Mn) with number of employees over 3800. Sona group is diversified in auto components & services. It has 17 manufacturing plants with 4 companies overseas..
Technology Tie-Ups
1990
The Beginning
1985
Extending Partnership
1995
Growth for Domain Leadership

2000
Global Footprint
Laurels
2010
2005
Technical Agreement with Koyo for Manual Steering Gear and Column Sona Steering enters a JV agreement with Maruti Udyog Ltd. Sona Steering Systems Ltd. commences production
Incorporation of Sona Somic Lemforder Components Ltd. Incorporation of Mahindra Sona Ltd. Mahindra Sona acquired the MSL Division of M & M
Incorporation of Sona e-Design Koyo increases stake in Sona Koyo to 20.5% Sona Cold Forgings commences productions Sona Okegawa commences production of bevel gears for domestic market & exports
Sona Koyo Steering Systems Ltd. receives Deming Prize
New JVs JTEKT-Sona Automotive India Ltd. Sona Fuji Kiko Automotive Ltd. Sona Okegawa, Pune started commencing Production Acquisition Sona BLW Prazisionsschmiede GmbH formed
Awards Sona Okegawa Gurgaon Plant Received TPM Excellence Award
Technical Collaboration with Sona Steering Systems Ltd., a JV with Koyo for Power Maruti, lists through an Steering Gear IPO Joint Venture company formed with MMTLSona Okegawa Precision forgings Ltd.
Acquire 21% stake in Fuji Autotech France S.A.S. Merger of Sona Somic Lemforder and Sona Cold Forging Ltd.
Certifications Sona Okegawa Certified for IMS (QMS,EMS & OHSAS)
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Sona is a Company with a Global Footprint

Sona BLW Precision Forge
North Carolina, USA 100% Subsidiary of Sona Group
Fuji Autotech Europe

Mandeure, France Sona 17%
Sona AutoComp Europe

Montbeliard, France 100% Subsidiary of Sona Group
Sona BLW Przisionsschmiede Sona AutoComp USA

South Carolina, USA 100% Subsidiary of Sona Group 3 Plants in Germany 100% Subsidiary of Sona Group
Fuji Koyo Czech (FKC)
Sona Group India Fuji Autotech Brazil

16 Plants
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Sona Group - Overview

The Sona Group it one of Indias leading companies Turnover Employees 11/12: 11/12: > ` 40 billion ( $ 810 Million) > Over 3800
The Sona Group has a strong portfolio of established businesses that includes manufacturing and IT.
Manufacturing
SONA KOYO STEERING SYSTEMS SONA OKEGAWA PRECISION FORGINGS
INFORMATION TECHNOLOGY
SONA EDESIGN AND TECHNOLOGIES
MOBILITY SERVICES
MAHINDRA SONA
SIXT RENT A CAR
Steering and Driveline Systems
Propeller Shafts, Axle & Clutches
Forgings,Differentials
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Company Profile
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Plant Layout
Hall 1
Hall 2
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Milestones
2012
OHSAS 18001Sep12
2011 2009 2008 2007
TPM Excellence in Dec 2011 TPM Re-Kickoff in Jan2009 30th Jan Acquisition of Sona BLW TPM Kickoff & Diff. Case Assembly started. New Agreement Signed with MMTL
2006
2005 2004
Commercial Production Started at Pune Plant ISO 14001:1996/EN ISO 14001in Feb ISO / TS 16949 Certified in Nov. Synchronizer Ring Production Started 20th Nov. Commercial Production & Exports to Japan Started
2003
2002
1998
1995
JV Company Promoted by Sona Koyo in Collaboration with MMC, Japan
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Products
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Product Range
Rear axle Propeller shaft Clutch diaphragm
Differential Assembly
Bevel Gear
Speed Gear
Seat Recliner
Steering Gear Assy
Steering column
11
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Main Products
Over 250 Parts
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12
Key Products
Precision Forged (net shaped) Bevel Gears, Differential Case Assemblies and Synchronizer Rings for Automotive and Other applications.
Customers
Passenger car & SUV Commercial Vehicles Tractor Off Highway Equipments Farm Equipment Construction Equipments
Fiat India (SKSSL) Mahindra & Mahindra Maruti Suzuki Spicer India Ltd. Suzuki Powertrain Tata Motors Ltd. (SKSSL)
Albion Automotive American Axle Automotive Axle Axle India Axle Tech Diamler India Force Motors HV Axle Spicer India Tata Motors Volvo Eicher
Carraro India Escorts Tractors International Tractors Ltd. John Deere Mahindra & Mahindra Mahindra Swaraj New Holland India TAFE TMTL (Eicher)
Dana India Grazziano Lombardini Mahindra & Mahindra Mahindra Swaraj New Holland india TAFE TMTL (Eicher)
Case New Holland (USA) John Deere (Iberica) Tirth Agro
JCB
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Process Chain of Precision Parts
Die Manufacturing
Precision Hot Forging on Conventional press lines 300 t bis 1250 t
Cold Coining of the functional surface with hydraulic press lines 700 t
Machining on full automatic cutting lines
Design
Broaching of precision forged parts
Continuous quality from tooling to finished part
Flexible packaging according to customers requirements
Heat Treatment exactly matching to product requirements
Automotive World 2/26/2013
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Facilities
Forging Capabilities
Forging Press Capability Type
Servomotor Driven (Simplex) Friction Driven (Duplex) Friction Driven (Duplex) Servomotor Driven (Simplex) Servomotor Driven (Simplex) Servomotor Driven (Simplex)
Friction Driven (800 Ton) Wt.

