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WEL-COMES

Zanvar Group of Industries (Established in 1982). WEL-COMES. MANUFACTURERS OF MACHINED COMPONENTS IN GRADED GREY CAST IRON, DUCTILE IRON, COMPACTED GRAPHITIC IRON . Presentation Update. Zanvar Group update Customer Base Manufacturing Capabilities Design & Development Capabilities

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WEL-COMES

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  1. Zanvar Group of Industries(Established in 1982) WEL-COMES MANUFACTURERS OF MACHINED COMPONENTS IN GRADED GREY CAST IRON, DUCTILE IRON, COMPACTED GRAPHITIC IRON .

  2. Presentation Update • Zanvar Group update • Customer Base • Manufacturing Capabilities • Design & Development Capabilities • Technical Strengths & Up-gradation • Employee Involvement initiatives • Rewards & recognitions • 2014 & beyond

  3. ZANVAR GROUP UPDATES

  4. Quality Policy It is our policy to provide customers with product or services that meet or exceed their expectations emphasizing product & employee safety. Everyone should look at their next process as the “Customer". Continual improvement shall be the way of our life by which we shall strive to achieve customer delight in our Business of Finished Castings. R. S. Zanvar Date : 22/11/08 Chairman

  5. Sales Growth. 500 Crs. 420 Crs. Export 405 Crs. Domestic

  6. GROUP COMPANIES(Foundry Division)

  7. GROUP COMPANIES (Machine Shop)

  8. Machining Facilities

  9. CUSTOMER BASE

  10. Customer (Domestic) FARIDABAD PITHAMPUR ESCORTS LIMITED & CLASS INDIA VOLVO EICHER UTTARAKHAND RUDRAPUR CUMMINS INDIA TATA MOTORS , MAHINDRA TATA MOTORS CARRARO INDIA PUNE TACO HENDRICKSON JOHN DEERE KNORR BRMESE NAGPUR & RUDRAPUR MAHINDRA & MAHINDRA KOLHAPUR CHENNAI

  11. Customer (Overseas) Cummins UK Conmat USA John Deere France Knorr-Bremse France Cummins Inc. USA Italy & Poland FMC USA MJD Mexico Germany International Truck

  12. MANUFACTURING CAPABILITIES (Casting WT. 1 Kgs. – 150 Kgs.)

  13. Engine Components Cylinder Block (3 variants) Cylinder Head (2 variants) Flywheel & FWH (8 variants) T. G. Covers (4 variants) Bearing cap & pulley (7 variants) Manifold (20 variants)

  14. WABCO CRANKCASES & HOUSINGS • Shriram’s Business Expectations from Wabco • To reach the volume of 50,000 Crankcases per month in 2014-15 with Sales 60 Crs. • Joint Venture with Wabco for ASA Body project. • Development of Rotors for Wabco and expansion of annual capacity to 1 lacks. • Up-gradation of Machine Shops in line with Wabco Standards for Crankcases, Housings, ASA • Body & Rotors.

  15. PULLEYS

  16. Drivetrain Components Structural castings (3 variants) Front Axle support (3 variants) Axle housing (8 variants)

  17. Hydraulic Components Rockshaft housing (5 variants) Rockshaft Cylinder (3 variants) Housing (5 variants) Hydraulic lift hsg. (2 variants) Oil Filter Adapter Housing

  18. Braking System Components Ventilated brake disc (7 variants- CG iron) Brake Drum (10 variants) Brake Hub (30 variants) Crankcases (15 variants)

  19. Heavy Engineering Components Backhoe (2 variants) Support/ Brackets (3 variants) Transmission Covers (8 variants) Head Lube Oil Filter Gear Cover Gear Housing

  20. Development of John Deere Components in shortest period Saddle FT4 Intake air manifold FT4 55 HP Flywheel Hsg. VASCO FT4 Pulley FT4 Clutch Housing SU28837PY op. 10 Rear Axle Housing SU29522

  21. Cummins IPO - Engine Parts Nut Plates Gear Housing Front Engine Supports

  22. Customer wise Capacity Distribution

  23. DESIGN & DEVELOPMNET CAPABILITIES

  24. PROCESS DESIGN JIGS , FIXTURE & GAUGE DESIGN Design Capability SPECIAL PURPOSE MACHINE DESIGN • Zanvar Group has a Process Engg . capabilities to design the robust process for Critical automotive & other Engg. Application parts • Involvement of MDT in APQP helps to develop the parts in record time • FMEA in place to Eliminate the failures at development stage & supply of parts right first time. • Development of Cummins FES in one Month time • Zanvar Group has state-of-the art infrastructure to design and Manufacture Jig & Fixtures in House. • Design & Development of new SPMs / solutions with advanced Technology for Group’s internal requirement

