caparo india
TRANSCRIPT
CAPARO INDIA
Caparo, founded in 1968 by Indian born British Industrialist, Lord Paul of Marylebone, is a fast growing UK based group with a 1bn Euro turnover. With business interests predominantly in the manufacture of steel, automotive and general engineering products, the group has a grown as a global entity. Caparo group is now a collection of over 40 companies operating from over 60 sites worldwide.
Caparo India, the Indian business arm of Caparo Group, began its operations in 1994, as a joint venture with India’s largest car manufacturer— Maruti Udyog. Today, through its two strategic business entities, Caparo Engineering India Pvt. Ltd. and Caparo Maruti Ltd, the group offers end-to-end solutions in designing, developing and manufacturing automotive systems, assemblies, advanced composites, modules and components to Indian Automotive OEMs and Engineering Industry.
Caparo India leverages its exhaustive capabilities in metal Stamping, Fastening, Tubing, Forging and Aluminium Foundry businesses, coupled with its state-of-the-art Tool Room and R&D Centre, to service top-notch clients such as GM, Ford, Maruti, Honda, Tata Motors and JCB. The company’s ability to offer complete lifecycle solutions backed by a global support system, technological superiority and customer orientation, make it a force to reckon with in its areas of expertise.
"Caparo India currently employs 5000 direct and indirect employees across 25 world-class functional and upcoming facilities.
Caparo Group, a UK based diversified conglomerate, is a world-leader in the manufacture and supply of sophisticated steel and engineering products. Headquartered in London, Caparo’s global operations are spread across over 60 sites in the UK, India, Spain, North America, Canada and Dubai and employ more than 6000 associates worldwide.
Its exhaustive product portfolio comprises of steel tubes, aluminium die-castings, sheet metal pressings, steel pressings, steel bars and wires, auto fasteners, forgings, hand tools and engineering products custom-made for the world’s leading automakers and engineering companies. Additionally, the Group is also involved in a wide range of activities encompassing materials testing services, hotels, film distribution and private equity investment.
CAPARO’S VALUE PREPOSITION
Caparo is amongst the fastest growing auto component companies in India. It is well-equipped to become one of the top 3 Tier I vendors in the country. A relatively late entrant to the domestic market, Caparo has made rapid progress in setting up world-class facilities and attaining the preferred vendor status, making it a strong contender for the leadership position in Indian auto component industry. CAPARO – Differentiating Factors
Scale of operations
Caparo has set up 19 plants across various geographies in India. This is amongst the highest number of plants across all Tier I vendors in India. The Group has grown to this level from 3 plants in 2003.
The Group currently has a land base of over 500 acres, strategically located across Chennai, NCR (Gurgaon, Noida and adjoining areas), Indore and Pune. A large part of this land base is still unutilised, making it easier for Caparo to put its expansion plans into effect.
Caparo can profitably scale up to fill these capacities and yield more than INR 30bn of revenues by 2010. This would make Caparo India one of the largest Tier I vendors.
Investment in people and processes
The Caparo Group was founded by Lord Swraj Paul, a first generation entrepreneur, who
combined strong ethics, astute business acumen and hard work to create a vast business empire in less than 4 decades. The same business philosophy and ethics have been extended by his son Angad Paul in developing the India business.
Caparo India is run by an independent and professional set of managers drawn from premier auto component companies in India. Unlike normal trade practices, this senior team has been put in place much in advance of the actual com mencement of production at some of the plants Caparo has also invested in setting up a very robust and effective management information system (MIS), reflective of the professional nature of management and the strong corporate governance in place.
Quality of manufacturing facilities
Caparo, being a relatively late entrant to the automotive industry in India, has developed
its key infrastructure over the last 2- 3 years. However, this has given Caparo the ability to set up new facilities and employ ‘Best Practices’ in terms of manufacturing equipment and processes. This is a key differentiator over competitors, who still rely on facilities and processes that were set up in a very different industry scenario.
The strong focus on manufacturing facilities and processes has also resulted in Caparo having the lowest rejection rates in the country. For the last 6 months, Caparo has been the #1 of 101 suppliers to Honda Siel, a distinction it has earned competing with Japanese vendors of Honda cars in India.
Diversified products and customers Caparo has the unique distinction of being the only Indian automotive vendors with
product capabilities ranging from metal pressing to forging, aluminium castings, tubing and fasteners.
Caparo is an approved vendor to practically all major OEMs across the passenger car, commercial vehicle and two-wheeler segments in the country – another distinction available with very few automotive vendors in India.
Caparo’s large management team has extensive relationships across all IPOs in India and are leveraging these rela-tionships to drive export business.
Caparo has been able to leverage these product capabilities in reaching out to its diversified customer base and being able to cross-sell various products to the same customer. This position insulates Caparo from the risk of product obsolescence as well as makes it neutral to the market share position within OEMs in the country. Moreover, the ability to sell a cross-section of products to the same set of customers will enable Caparo to out-grow their competitors at a much faster pace.
Access to technology
Caparo India’s superior design and development capabilities are a key differentiator vis-à-vis competitors. Tool room facilities, such as Caparo’s sophisticated tool room set up in Chennai, are available with a couple of leading independent specialist tool room companies in India, but no other auto component manufacturers has such facilities in-house.
Focus on technology is another aspect which will assist Caparo India in enhancing their profitability as there is a sig nificant difference in the operating margins of ‘build-to-print’ products and engineered and designed components and assemblies.
As the Indian automotive industry gets more focussed on technology upgradation and produces automobiles for global consumption, there is a greater tendency for OEMs to develop strategic relationships with vendors who are interested in technology and who can partner them in meeting stringent quality norms.
The Group intends to continue passing on their technologies employed in European and North American markets, a key differentiator with other competitors who have to rely on external partners to get access to such technologies.
CAPARO’S CORPORATE RESPONSIBILITIES
Caparo, as an organization takes pride not only in bringing world-class technology to its customers; but also in discharging its responsibility of creating an environment of inclusive growth in the country. At Caparo, Corporate Social Responsibility and concern for environment, health and safety are the intrinsic elements of the company's long term strategy.
Caparo's CSR commitment is a manifestation of its determination to improve the quality of life of not only its employees, but the society at large. Some of the Company's key CSR initiatives are:
Ambika Paul Foundation:
Ambika Paul Foundation was set up in the memory of late Ambika Paul, Lord Paul’s daughter, who sadly lost her battle with Leukaemia in 1968.The Foundation, promotes the well-being of children around the world through education, culture and health, and seeks to encourage and inspire them to learn about the world they live in
In the UK the foundation supports a number of children’s charities, besides the Zoological Society of London. When London Zoo was under threat of closure, Lord Paul gave £1million to the Zoological Society of London, which used that donation for the rebuilding of the London Childrens’ Zoo in her name.
In the United States, the Foundation supports the Ambika Paul Infant Lab Suite at Carnegie Mellon. Two research teams are working at this lab, to understand infant development with the objective of designing interventions to help children with developmental disabilities such as autism and specific language impairment.
Bal Vadis:
Caparo has joined hands with Bal Vadis to take care of the pre-school children of the labour class in Chennai. They are supported with healthy environment and proper nutrition. Bal Vadis help in building a good foundation for these children, so that they can be a part of any good school when they grow up.
In addition to the above, Caparo, as an organisation, is sensitive about environmental issues. Hence all the Company units have technologies in place to ensure that the pilferage and emissions are well within the limits. The units observe tree plantation drives to build a green look while keeping the environment healthy and safe.
AWARDS AND RECOGNSITIONS
Caparo India has time and again received recognition from its esteemed customers, in form of Awards. Some of the major awards our manufacturing plants have received are:
Plant Name Customer Year Award
Caparo Maruti
Limited, Bawal and Gurgaon
MSILJune - 2010
CML got awarded for: 1. Incoming Quality2. Yield Improvement3. Design & Development
Caparo Maruti
Limited, Bawal
MSILJan – Feb 2010
Able to sustain ‘A’ grade performance in MSIL’s
vendor rating system with zero defects and zero
rejections coinciding with peak volumes
Caparo Metal
Systems, Chennai
Hyundai Motors
Feb 2010
100 PPM Award
Caparo Forging, Chennai
Iljin Automotive
Private Limited
March, 2010
Best Supplier Award and certified for “SQ” Mark in
Hot Forging and Heat Treatment Process
Pithampur
- I
VE Commercial Vehicles Ltd.
07-08Outstanding contribution in the area of supply
chain management
Pithampur
- IEicher Motors 06-07
Outstanding Contribution — For best contribution to Supply Chain Mgmt.
Noida HSCI 2007 Outstanding development
CML HMSI 06-07 Achieving Quality & Delivery Targets
CML Maruti 2006 Overall Performance Commendation
CML Maruti 2007 Yield Improvement
STAMPINGS | OVERVIEW
Caparo India specializes in providing complete steel and aluminium metal stamping solutions for a variety of applications. It is the only supplier in India possessing capabilities to meet all stamping and stamping assembly requirements of OEMs. Starting right from the process design and development stage to providing tools, migration to mass production and effective delivery management, the company offers tailor-made solutions to its customers.
Having started with a single unit at Gurgaon, Caparo India's stamping operations are now spread across several hi-tech facilities in India. It has developed capabilities to supply complete body-in-white systems to OEMs like Tata motors - a skill set unmatched in the Indian industry. The company's wide range of stamping products include body parts, chassis parts, long members, reinforcements, brackets, frame add-on parts, and other general stampings.
Caparo India is also strongly focused on developing technologies to get into Advanced Composite Materials- perhaps the technology most likely to replace sheets metal over the next 7-10 years.
STRATEGIC GROWTH AREAS
High Tensile Parts
Caparo India has developed High Tensile parts at its Greater Noida facility. It is currently supplying more than 15 parts to Honda cars and more than 10 parts to General Motors. These parts were earlier imported by the OEMs.
Coil Blanking
Caparo India is setting up a coil blanking facility as an extension to its TWB facility at Bawal. The facility shall both cater to the internal requirements of Caparo and supply externally to Maruti and Honda from July'08.
Tailor Welded Blanks
TWB's technology is gaining popularity due to the advantage it offers in terms of reduction in weight, costs and improvement in aerodynamics and fuel efficiency. Caparo has set up a TWB facility at Bawal, Gurgaon as a JV with Marubeni -itochu steel, Japan.
STAMPINGS | Products
Product Specialisation
Outer Body Panel
Large Inner Panels
Reinforcements
Brackets
Frame add-on parts
Cross members and Chassis parts
General Stampings
STAMPINGS | Applications
Skin Parts - Caparo India manufactures all kinds of skin parts such as outer panels and inner panels in various sizes (t = 0.5 - 6.0 mm). It fabricates deep draw and extra deep draw panels and specializes in hemming of doors.
At present, Caparo is manufacturing complete doors for General Motors India's MUV, Tavera.
High Tensil Parts - High tensile parts are used by OEMs to lend strength and stiffness with a favourable mass to cost ratio. The manufacture of high tensile parts needs special die designing capabilities.
Caparo has pioneered this concept in India and supplies 15 such parts to Honda. While each high tensile die capability requires an average of 10 years of experience, Caparo India has built such capabilities within one year at their plant at Greater Noida.
Long Members - They are the members on which the complete chassis and body of commercial vehicles rest, making them a critical component for strength and safety.
Caparo India is making long members for Eicher motors at its Pithampur plant. The company is the only independent component supplier to import a 4000 ton machine for making a long member automatically. This will increase the speed of production and ensure quality for this critical component. These capabilities were hitherto available only with the OEMs.
Assembly Systems - This involves assembling the various body parts including frames, members, floors, etc through a combination of processes like welding and adding nuts and bolts.
FASTNERS | Overview
Having started its operation in 2005 from Chopanki (Rajasthan), Caparo Fasteners India (CFI), is today one of India's fastest growing manufacturers of High Tensile Fasteners. It is backed by complete technical support from the group company Caparo Atlas fastenings, UK, a leading manufacturer of fasteners, catering to the European automobile industry for the last 100 years.
CFI's manufacturing facilities are housed in a state of the art plant with a capacity to produce 26000 MT of fasteners per annum. Within the last two years of operation, it has established itself as a reliable supplier of fasteners to almost all the Automobile OEMs in the country and their manufacturing locations abroad. Today, Caparo is a strategic source for fasteners to leading OEMs like Ashok Leyland, Asia Motor works, Eicher Motors, Ford, General Motors, HMSI, Tata Motors and many more.
Certified for TS 16949, Caparo Fasteners is a process driven company. New product development has been the hallmark of CFI. A wide range of products catering to the automobile industry, aerospace and general engineering applications have been developed at CFI.
It manufactures standard fasteners that conform to the International Standards JIS, Metric, Inch series. The products manufactured are forged from cold headed quality medium carbon steel, alloy steel and stainless steel.
FASTENERS | Applications
Fasteners are mechanical devices whose basic function is to join together two or more components in product or structural assemblies, systems and subsystems. Metal fasteners such as rivets, screws, studs, nuts and bolts are used to join discrete parts to produce the finished product.
Depending of the design requirements, fasteners can be classified into:
Standard Fasteners
These are fasteners that are pre-classified with respect to their shape, size and strength by worldwide organizations. They are generally designed for use in applications where fastener performance is less critical and largely commoditized in nature.
Special Fasteners
These are fasteners that require drawings and are customized for use in specific settings. They are generally manufactured in smaller quantities in accordance with the customer's design specifications.
Key Applications
Automotive Fasteners – These fasteners can be found in virtually every motor vehicle subsystem, including the body, engine, fender, lights, moulding, suspension system and wheels. The average automobile manufactured contains more than 2,000 individual fasteners
Industrial Fasteners - These fasteners cater primarily to the industrial machinery, aerospace and electrical and electronic equipment industries.
Aftermarket Sales - There is a large demand for fasteners for the replacement market in the industrial, service and government and institutional sectors. The service sector demand is primarily driven by repair services, especially for motor vehicles, aircraft and other transportation equipment.
TUBE | Overview
Caparo India initiated its tubes and tubular products operations with the acquisition of the over 30 years old, Dewas based company Steel Tubes of India in August 2006. The company manufactures precision steel tubes for Automobile Industry, General Engineering and Power Sector.
Caparo Tubes (CTI) specialises in producing ERW (electric resistance welded) precision tubes and CDW (cold-drawn welded) tubes with adverse D/T ratio and special grades. The group is working towards enhancing its capacity by modernizing and expanding its Indian tube manufacturing setup.
TUBE | Products
Product Specialities ERW (electric resistance welded) precision steel tubes, structural hollow sections and conduit.
CDW (cold drawn welded) tubes
TUBE | Application
Automobile Industry Main Beam, Handle Bar, Links, Spacers, Propeller Shaft, Steering Column, Automobile Axle, Exhaust Tubes, Stand Tubes, Accessories Tubes, Brake Tubes etc.
Shock Absorber IndustryDust Cover, Inner Tube, Cylinder Tubes, Eye Ring , Bush Etc
Boiler and Heat exchangerBoiler Tubes and Air Pre-heater Tubes
Furniture Industry
Transformer tubes-Radiator tubes
General Engineering applications
Cycle Industry
ALUMINIUM FOUNDARY | Overview
As a manufacturer of complex aluminium precision casting, Caparo Group has been offering complete solutions from concept to production stage, for more than 30 years. It has an excellent track record of servicing a number of high profile customers through its group companies Caparo Aluminium Technologies and Bridge Aluminium Limited situated in the West Midlands, UK.
With support and technological know-how from its UK operations, Caparo India started a green field project for its Aluminium Foundry operations in October 2007. This world-class facility has been set up at Industrial Park in Sriperumbudur, Chennai to manufacture High Pressure Die Casting and Gravity Die Casting parts. Caparo India aims to become the best in class Aluminium Foundry in India and offer products and services of uncompromising quality and integrity, consistent with its brand image.
ALUMINIUM FOUNDARY | Proucts
Rack Housing for Steering Column Assembly
Cylinder Blocks – 2 /3/4 Cylinder
Crank-Case Covers / Oil Pans
Wheel Hubs / Brake Drums
Clutch Housings
Bearing Ladders / Ladder Frame
Timing Cases and Timing case cover
Rocker Covers / Cylinder head cover
Hydraulic Valve Blocks
Transmission Cases
Power Train Components
Fly Wheel Housings
Compressor Housings / Compressor Cover
Diesel Injection Pumps
ALUMINIUM FOUNDARY | Applications
Pressure tight parts with highest precision Safety parts with documented process parameters and certificate Aluminium engine block for cars Casting parts with minimum porosity using
Squeeze casting
For safety parts like forks, mounting brackets, steering housing, rack housing Where ever wall thickness is more and high mechanical properties are needed.
Vacuum Die Casting
Minimum gas porosity in automotive components - bearing caps etc. Structural components where elongation, weld ability and heat treatment is needed.
Thixoforming - Semi solid metal casting
Higher productivity - Shorter solidification time Blow hole free - Less shrinkage porosity Longer die service life Very good strength, elongation and weld ability
FORGING | Overview
Caparo is commencing its forging operations in India at Sriperumbudur near Chennai, by setting up a Greenfield project for the production of forgings and machined components for various automotive and non-automotive applications. Additionally, Caparo India is in process of setting up state-of-the-art machining facilities for Crankshafts, Connecting Rods and other components.
Caparo Group is already a leading player in this domain, with group companies like Clydesdale Forge in UK. The Group has two manufacturing sites in UK at Hartlepool and Dudley and a heavy forgings manufacturing site in Poland.
FORGING | Products
Caparo is commencing its forging operations in India at Sriperumbudur near Chennai, by setting up a Greenfield project for the production of forgings and machined components for various automotive and non-automotive applications. Additionally, Caparo India is in process of setting up state-of-the-art machining facilities for Crankshafts, Connecting Rods and other components.
Caparo Group is already a leading player in this domain, with group companies like Clydesdale Forge in UK. The Group has two manufacturing sites in UK at Hartlepool and Dudley and a heavy forgings manufacturing site in Poland.
TOOL ROOM / R & D CENTRE | Overview
Caparo India set up a sophisticated Tool room and R&D centre at Chennai, Tamil Nadu in June 2007. Established as a machine shop for the designing and manufacturing of Dies, Prototypes, Fixtures, and Testing Rigs, the tool room is a strategic step towards branding the CAPARO Group as an end-to-end solutions provider for automotive OEMs.
TOOL ROOM /R & D CENTR | Services
The tool room undertakes design and manufacture of Dies, Prototypes, Fixtures, and Testing Rigs for industrial and automotive applications.
Services offered by the tool room are:
Design:
Product optimizationPlacement of our resident engineering at customer’s
source during project inception and execution.Value addition / value engineering on assembly designDesign of welding / assembly fixtures
Manufacturing of dies
Supply of dies
Manufacture of welding / assembly fixtures
Testing of assembliesManufacture of Pre-production tools.
Supplying prototypes.
AUTOMOTIVE STAMPING
A vast range of products including body parts, chassis parts, reinforcements, brackets,
frame add-on parts, and other general stampings are manufactured by Caparo
Engineering India Pvt Ltd (CEIPL). The product range spans from 0.5 mm to 4 mm, from
as small as a few centimeters to as large as 2.5 meter x 2.0 meters.
Starting right from process design stage to development, proving tools, migration to mass
production and then effective delivery management, CEIPL team up with customers to
complement their strengths and provide a tailored solution.
Stamping
A mix of technologies and equipment ensures the facility is versatile and capable of
addressing varied needs in a cost effective manner. The facility has both tandem line and
stand alone presses and uses hydraulic and mechanical technologies. Range of
equipment starts from 1200 ton large bed size (4 meter x 2.5 meter) hydraulic press. This
gives immaculate finish to large size and complex parts , very important quality criterion for
outer body parts of any vehicle. A tandem line of 4 mechanical presses (1000 ton, 600 ton,
400 ton and 315 ton) with large bed size (3.25 meter x 1.8 meter) operates very efficiently
on large size panels.
Stand alone 315 ton press with bed size of 2.5 meter x 1.6 meter accommodates
progressive tools of medium and small size components. 160 ton and 100 ton presses
address needs of brackets, reinforcements, frame add-ons and other small and child parts
with low and medium volumes.
Welding and Assembling
CEIPL have in-house welding and assembling facilities to deliver parts in form of a
complete assembly. The facility is capable of Nut/stud welding, spot welding and MIG
welding. An effective network of local suppliers for many ancillary processes ensures that
customers get final product in the shape and finish they need. Processes outsourced
include painting, coating, riveting, hardening, tempering, brazing, etc. All vendors are
ISO/QS certified and are dedicated to honour our commitments to customers. CEIPL also
offer door hemming services to leading automobile OEMs. Set in view are hemming
operations on doors of Eicher's commercial vehicles.
Tools and Dies
CEIPL provides its clients with end-to-end solutions. We organize tool procurement for a
wide range of automotive parts. Tools are sourced from Vendors across the globe with
proven expertise. Having an effective network of tool manufacturers has helped us
crashing pre-start of production time and tool costs drastically, particularly for large scale
product development projects. Our customers have trusted us for tool procurement. The
plant also contains a Tool Maintenance facility, which takes care of routine maintenance. It
has skilled people and necessary equipment for maintenance like Die-spotting press,
Lathe, Surface Grinders, Radial Drill, milling machines, etc.