10 Kg
Age
Qty. L
300 mm
1250 Ton
2 Yrs
200 mm
800 Ton
14 yrs
180 mm
220 mm
6.5 Kg
400 Ton
14 yrs
115 mm
75 mm
2 Kg
400 Ton
5 yrs & 8 yrs
Servomotor Driven (1250 Ton)

2 90 mm 70 mm 1 Kg
400 Ton
1 yrs
90 mm
70 mm
1 Kg
300 Ton
5 yrs
65 mm
30 mm
0.6 Kg
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Facilities
Machining Capabilities
Machine
Automated CNC Turning Centre CNC Turning Center Vertical Turning Lathe Angular Head Grinder Drilling & Tapping Center Broaching Centerless Grinder Honing Hobbing CNC Gear Hobbing SPM (Case Line) Shaving
Make
Mazak Takisawa, Mazak, Ace, LMW Takishawa Micromatic AMS, Fanuc Taiga, Cranebell HMT Nagel Cooper Mitsubishi Tasa Kanzaki
Age
1yr 1 Yr. to 14 yrs 1yr 7 months to 12 yrs 1Yr to 4 yrs 6 yrs to 14 yrs 1 Yr 14 yrs 22 yrs 1 yr 10 yrs 1 yr
Qty.
6 Nos. 35 Nos. 3 No. 3 Nos. 3 Nos. 2 Nos. 1 No. 1 No. 2 Nos. 1No. 4 Nos. 1 No.
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Facilities
Heat Treatment
Machine
Make
Age
Capacity
Qty.
5 yrs Sealed Quench Furnace Line Oriental Engg. Japan 6 yrs 12 yrs IPSEN India Nitriding Furnace IPSEN India 1 yrs 1 Yrs
1000 Kg 1000 Kg 600 Kg 1200 Kg 600 Kg
3 Nos. 3 Nos. 3 Nos. 4 Nos. 1 No.
Processes:
Case Carburizing Carbo Nitriding Hardening
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Facilities: Design & Development Software
Solid Edge V20
Deform-Form Simulation
Unigraphics-NX7
ANSYS
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HYPERMILL
Frenco Spline Software

18
Quality Assurance - Process Validation
Pyrometer For Billet Temp.
Load & Pressure Gauge For Forging Press
Pressure Gauge For Coining Press
Dial & Gauges For Inspection
Forging
Coining
Soft Machining
Sequential Pokayoke
100 % Gauging Inspection
100 % Visual Inspection
Air Gauges & Dial For Inspection
Diff. Case Assembly
Process Confirmation
Visual Inspection
Hard Machining
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Quality Assurance- Metrology & Metallurgical Lab
Bearing Contact Tester
CMM
Gear Accuracy Tester
Metallurgical Microscope
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Micro Vickers Hardness Tester

