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WELCOMES

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Title: WELCOMES


1
PUNJAB BEVEL GEARS
WELCOMES
2
INTRODUCTION
Sahibabad
Sitarganj
Sahibabad
3
INTRODUCTION
GROUP COMPANIES
LUDHIANA PUNJAB 2 PLANTS
SITARGANJ UTTARAKHAND 3 PLANTS
SAHIBABAD UTTAR PRADESH 4 PLANTS
Differential Transmission Gears and Shafts
Forging Machining Axle Shaft
Differential Transmission Gears, Differential
cage and Drive line parts
There are 4 manufacturing units all located
within 500 metres in Sahibabad.
4
INTRODUCTION
  • Started operations in 1979
  • Manufactures more than 2000 different type of
    gears
  • Leading manufacturer, supplier and exporter of
    automotive and tractor parts
  • Caters to industries like commercial vehicles,
    agricultural tractors, passenger cars, three
    wheelers construction equipments

5
INTRODUCTION
  • 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
    comparatively shorter period

6
INTRODUCTION
  • Financially sound having credit rating of care
    BBB-
  • (Triple B Minus) For long term bank facilities
    for 2014
  • Having assurances from financial institutions
    for support in the on going 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 at all plants
  • An ISO/TS 16949 2009 Certified Company

7
PRODUCT RANGE
  • Crown Wheel Pinion
  • (Face Mill, Face Mill Completing
  • and Face Hob in both Dry and
  • Wet cutting)
  • ST. Bevel Gear Pinions
  • (Gleason Coniflex System)
  • Transmission Gears(Spur,Helical)
  • Differential Cages
  • Axle Shafts
  • Forgings/Machined Forgings
  • Drive Line Parts

8
PRODUCT RANGE
Crown Wheel Pinion (Face Mill and Face Hob
Wet Cutting process)
Crown Teeth Cutting
Pinion Teeth Cutting
Crown Pinion Testing
9
PRODUCT RANGE
St. Bevel Gears Pinions (Gleason Coniflex
System)
Teeth Cutting
Gear Pinion Testing
Teeth Cutting
10
PRODUCT RANGE
Transmission Gears and Shafts (Spur, Helical)
CNC Blanking
CNC Hobbing
Spline Hobbing
Stack Hobbing
11
PRODUCT RANGE
Transmission Gears and Shafts (Products)
12
PRODUCT RANGE
Differential Cages
CMM
CNC Machining
13
PRODUCT RANGE
Axle Shafts
14
GROUP TURN OVER (Mio Rs)
15
GROUP TURN OVER (Mio )
16
SEGMENT WISE SALES FY13-14
17
CAPACITY INSTALLED
  • Sl.No. Product Annual
    Utilization
  • Capacity
    of
  • capacity
  • 1. Crown Wheel Pinion 720,000 Sets
    60
  • 2. Straight Bevel Gears 1,500,000 Nos.
    80
  • 3. Transmission Gears 1,600,000 Nos. 60
  • 4. Axle Shafts 100,000
    Nos. 25
  • 5. Forgings 12,000
    MT 70
  • Differential Cage 48,000 Nos. 40
  • Drive Line Parts 200,000 Nos. ---
  • On 2 Shift Basis

18
CAPABILITIES - GEARS
TYPE SPIRAL/ HYPOIDS STRAIGHT BEVEL SPEED GEAR TRANS. SHAFT
MAX. SIZE (DIA) MM 600 216(101) 152(11) 400 80
MAX. FACE WIDTH/L 70 50.80 135mm Shaving 1000mm
MAX. MODULE (mm) 13.00 8.50 8.00 8.00
ACCURACY DIN CLASS 6-7 in Dry Cutting 8-9 in Conventional DIN CLASS 8-9 DIN CLASS 8-9 DIN CLASS 8-9
19
CAPABILITIES - FORGINGS
  • Weight 0.5 Kg to 50 Kgs
  • Round Forging Min. Dia 80 mm
  • Max. Dia 500 mm
  • Shaft Forgings Length 1200 mm
  • Flange Dia 325 mm

20
PLANT AREA IN SQ. FT
Sahibabad Ludhiana Sitarganj
Total Area 500,600 152,500 183,140
Covered Area 179,390 46,000 95,200
General Office Area 5,420 5,000 11,600
21
MANPOWER
Sahibabad Ludhiana Sitarganj
Hourly 335 165 100
Supervisory 47 07 12
Manager 13 01 02
Total 395 173 114
22
CERTIFICATION / AWARD
  • QUALITY SYSTEMS
  • Plants at Sahibabad and Sitarganj are ISO/TS
    16949 2009 certified
  • Forging plant at Ludhiana is ISO 9001 2008
    certified
  • Differential gear plant is ISO 9001, ISO 14000
    ISO 18000 certified
  • EXPORT PROMOTION
  • Recognized star export house
  • Awarded silver shield for export performance
    during 2005-06,
  • 2007-08, 2008-09, 2009-10, 2010-11
    2011-2012 by Engineering Export Promotion
    Council, India

23
CERTIFICATION / AWARD
  • CUSTOMER AWARDS
  • Best supplier award for new product development
    by TAFE in 2010
  • Best supplier award for consistent delivery
    performance through pull system-KANBAN by TAFE in
    2013
  • Supplier recognition award by American Axle in
    2010
  • Direct on line supplier award by TAFE
    International Tractors Limited

24
CUTTING EQUIPMENT INSTALLED AT SAHIBABAD/LUDHIANA
CNC Turning Lathes 39 Nos. Vertical Machining
Center 10 Nos. Gleason Crown Wheel 9
Sets (608/609, 606/607, No. 22, No.11
No.112) Gleason Pinion 7
Sets (No.116) Oerlikon 9 Nos. (SM3,
S17, SKM1)
25
CUTTING EQUIPMENT INSTALLED AT SAHIBABAD
Transmission Gears Hobbers 30
nos CNC Hobbers 3 nos CNC
Shaper 1 no. Shapers 34
nos Shavers 14 nos Shobbers 1
no Straight Bevel Gears Gleason Coniflex114
02 nos Gleason Coniflex104 02
nos Coniflex WMW 34 nos
26
HEAT TREATMENT FACILITIES
Sealed Quench Furnace
Sealed Quench Furnace
Continuous Gas Carburising Furnace
27
HEAT TREATMENT FACILITIES
  • Sealed Quench Furnaces
  • Continuous Gas Carburizing Furnace
  • Rotary Hearth Furnaces
  • Induction Hardening / Softening
  • Quench Presses Gleason
  • Tempering Furnaces
  • Manganese Phosphating Facilities
  • Shot Peening Equipment
  • Shot Blasting Equipments
  • Straightening Presses

28
FINISHING EQUIPMENTS
  • Cylindrical Grinding Machines
    -15 Nos.
  • CNC Internal Grinder
    - 1 No.
  • CNC Lathe for Hard - 2 Nos.
  • Internal Grinding Machines - 8 Nos.
  • Spline Grinding Machines - 3 Nos.
  • Lapping Machine
  • Gleason - 12 Nos.
  • (503/506/119/516)
  • Gear Testers-Gleason - 18
    Nos. (502/511/17-A)

29
METALLURGICAL LAB FACILITIES
  • Full range of Hardness Testers
  • ( Rockwell, Brinell, Micro Vickers)
  • Hardenability (Jominy) Apparatus
  • Microscope with camera and image analyzer
  • Magnetic Particle Inspection
  • Macro Etching
  • Muffle Furnaces
  • Manganese Phosphating Solution Analyzer

30
METROLOGY LAB FACILITIES
  • CMM with Gear Analyzer
  • Lead and Profile Testers
  • Surface Roughness Tester
  • Contouro Graph
  • Profile Projectors
  • Gear Roll Testers
  • Digital Temperature Calibrator
  • dB Meter

31
QUALITY SYSTEMS
  • RAW MATERIAL
  •  Forgings are received Heat Code wise duly
  • Isothermally Annealed/ Normalised from approved
    Forge shops.
  • Checks carried out before processing are
  •      Visual Inspection for cracks and folds.
  •    Check of chemical composition by Spectro
    Analysis at forging plant.
  •      Hardness.
  •      Jominy Hardenability.
  •      Micro structure and Inclusions.
  •     Grain Size.
  • Inclusion Rating.
  • Macro etching/Grain flow.

32
QUALITY SYSTEMS
  • IN-PROCESS
  •       First off inspection as per control plan.
  •   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.  

33
QUALITY SYSTEMS
  • 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

34
TRACEABILITY
  • RAW MATERIAL TRACEABILITY
  • - Unique TR No. Identifying steel mill, grade
    forge
  • shop punched on parts wherever
    possible
  • HEAT TREATMENT TRACEABILITY
  • - Unique charge No. identifying furnace, month
  • process parameters punched on
    parts wherever possible
  • CWP SET TRACEABILITY
  • - Unique set no. etched on both the members
  • LOGO MARKING
  • - Customer / PBG logo punched / Laser marked /
    Bar Code as
  • per customer requirements

35
INVESTMENT COMMITTED
  • Additional Continuous Gas Carburizing Furnace
  • Additional Sealed Quench Furnaces
  • Shaving Cutter Sharpening- Gleason
  • Additional CNC Hobbers
  • Additional CNC Shapers
  • CNC Shavers
  • Additional CNC Internal Grinder
  • CNC External Grinders
  • Additional Vertical Machining Center

36
CUSTOMER PROFILEDOMESTIC OEMs
AUTOMOTIVE
  • Tata Motors
  • Mahindra Mahindra
  • American Axle
  • Manufacturing
  • Scooters India

37
CUSTOMER PROFILEDOMESTIC OEMs
AGRICULTURE
  • Tractors and Farm Equipment
  • International Tractors
  • John Deere Equipment
  • Dana India
  • Indo Farm Equipment
  • Sicma India

38
CUSTOMER PROFILEEXPORT OEMs
  • Meritor, Brazil
  • Dana, USA
  • Hema Endustri A.S.,Turkey
  • Mega Motors Company, Iran
  • Iran Tractor Mfg Company, Iran

39
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, Myanmar, Syria, Egypt, Turkey,
Bangladesh, Sri Lanka, Iran, Dubai, Italy,
Argentina, Australia, Hungary, Germany, Brazil.
40
FORGING FACILITIES AT LUDHIANA
Steel Yard
Friction Belt Drop Hammer
Up Setter
Annealing Furnace
41
FORGING FACILITIES AT LUDHIANA
  • Friction Belt Drop Hammer (1.00, 1.50, 2.00,
    2.50, 3.00, 6.00, 8.00 M.T. and a 25T Counter
    Blow hammer)
  • Up Setter - 3 Inches 7 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

42
FACILITIES AT SITARGANJ
Latest Generation Gleason Phoenix CNC Dry/Wet
Cutting System
43
FACILITIES AT SITARGANJ
Crown Teeth Cutting Line
Pinion Teeth Cutting Line
Lapping Testing Line
Metallurgical Lab
Sealed Quench Furnace
Phosphating Plant
Annealing Furnace
Forging Press
Forging Press
44
FACILITIES AT SITARGANJ
  • Green Field Plant Production started from March
    2010.
  • Equipment at the Plant
  • Gleason Phoenix CNC Cutting(600 HC) -- 1 No.
  • Gleason Phoenix CNC Cutting(275 HC) -- 1 No.
  • CNC Blade Profile Grinder -- 1 No.
  • CNC Cutter Build Machine -- 1 No.
  • CNC Gear Measuring Machine -- 1 No.
  • Gleason Pinion Generator(No.116)
    -- 5 sets
  • Gleason Crown Wheel(606/607, No.22)
    -- 5 sets
  • Hobber -- 15 nos.
  • Shaper -- 9 nos.
  • Shaver -- 5 nos.
  • Milling -- 4 nos.
  • External Grinder -- 6 nos.
  • Internal Grinder -- 6 nos.
  • CNC Lathe -- 4
    nos.

45
FACILITIES AT SITARGANJ
  • Gleason Lapper(503, 506, 514) -- 4 nos.
  • Oerlikon Lapper SKL 1
    -- 1 no.
  • Gleason Tester(511, 512, 17A) -- 6 nos.
  • Continuous Gas Carburising Furnace -- 1 no.
  • Sealed Quench Furnace -- 1 no.
  • Gas Carburising Furnace -- 2 nos.
  • Rotary Furnace -- 1 no.
  • Gleason Quenching Press (537) -- 2
    nos.
  • Shot Blasting Equipment -- 1 no.
  • Fully Equipped Metrology and Metallurgical
    Laboratory
  • 100 captive power back up

46
PLANT ADDRESS
PUNJAB BEVEL GEARS LIMITED Unit-I Address for
communications B-44/1 52/2, Site-IV,
Industrial Area, Sahibabad-201010, Ghaziabad
(U.P) INDIA Tel. 91-120-4505100-129, Fax
91-120-4505104/4505105 Email mktg_at_pbgl.in URL
www.pbgl.in Unit-II B-174, Phase I, Eldeco
Sidcul Industrial Park, Sitarganj -261453,
Udhamsingh Nagar , (Uttarakhand), INDIA Email
sitarganj_at_pbgl.in
Unit-III VPO Bhama Kalan, Kohara-Machiwara
Road, Ludhiana- 141115(Punjab), INDIA E-mail
ldh_at_pbgl.in
47
THANK YOU
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