COMPANY HIGHLIGHTS 3

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3 COMPANY HIGHLIGHTS 3

4 Company details Abilities India Pistons & Rings Limited -- a renowned name in Piston manufacturing Established in the year 1968 by Mr. R.S. Arora. Converted into a limited company in No. of employees is Customer value driven approach - Practice of Lean Manufacturing System - Structured Problem Solving Approach such as Six Sigma - Quality Circles In All Departments - 5S, POKA YOKE & Kaizen Part of Daily Activities - Focus on Employee Engagement & Involvement 4

5 Started OEM supplies to TVS Motor & Enfield Converted Into a Limited Company STARTED PRODUCTION OF PISTON RINGS AQUIRED ISO 9001 CERTIFICATION 1 st EXPORT OF OEM SUPPLIES TO EUROPE AQUIRED ISO /TS CERTIFICATION JOINED ACMA UNIDO CLUSTER PROGRAM COMMENCED SUPPLIES TO FIRST OEM CUSTOMER IN USA JOINED ACMA ACT ADVANCE CLUSTER PROGRAM COMMENCED SUPPLIES TO FIRST OEM CUSTOMER IN CHINA RECEIVED EXPORT HOUSE CERTIFICATION FROM GOVERMNMENT OF INDIA JOINED ACMA ACT ENGINEERING EXCELLENCE CLUSTER PROGRAM About the Acquirer/Applicant

6 AQUIRED ISO & OHSAS CERTIFICATION COMMENCED SUPPLIES TO MARUTI SUZUKI FOR 2W ENGINES COMMENCED SUPPLIES TO OEM CUSTOMER IN JAPAN ACHIEVED STAR EXPOET HOUSE CERTIFICATION FROM GOVERNMENT OF INDIA SILVER WINNER ACT CASE STUDY COMPETITION - INNOVATION GOLD WINNER ACMA EXCELLENCE IN EXPORT CERTIFICATE OF APPRECIATION FROM ACMA FOR EXCELLENCE IN TECHNOLOGY Major Expansion, Introduction of New Technology & Moving Towards Green Manufacturing System About the Acquirer/Applicant Certificate of Appreciation from Maruti Suzuki on 2 wheeler Engine Certificate of Appreciation from HONDA 6

7 2008- Received Export Excellence silver trophy from EEPC of India Won ACMA Productivity & Quality award Bronze trophy Received Export Excellence Silver trophy from ACMA Received Export Excellence silver trophy from EEPC of India 7

8 2009- Achieved Gold trophy from ACMA for Excellence in Quality & Productivity Achieved Gold trophy from ACMA for Excellence in Export Achieved 1 st Prize in IMTMA-Siemens Productivity Champion Ship Award Achieved 1 st Prize for TEI in CII National Cluster Summit 8

9 2011- Commendation Certificate in Rajiv Gandhi National Quality Award For The Year Commendation Certificate in DL- Shah National Awards on Economics of Quality For The Year National Award Special Recognition For Research & development Efforts By MSME For The Year Received Export Excellence Star Performer Trophy from EEPC of India for the Year &

10 Gold Trophy for Excellence in Export Trophy Received Silver Winner for the ACMA - ACT Case Study Competition Innovation on 16 th & 17 th February, 2015 Pune Received EEPC(Govt. of India) Star Performance National Award for the year at Mumbai on 22 nd January,

11 Appreciation Certificate Certificate of Appreciation From Maruti Suzuki 11

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13 TECHNOLOGY Company details We have developed here at Abilities the technology/ expertise for manufacturing Pistons for chain saws and 2 & 4 stroke engines, right from raw material to finished product ensuring Higher Level of Quality and durability. 20,000 Sq Meters Factory Land. Well Trained Staff & Skilled Associates CAD / CAM Interface Through Uni-Graphics, Solid Works & PRO-E Creo Parametric 4.0 M020 WINCAST software Well Equipped in House Tool Room including VMC from Mazak Japan CNC CAMLESS Machining Facility 4 Index Fine Boring & Circlip Grooving Facility 13

14 Key Products / Product Families Pistons & Rings Pistons With Connecting Rod Assembly Cylinder 14

15 Business Contribution Business Share Export V/s Domestic Export 55% Domestic 45% 15

16 16 Our Valued OEM Customers

17 Company details Additional investments for increased capacity year New Piston Line Installed (Capacity increase 3 million pistons/ year) 1 CNC For Rough Turning 2 CNC IS/RG/HF 1 Circlip Grooving CNC 1 Casting M/c 2 SPM s Made in House 1 Stamping M/c Piston Ring (Capacity increase 10 million Piston Rings / year) 1 DD grinder 1 Cam Turning 1 Vertical Boring 1 CNC Barrel Honing 1 Lapping M/c Laser Marking M/c 17

18 Expansion Plan (Piston Capacity 4 million / year) -Complete Piston Machining Line (2 Sets) - Gravity Casting Machines (3 Nos.) -Heat Treatment Automatic Quenching Furnace (T6) -Ultrasonic Cleaning For Packing - New Line June

19 Company details PISTON FOUNDRY SHOP PISTON MACHINE SHOP 19

20 Company details TAKISAWA CNC CAMLESS OVAL TURNING FOUR INDEX FINE BORING & CIRCLIP GROOVING YOU JI OVAL TURNING CNC MACHINES CNC OIL HOLE DRILLING VMC MAZAK 20

21 Company details SAM Casting Machine Casting Machining Line Pressure Die Casting 250 Ton with Vacuum attachment 21

22 Company details CNC Barrel Turning Piston Ring Machine Piston Ring Finish Gap Sizing Machine 22 Piston Ring Finish ID Boring Machine Piston Ring CAM Turning Machine

23 Company details Automatic Piston Ring Mounting Machine (on Pistons) Machine Movie 23

24 Company details CMM IMAGE ANALYZER SPECTROMETER ROUNDNESS TESTER MICRO HARDNESS TESTER CONTOUROGRAPH FORM MEASURING STATION 24

25 Company details Digital Read Out Gauge For Connecting Rod Checking Fully Automated Piston Inspection System 25

26 Distinctive TEI Initiatives All activities started during ACMA Advance Cluster Program 1. Employee Family Visit - Every Week 2. Annual Family Day Function 3. Birth Day Celebration 4. Summer Computer Class 5. Kitchen Garden 6. Potable Drinking Water 7. Canteen 8. In House Dispensary 9. Common Uniform 10. Safety Awareness activities 11. Talent Development Program 12. Conducting Training Session 13. Quality Circle Activities 14. Reward & Recognition 15. CEO Monthly Address 16. Tea with MD 17. Best Employee of the Month 18. Tobacco & Pollution Free Company 19. Care for the Environment 20. Suggestion Scheme 26

27 Number Total Employee Involvement Safety Audits and NC Cum.NC Identified Cum.NC removed A 11-A Family Day Photo Kaizen Reward Training Session Safety Audit Information Centre Kitchen Garden 27

28 Annual Family Day Function Musical Chair Competition Families enjoying their Lunch Race Competition Painting Competition Employee Children's are playing 28

29 Distinctive TEI Initiatives Birth Day Gift to the Employee Tea with MD 29

30 Corporate Social Responsibility - Company and Its employees regularly contribute for Prime Minister Relief Fund in case of natural calamities such as UTTARAKHAND & NEPAL - Scholarships granted to employee children to encourage them in studies, sports activities etc. 30

31 Distinctive TEI Initiatives Common Canteen In House Dispensary for all the employees 31

32 Proud Achievements Star Export House 2015 TS16949 Certificate OHSAS Certificate ISO Certificate 32

33 1st Jun'07 Jul'07 Aug'07 Sep'07 Oct'07 Nov'07 Dec'07 Jan'08 Feb'08 Mar'08 Apr'08 May'08 Jun'08 Jul'08 Aug'08 Sep'08 Oct'08 Nov'08 Dec'08 Jan'09 Feb'09 Mar'09 Apr'09 30th May'09 ACMA Advance Cluster Road Map Time in Months Value adding management, concepts design and Implementation 1.1 Implementation of 14 steps 1.2 Production balancing and leveling 2. Integrated cellular manufacturing - Implementation and Practice 1. Concept of Cell design & Implementation 1.1 SMED (Integrate to SPF ) 1.2 LCA ( Integrate to operator fatigue / Stresses 1.3 Integrated Quality Control ( Poka-yoke, Vision Control ) 2.Equipment Maintenance 2.1 Implement step 1, 2,3 & Practice 2.2 Preventive maintenance - Implement and Practice 2.3 Organisation / Management 2.4 Cost loss analysis 3. FIFO 3.1 First IN First Produced ( Integrate to quality traceability ) 3.2 Production planning & control 1. Institutionalize all 5 S Basics 2. 6 M concept design & implementation 3. Holding gains and Corrective actions 1. Kaizen 2. QCC 3. 7 QC Tools 4. QC Story 5. 7 Management tools 6. Talent Development TEI (Continuous Improvement culture through TEI ) Road map for Advance Cluster Advance 5 S (Sustenance culture through Discipline) Cellular Manufacturing (Productivity Culture ) Total Employee Involvement Satisfaction Score Participation Kaizen / QCC Audit Score PQC Improvement Integrated Flow Manufacturing (Business Result Culture ) Lead time ITR Process Stability - Quantity - Quality Customer Quality - PPM OEE / OLE / OPE Cost Losses Deliverables VAPCO VAR Month We are part of ACMA ADVANCE CLUSTER program to upgrade our facilities to BEST IN CLASS standards. 33

34 ACMA-ACT Engineering Excellence Cluster Road Map 34 We are part of ACMA ACT ENGINEERING CLUSTER program to upgrade our facilities to BEST IN CLASS standards.

35 35 ACMA-CII ZED Cluster Road Map

36 RAJNARAYAN LAXMAN DEVENDER Best Practices Preventive Maintenance GAUGE REPEATABILITY & REPRODUCABILITY STUDY Part Name PISTON Part Number OM-2930; Ø34MM Upper Control Limit Performed By DHIRME Gauge / Equipment Name BALL MICROMETER Gauge/Equip. No. 9M2 Lower Control Limit Date Decemb Gauge / Equip. Least Count 0.01mm Characteristics RADIAL THICKNESS Tolerance 0.10 Record Number 4 DATA COLLECTION RESULTS / EVALUATION No of Trials / Parts Average Repeatability ( Equipment Variation) EV = R double bar * K Reproducability ( Appraiser Variation) Avg. Xa AV (X diff * K2)²-(EV²/nr)} A Range Ra Repeatability & Reproducability (R&R) P No of Trials / Parts R & R (EV² + AV²) P Part Variation ( PV ) R Pv = Rp X K3 A Total Varaiation ( TV ) I S Average Xb TV (R&R² + PV²) E Range Rb % Equipment Variation ( EV ) R No of Trials / Parts % EV = ( EV / TV ) * % Appraiser Variation ( AV ) % AV = ( AV / TV ) * % Repeatability & Reproducability (R&R) Average Xc % R & R = ( R & R / TV ) *100 Part Average R D.bar= {(Ra+Rb+Rc)} /3 Range Rc % Part Variation ( PV ) % PV = ( PV / TV ) * 100 X D.Bar= No. of Distinct Data Categories Rp = ndc = 1.41 (PV / GRR) UCLr = R D.bar X D UCLx = {X D.bar + (A2 * R)} X Diff ={ Max X - Min X } LCLr = R D.bar X D3 0 LCLx = {X D.bar - (A2 * R)} Repeatability & Reproducability (R&R) w.r.t Total Tolerance Trials / Appraisers A2 D3 D4 K1 K2 K3 n = r = 3 Trials 3 Appraisers Number of Parts Number of Trials Analysis of Results : Condition 1 : % GRR < 10 Acceptable Results Accepted 10 < % GRR < 30 Conditionally acceptable (if % GRR w.r.t Total tolerance is less) % GRR > 30 Not acceptable Condition 2 : The number of out of control points in Average chart should be more than 50 % to ensure part-to-part variation Results Accepted Condition 3 : No out of control points in the Range Chart Results Accepted Condition 4 : The number of distinct data categories (ndc) should be greater than or equal to 5 Results Accepted Conclusion & Remarks : Prepared By Approved By F/QA/16 Gauge R & R, Calibration Machine Sr.N o. 1 2 Casting machine PISTON M/C SHOP Line no. 1 to 5 3 Face grinders( rings) Less than 5 Minutes Nov' 08 Dec' 08 Jan ' 09 Nov' 08 Dec' 08 Jan ' 09 Nov' 08 Dec' 08 No of dies >=5 Minutes < >=10 Minutes < >=30 Minutes 10 Minutes 30 Minutes < 1 Hour Jan ' 09 Nov' 08 Dec' 08 Jan ' 09 Nov' 08 Dec' 08 Jan ' 09 Nov' 08 Total Dies Dec' 08 Jan ' Cam turning Boring Notch grinding/milling Honing SMED Matrix >=1 hour Minutes < 2 Hours Example of Cp & Cpk Calculation POKA YOKE Station Laser Low Cost Automation 36

37 Improving competitiveness. Aligning with customer varying demand using the tools like: Takt Time Value Stream Mapping Production Leveling & Balancing To Identify & Eliminate The Waste We Use Process Mapping Low Cost Automation Operating Ratio Cycle Time Study By Video Graphy Standard Work Combination Standard Operating Procedures CLITA Standard 37

38 Manual Auto Total VALUE STREM MAPPING PRODUCT FAMILY PO-414 (Feb,16) Quality Tools Used Standardised Work Combination table REV 03 Product : PO414 Machine : LINE # 2 Required output/ day : 2000 Manual Process : MACHINING DATE: 15 th JAN08 Department: MACHINE SHOP Takt Time : 37 Auto Step 1 Rough turning Center bore drilling Locating seat Size turning and ring grooving & HF Lock pin drilling, fitting & pressing Rough boring Fine boring Circlip grooving Bore chamfer Bore burnishing Boss facing IBC VAR :- :- Before = = 0.76 After = = Value Stream Mapping Oval turning PORT FILE Standard Work Combination CLICK HERE FOR DETAILS Process Mapping 38

39 Technology Focus Areas Virtual Designing & Validation Design capability acquired from consultants retired from FM plant. Have recently engaged a retired Chief Engineer from HGA -Honda Two Wheelers, Japan for augmenting our design & innovation capabilities Have successfully designed Two Piston assemblies for an OEM European company & received order for production of one assembly & for tooling of the second assembly 39

40 Have offered successful solutions to OEM customers for eliminating seizing problems in customer s own designed pistons Modified existing piston ring design of OEM customer with new material & changed OD profile achieving 20% better engine life & 3% reduction in emissions. Introduced NPD Systems Product & Process Optimization & Validation Engine Testing Technology Focus Areas FEA techniques initiated to prepare the company to be Design Enabled 40

41 Technology Focus Areas - Rapid Prototyping Conventional Prototyping Rapid Prototyping SAMPLE KICK OFF 6 Weeks Die Manufacturing Solid Bar Casting Readily Available 1 Weeks Proofing Rough Counter Milling 2 Days 1 Weeks Casting 5 Axis Milling M/c 3 Days 1 Day Heat Treatment Heat Treatment 1 Day 3 Day Machining Machining 2 Day 1 Day Inspection Inspection 1 Day 41

42 Technology Focus Areas - Rapid Prototyping Pistons are made out of standard solid bars through gravity Die Casting. Casting Quality is similar to Conventional Casting technique. Piston is completely machined from all around. Solid are in steps of 5mm each depending on size / diameter of the piston. 42

43 Technology Focus Areas - Rapid Prototyping ROUGHING INTERNAL CONTOUR MILLING By VMC Solid bar is milled down to achieve desired internal cast contour through high Speed Axis milling operation 43

44 Technology Focus Areas Phosphating D10 Moly coating for Pistons (Dow Corning) Graphite coating 44

45 Technology Focus Areas Tin Coating Nickel Plating 45

46 Technology Focus Areas Engine Test Control Cell Dynamometer 46

47 Planting New Trees 47 UPDATED INFORMATION

48 HOUSE OF QUALITY Global data mapping for similar application for Power, torque etc. Optimizing from perspectives of Optimized design - weight, chamfers, tolerances Reduction in weight of Pistons by VA/VE 48

49 HOUSE OF QUALITY Technology oriented solution - Lean manufacturing (Single Piece Flow, Adoption of LCA, Adoption of latest technology machines) - Lean Machines with Lean Hydraulics, Pneumatics, Electricals & no chips / coolant on floor 49

50 Abillities India Piston & Rings Ltd. Plot No. 3, F-301, IIIrd Floor Ashish Complex, Local Shopping Centre, New Rajdhani Enclave Vikash Marg, Delhi (INDIA) Phones: Telefax: aip@aippistons.net www. aippistons.com 50 धन यव द Gracias por su atención ご清聴ありがとうございました Thank you for your attention 感谢您的关注 Grazie per l'attenzione İlginiz için teşekkür ederiz