Sona Okegawa Precision Forgings Ltd. 20
Sona Vision 2020
VISION
Create a Company That India is Proud of

MISSION
To Make Sona A Partner Of Choice to Global Customers

An organization of energized and involved employees.
MOTTO
Think!
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
Respect for the Individual
Service to the Customer
Excellence in the pursuit of our Goals

21
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Inter-relation of Companys overall Policies
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Planned Maintenance Organisational Structure :
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Relation Between TPM Policy And PM Pillar:
TPM Policy To enhance the operational efficiency and equipments by achieving Zero breakdowns and Zero defects Optimization of process and resources Create Visual Factory
Planned Maintenance Pillar Data collection of all the break down, break down matrix, why-why analysis and implementing PM,CBM and TBM activities Optimization of process and resources by eliminating minor stoppage and re-storing optimal condition Expose losses and problems
Trained ,Skilled and Motivated Motivations by autonomous maintenance employees for the first time right job and Implementing MP Kaizen To achieve a safe and green factory through Zero accidents and Zero Pollutions
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By eliminating un-safe conditions, arresting air, oil and water leakage and conservation of natural resources
24
Methodology to achieve Zero Break Down
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Zero Breakdown Approach
OPERATION (Operator error, Fatigue, Equipment & personnel safety)
ENHANCING RELIABILITY (Accelerated Deterioration, Restoration & Improvement of Equipment Condition)
ENHANCING DESIGN ( Uncontrolled Stresses & Insufficient Stress) Problem Discussion with DM team Problem Analysis
Problem Discussion with J-H
Problem Discussion with PM team
Problem Analysis with J-H
Problem Analysis with Electrical & Mechanical Engineers
DO FMEA
Root Cause Analysis
Root Cause Analysis
Release DCN(Design Change Note)
NO
Countermeasures
Countermeasures
Implementation of Design Changes
NO
Implementation of Countermeasures
Implementation of Countermeasures
Monitor for 3 Months Raise MP Sheet / Update Standards Horizontal Deployment
IF OK
Horizontal Deployment
Raise MP Sheet / Update Standards
IF OK
Horizontal Deployment
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Activity :
Step Wise Activity for Zero Break Down

Step
Step-1
Activity
Maintaining Basic Condition
Step-2
Restoring or Preventing Deterioration
Step-3
Maintaining Operating Standards
Step-4
Time Based Maintenance
Step-5
Predictive Maintenance (CBM)
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Step 1 Maintaining Basic Condition
Jishu- Hozen
Initial Cleaning
Keikaku - Hozen
Analysis of Present Status
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Step 2 Restoring Or Preventing Deterioration
Jishu- Hozen
Counter Measure Against SOC & HTA
Keikaku - Hozen
Restoration and Improvement of the Deteriorated Equipment
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Step 3 Maintaining Operating Standards

Jishu- Hozen
Draft Tentative Cleaning, Oiling & Inspection Standards
Keikaku - Hozen
Tentative Standard Maintenance Procedure
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Step 4 Time Based Maintenance

Keikaku - Hozen
Time Based Maintenance Methodology Example
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Step 5 Predictive Maintenance (Cbm)

Keikaku - Hozen
Predictive Maintenance (CBM) Methodology Example
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CASE STUDY
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Equipment
Induction Heater
Forging Press
Slow Cooling Conveyor
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Failure Analysis :- Analysis by Branch wise Stratification of Mechanical & Electrical Failure ( Nos./Branch) 400 Ton press
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Failure Analysis :- Analysis by Equipment Wise (Electrical)
Total 17 Phenomenon
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Design Change Kaizen (Electricals)
Case Study- No. 1

1. Problem Description:- Convertor Failure Occurrence in Induction Heater Resulting in Tripping Equipment Under Study- 250 KW Induction Heater
Induction Coil Pusher Capacitor Bank Billet Loader Induction Heater
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Design Change Kaizen (Electricals)
Case Study- No. 1

2. Kaizen Theme:- To Eliminate Induction Heater Failure 3. Data Collection:- Phenomenon wise Break Down Data for 250 Kw induction
S.NO.
Phenomenon
Induction Heater Trip Converter Failure LMD Wheel Not Working Temp Problem Starting Failure Bus Bar Clamping Problem Over Frequency Alarm
F08
F09
F10
F11
F12
F13 (Till 10 Jul' 2012)
Break Down Frequency 1 2 3 4 5 6 7 53 17 14 4 1 0 0 14 6 3 1 1 3 0 59 21 10 3 1 12 0 16 10 3 3 1 3 2 20 6 0 44 1 1 0 4 5 0 10 7 0 0
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Case Study- No. 1 4. Root Cause Analysis

Problem:- Induction Heater Tripping
Why Phenomenon
Why -1 Converter Failure

Why Phenomenon
Why -1 Converter Failure
Answer
Dc Voltage Is Not Converted In To Ac Single Phase Inverter Circuit does Not perform Thyrister Blow off Not Known
Action
Check Inverter Section Check Protection Circuit Replace Thyrister
Answer
Action
Reset Induction Heater
Dc Voltage Is Not Converted In To AC Why-2 Single Phase Inverter Circuit does Why-3 not perform Why-4 Thyristor Blow off
Problem:- Temperature Variation

Why Phenomenon
Billet Temperature Why -1 Drops
Answer
Action
Stop Induction Heater and reset

Why Phenomenon Answer
Dc Voltage Is Not Converted In To Ac Single Phase
Action
Check Inverter Section Replace Thyrister Provide More Cooling
Why -1 Converter Failure Dc Voltage Is Not Converted In To Ac Why-2 Single Phase Thyrister Failure Why-3 Thyrister Failure
Insufficient Cooling Water Pressure (1kg/Cm2) & Flow (11 Lpm) Is Less At Heat Increase Water Why-4 Insufficient Cooling Exchanger Inlet Pr. & Flow Water Pressure (1kg/Cm2) & Flow (11 Lpm) Is Less At Increase Pump Why-5 Heat Exchanger Inlet Pump Efficiency Is Low Efficiency
Every Individual part of the induction Heater was replaced with New part including PCB cards, But Problem could not be solved
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Case Study- No. 1

What Next When No Root Cause is found ?
Why- Induction Heater Not Working ? Why- Convertor Failure Caption Illuminate ?
Why- Over Voltage, Over Frequency & Starting Failure LED "Glow " inspite of all the parameter within range ? Why- Temperature drop in Billet when 41 & above Diameter is heated ?
4. Brain Storming
Cross Functional Team

Name Mr. Vipin Mr. Vivek Mr. Jaideep Mr. Amit Sharma Mr. Mukesh Mr. Harcharan Mr. Multan
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Dept. Manufacturer Manufacturer Project Design Project Design Maintenance Maintenance Maintenance
40
Case Study- No. 1 5. Design Change for Electrical & Electronic Circuit
12 PCB cards are attached to one Mother board with interlocking to each other
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Case Study- No. 1 6. Outcome One Single Card was developed 7. Result For Induction Heater
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Case Study No.- 2
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Case Study- No. 2

1. Problem Description:- Interruption Due to Die Lubricant Equipment Under Study- Die Lubricant System
Die Lubrication Tank Diaphragm Valve with solenoid coil
Stirrer
Tank
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Pump
Diaphragm Valve with solenoid coil

44
Design Change Kaizen (Mechanical)
Case Study- No. 2

2. Kaizen Theme:- To Eliminate Die Lube Breakdown Phenomenon 3. Data Collection:- Phenomenon wise Break Down Data for 400Ton Forging Press
Phenomenon
DIE LUB NOT WORKING INDUCTION HEATER TRIP MIDDLE CONVEYOR NOT WORKING PRESS NOT WORKING UP & DOWN PRESS LOAD PROBLEM COIL LEAKAGE / WATER PIPE LEAKAGE CONVERTER FAILURE EJECTOR PIN NOT WORKING LMD WHEEL NOT WORKING FOOT SWITCH NOT WORKING
S.NO.
F08
F09
F10
F11
F12
Break Down Frequency 1 2 3 4 5 6 7 8 9 10 81 53 34 27 0 26 17 16 14 11 39 14 9 10 16 24 6 14 3 2 81 59 0 30 13 0 21 0 10 6 80 16 0 26 6 0 10 0 3 0 108 20 0 16 9 0 6 0 0 5
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Case Study- No. 2

4. Root Cause Analysis
PROBLEM:- INTERRUPTION DUE TO DIE LUBE FLOWING CONTINUE FROM VALVE
WHY PHENOMENON
DIE LUBE FLOWING WHY CONTINUOSLY FROM 1 NOZZLE WHY- DIE LUBE VALVE REMAIN 2 OPEN
PROBLEM:- MTTR IS HIGH

WHY PHENOMENON ANSWER
FAULT DIAGNOSYS IS TIME CONSUMING
ANSWER
DIE LUBE VALVE REMAIN OPEN
ACTION
CLOSE DIE LUBE VALVE ALLOW DIAPHRAGM TO SETTLE PROPERLY CLEAN DIAPHRAGM OF VALVE ELIMINATE SHARP BENDS
ACTION
MAKE FAULT DIAGNOSYS EASY
WHY -1 MTTR IS HIGH
VALVE DIAPHRAGM RAISED FROM ITS SEATING
WHY-2
FAULT DIAGNOSIS IS TIME CONSUMING FIVE TIMERS , CONTACTORS AND RELAYS ARE INTER CONNECTED WITH TOO MANY WIRES
FIVE TIMERS , CONTACTORS AND RELAYS ARE INTER REDUCE THE CONNECTED WITH TOO MANY WIRE WIRES CONVERT RELAY ELECTRICAL CIRCUIT IS MADE LOGIC TO PROGRAMME WITH RELAY LOGIC LOGIC
DIE LUBE SEDIMENTS WHY- VALVE DIAPHRAGM RAISED ACCUMULATE IN DIAPHRAGM 3 FROM ITS SEATING SEAT DIE LUBE SEDIMENTS WHYSHARP BEND IN DIE LUBE ACCUMULATE IN 4 TRANSFER PIPE LINE DIAPHRAGM SEAT WHY- SHARP BEND IN DIE LUBE 5 TRANSFER PIPE LINE
WHY-3
DIE LUBE TANK TOO FAR FROM BRING TANK NEAR THE PRESS TO THE PRESS

WHY PHENOMENON ANSWER ACTION
DIE LUBE FLOWING WHY - CONTINUOSLY FROM NOZZLE 1 CLOSE DIE LUBE DIE LUBE VALVE REMAIN OPEN VALVE ALLOW DIAPHRAGM TO DIE LUBE VALVE REMAIN VALVE DIAPHRAGM RAISED SETTLE OPEN FROM ITS SEATING PROPERLY CLEAN DIE LUBE SEDIMENTS VALVE DIAPHRAGM RAISED ACCUMULATE IN DIAPHRAGM DIAPHRAGM OF FROM ITS SEATING SEAT VALVE CLEAN PILOT DIE LUBE SEDIMENTS ACCUMULATE IN PILOT PRESSURE ORIFICE IS RESSURE DIAPHRAGM SEAT CLOGGED ORIFICE DIE LUBE SEDIMENTS ACCUMULATE IN PILOT INCREASE ORIFICE ORIFICE SIZE IN ONLY 1MM ORIFICE SIZE STANDARD DESIGN CHANGE DESIGN
PROBLEM:- INTERRUPTION DUE TO DIE LUBE NOT FLOWING FROM VALVE

WHY PHENOMENON ANSWER ACTION
OPEN DIE LUBE VALVE WHY - DIE LUBE STOPS FLOWING DIE LUBE VALVE DOES NOT 1 FROM NOZZLE OPEN
WHY2 WHY3 WHY4
WHY- DIE LUBE VALVE DOES NOT REMOVE 2 OPEN VALVE OUTLET GETS CLOGGED CLOGGING DIE LUBE SEDIMENTS WHY- VALVE OUTLET ORIFICE ACCUMULATE AT THE OUTLET 3 GETS CLOGGED ORIFICE OF VALVE CLEAN VALVE DIE LUBE SEDIMENTS WHY- ACCUMULATE AT THE 4 OUTLET ORIFICE OF VALVE WHY5 ORIFICE SIZE IN 1MM INCREASE ORIFICE SIZE CHANGE DESIGN
ORIFICE SIZE IN ONLY 1MM STANDARD DESIGN
WHY5 WHY6 ORIFICE SIZE IS 1MM
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Case Study- No. 2

4. Design Change for Die lube Pump and Valve
06 DIAPHRAG M VALVES ARE USED FOR SPRAYING DIE LUBE
WHY PHENOMENON
ANSWER
ACTION
1 MM ORIFICE
2/26/2013
DIE LUBE FLOWING WHY - CONTINUOSLY DIE LUBE VALVE REMAIN CLOSE DIE 1 FROM NOZZLE OPEN LUBE VALVE ALLOW DIAPHRAGM VALVE DIAPHRAGM DIE LUBE VALVE RAISED FROM ITS TO SETTLE WHY-2 REMAIN OPEN SEATING PROPERLY VALVE DIAPHRAGM DIE LUBE SEDIMENTS CLEAN RAISED FROM ITS ACCUMULATE IN DIAPHRAGM WHY-3 SEATING DIAPHRAGM SEAT OF VALVE DIE LUBE SEDIMENTS CLEAN PILOT ACCUMULATE IN PILOT PRESSURE RESSURE WHY-4 DIAPHRAGM SEAT ORIFICE IS CLOGGED ORIFICE DIE LUBE SEDIMENTS ACCUMULATE IN ORIFICE SIZE IN ONLY INCREASE WHY-5 PILOT ORIFICE 1MM ORIFICE SIZE ORIFICE SIZE IS CHANGE WHY-6 1MM STANDARD DESIGN DESIGN
47
Case Study- No. 2

02 Rotary Actuator with less bends Introduced
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48
Case Study- No. 2

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Kaizens done to eliminate Breakdown Phenomenon
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50
Result for Die Lubrication Problem

YEAR Phenomeno n 81 Reason F08 Die Lub. Valve Choke Timer Setting Disturb Die Lub .Pump Problem Relay Loose / Faulty Air Setting Disturb Die Lub Pipe / Line Choke Die Lub Sensor / Cable Problem DIE LUB Die Lub Stand Broken NOT Die Lub Fitting Wear / WORKING Broken Die Lub Valve Coil Faulty / Loose Die Lub Filter Choke MCB Trip / Supply Missing Air Pressure Disturb Wire Loose / Short Die Lub Cylinder Mounting Loose / Jam Die Lub Tank Empty 38 7 13 5 2 7 9 0 0 0 0 0 0 0 0 0 81 F09 28 3 0 3 0 0 0 1 4 0 0 0 0 0 0 0 39 F10 38 2 9 0 0 6 2 0 3 6 13 1 1 0 0 1 82 F11 30 2 12 1 0 2 0 0 0 6 23 0 0 4 0 0 80 39 82 80 108 50 0 52 2 Counter Measures Jan-13 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1 0 2 JH step 4 & 5 implementation JH step 4 & 5 implementation JH step 4 & 5 implementation JH Step 3 Diaphragm Valve Replaced with Rotary Actuator Relay Logic with timer Changed to PLC with MMI Pump Removed & Gravity Feeding Started From a height of 6 Mtr. Relay Logic Changed to PLC JH Step 3 No. of Bends Reduced & SS pipe introduced Relay Logic Changed to PLC JH Step 3 No. of Bends Reduced Diaphragm Valve Replaced with Rotary Actuator Filtering element Removed & Stirer system Design Improved
F13 DecF12 (NOV 12 12) 32 0 23 1 0 23 1 0 4 2 19 0 1 2 0 0 108 6 0 12 0 0 19 1 0 4 0 0 0 2 2 2 0 48 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
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Distribution of Kaizen to achieve Zero Break Down
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Counter Measure :- %age Contribution of Activities
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Background :
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Distribution of Kaizen to achieve Zero Break Down Zero Break Down Machine Category Criteria for Zero B/D
Zero B/D for last > 10 to 12 Month (<5 Hrs./ month) Zero B/D for last 7 to 9 Month (<5 Hrs./ month) Zero B/D for last 4 to 6 Month (<5 Hrs./ month) Zero B/D for last 2 to 3 Month (<5 Hrs./ month) Zero B/D for last 1 to 2 Month (<2 Hrs./ month)
No of Machine
Platinum
18
Diamond
16
Gold
33
Silver
51
Bronze
72
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55
Thank You
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56

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Moving Towards Zero Breakdown

Sona Okegawa Precision Forgings Ltd.

Sona Okegawa Precision Forgings Ltd.

MAHINDRA MAHINDRA SONA LTD. SONA LTD.

KOYO SONA KOYO SONA ELECTRONICS LTD. ELECTRONICS LTD.

GROUP SHARED SERVICES

FUJI AUTOTECH FUJI AUTOTECH EUROPE EUROPE

FAB FAB FKC FKC FAAB FAAB

Sona Okegawa Precision Forgings Ltd.

Growth for Domain Leadership

Sona Koyo Steering Systems Ltd. receives Deming Prize

Awards Sona Okegawa Gurgaon Plant Received TPM Excellence Award

Certifications Sona Okegawa Certified for IMS (QMS,EMS & OHSAS)

Sona Okegawa Precision Forgings Ltd.

Sona is a Company with a Global Footprint

Fuji Autotech Europe

Sona AutoComp Europe

Sona BLW Przisionsschmiede Sona AutoComp USA

Fuji Koyo Czech (FKC)

Sona Group India Fuji Autotech Brazil

Sona Okegawa Precision Forgings Ltd.

Sona Group - Overview

SIXT RENT A CAR

Steering and Driveline Systems

Propeller Shafts, Axle & Clutches

Sona Okegawa Precision Forgings Ltd.

Sona Okegawa Precision Forgings Ltd.

Sona Okegawa Precision Forgings Ltd.

JV Company Promoted by Sona Koyo in Collaboration with MMC, Japan

Sona Okegawa Precision Forgings Ltd.

Sona Okegawa Precision Forgings Ltd.

Rear axle Propeller shaft Clutch diaphragm

Steering Gear Assy

Sona Okegawa Precision Forgings Ltd.

Sona Okegawa Precision Forgings Ltd.

Case New Holland (USA) John Deere (Iberica) Tirth Agro

Sona Okegawa Precision Forgings Ltd.

Process Chain of Precision Parts

Precision Hot Forging on Conventional press lines 300 t bis 1250 t

Machining on full automatic cutting lines

Broaching of precision forged parts

Continuous quality from tooling to finished part

Flexible packaging according to customers requirements

Heat Treatment exactly matching to product requirements

Automotive World 2/26/2013

Sona Okegawa Precision Forgings Ltd.

Friction Driven (800 Ton) Wt.

5 yrs & 8 yrs

Servomotor Driven (1250 Ton)

Sona Okegawa Precision Forgings Ltd.

Sona Okegawa Precision Forgings Ltd.

1000 Kg 1000 Kg 600 Kg 1200 Kg 600 Kg

3 Nos. 3 Nos. 3 Nos. 4 Nos. 1 No.

Facilities: Design & Development Software

Solid Edge V20

Frenco Spline Software

Quality Assurance - Process Validation

Pyrometer For Billet Temp.

Load & Pressure Gauge For Forging Press

Pressure Gauge For Coining Press

Dial & Gauges For Inspection

100 % Gauging Inspection

100 % Visual Inspection