  25. TECHNICAL STRENGTH & UPGRADATION

  26. Technology Up gradation Program (DISA Flask less Molding Line at ALPL) • Weight and jacket • transfer station. • Auto Jacket & pallet cleaning station. • Box Size – 713 x 613 x 510 mm • 120 Boxes per Hour (Un-cored) • 100 Boxes per Hour (Cored) • Box Weight – 50 Kgs. Max. • Total Melting Capacity – 2500 Tons /Month, Melt Rate – 5 Tons per Hour. • Inductotherm Furnaces – 2600 KW Tritrack with converter. 1.5 Tons 3 crucibles with hydraulic & remote control system. • Auto Pour - 2 Tons Tundish with p3 • vision control auto • positioning & Z axis • (150mm) with manual changeover arrangement • High speed TM 190 Centrifugal • Sand Mixer • Capacity – 1 Ton per 80 Sec. • 150 Tons Sand Storage Hopper • Sand Cooling & Dust extraction system for a Plant • Horizontal parted Molds • Flexible down sprue system • Auto core setting station • Mismatch below 0.25 mm

  27. EMPLOYEE INVOLVEMENT INITIATIVE

  28. TRAINING QUALITY CIRCLES Employee Involvement EMPLOYEE MOTIVATION • The Management of Zanvar Group has taken an initiative for overall Development of all Level of Employees , Top Management, Middle Management, Supervisors & Workers. • To make this Group as a Learning Organization • Across the Zanvar Group, Total 40 Quality Circles have been formed and 400 Trained employees are working on various projects. One step towards the Employee empowerment & continuous improvement. • Under Employee motivation scheme, initiative has been taken to recognize the best Employees from all the Units of Zanvar Group on Quarterly and Yearly.

  29. VOICE OF THE CUSTOMER ‘SETU’ HOUSE JOURNAL PUBLICATION Initiative towards Customer Satisfaction ZERO DEFECT DAY & 5’S’ IMPLEMENTATION • A common platform for exchanging New Ideas, Customer expectations, Management expectations & directions, Technology up-gradation, recent changes in the Organisation and the Industry. • First day of new Year 2013 i.e. 2nd Jan.13 was celebrated as ‘Zero Defect Day’ in Zanvar Group. Commitment towards achieving excellence. • The Management of Zanvar Group is committed to satisfy the Customers by understanding their expectations. • Initiative introduced to organize visit of Customers to understand the ‘Voice of the Customer’ by all our Employees.

  30. REWARDS & RECOGNITION

  31. ISO 9001:2008 ISO accreditation for all Major machine Shops manufacturing precision components. ISO/TS 16949:2009 All Foundry units are TS 16949 :2009 certified. AWARDS & CERTIFICATIONS TATA Quality Excellence Award Quality Excellence Award from from TATA Motors for 2008 JD Overall performance Award Overall performance Award by John Deere for 2011 Cummins Excellency Award Project Management Excellence Award by CUMMINS in 2012.

  32. Best Supplier Award Best Supplier Award by TACO HENDRICKSON in 2012. Export Excellency Award Export Excellency Award by EEPC IN 2000. Star Export House Award Star Export Award by Govt. of India, Ministry of Commerce & Industry ‘Growth with Quality’ Award from Tata Motors for 2012. TATA - Growth with Quality ‘Product Development Process’ Award by John Deere in 2013. for shortest lead time in FT4 project. John Deere PDP Award

  33. Best Performer Award Overall Best Performer of the Year by Escorts in 2013. New Publication Award ‘New Publication’ for year 2013 for SETU by Association of Business Communicators of India (ABCI) Special Recognition IN Pokayoke. Special Recognition in Pokayoke by KOEL. Special Recognition for Development Special Recognition for Fast Development response by KOEL 2014.

  34. 2014 and beyond

  35. 2014 and beyond …….. • Sales Target – • 2013-14 - 500 Crs. (100 Million USD) • 2014 -15 - 600 Crs. (120 Million USD) • Expected Sales from new projects – • 2013-14 - 150 Crs. (30 Million USD) Additional 200 TPM from FT4 Project • 2014 -15 - 175 Crs. (35 Million USD)(Expect 500 TPM from Wabco with Annual 60 Crs. Sales) • Foundry Capacity – • 2013-14 – Generate Additional 1000 Tons/month • 2014- 15 –Generate Additional 500 Tons/month • Technology Up-gradation - • Up-gradation of conventional Foundry line with HPML – 2015. • Investment in Latest Machining Centers & development of Machine shops in line with Wabco’s Std. • