Presentation on Summer Training at

SONA KOYO STEERING SYSTEMS LTD, SANAND,GUJARAT

by Ashutosh Prakash(1021130074)

Under the guidance of Vinod Kumar(Training officer)

Department of Mechanical Engineering SRM University Delhi NCR Campus

April -2013

2

CONTANTS

• Introduction to SONA• Products• Departments in the company• Customers• Assembly lines• Differential case assembly• Kaizen• References

3

INTRODUCTION ON SONA

• Company was established in 1987• Now SONA group comprises of many companies each of which are in joint venture

partnerships • SONA KOYO Steering Systems Limited (SKSSL) is a technical and financial joint

venture company of Koyo Seiko Company, Japan• largest manufacturer of steering gears in India With a Market share of 50%

4

PLANT LOCATIONS

GURGAON PLANT CHENNAI PLANT

DHARUHERA PLANT SANAND PLANT

5

PRODUCTS

• Case Differential (Fiat Punto)• Collapsible Column (Tata Nano)• Column Assembly (Mahindra ltv)• IMV Column (Mahindra ltv)• Column Assembly (Tata Nano)

6

7

DEPARTMENTS IN THE COMPANY

• Production planning department• Human resource department• Production department• Quality control department• Packaging and dispatching unit

8

Customers

9

ASSEMBLY LINE’S IN COMPANY

Plant have three assembly lines:-

1. Differential case line

2. Column line

3. RPS line

10

DIFFERENTIAL ASSEMBLY

11

DIFFERENTIAL HAS THREE JOBS

• To aim the engine power at the wheels• To act as the final gear reduction in the vehicle, slowing the rotational speed of the

transmission one final time before it hits the wheels• To transmit the power to the wheels while allowing them to rotate at different

speeds (This is the one that earned the differential its name.)

12

WORKING

• When a car is driving straight down the road, both drive wheels are spinning at the same speed.

• The input pinion is turning the ring gear and cage, and none of the pinions within the cage are rotating -- both side gears are effectively locked to the cage

• When a car makes a turn, the wheels must spin at different speeds• the pinions in the cage start to spin as the car begins to turn, allowing the wheels to

move at different speeds

13

MANUFACTURING OF DIFFERENTIAL CASE

• Rough turning (CNC)• Semi finish turning(CNC)• Finish turning(CNC)• Milling ,drilling, reaming ,tapping(VMC)• Washing of the case• Pinion gears and yoke gears are assembled

with washer inside the case

14CNC USED FOR ROUGH,SEMI ,&FINISH TURNING

15

AFTER CNC OPERATIONBEFOR CNC OPERATION

16

VMC USED FOR MILLING,DRILLING,REAMING

17

AFTER VMC OPERATION

18SPM FOR WASHING PURPOSE

19

PTM

• Later the differential assembly is tested on PTM (Performance testing machine) for torque transmitted to the wheel

• Graph of the case plotted• first finished case is then checked by the quality department.

20AFTER TESTED IN PTM

21STACKED FOR PACKAGING

22

KAIZEN

• KAIZEN is a Japanese word meaning gradual and orderly, continuous improvement

• KAIZEN is a business strategy involves everyone in an organization working together to make improvements “without large capital investments”.

23

REFERENCES

• Google images• Wikipedia• Howstuffworks.com

24

Thank you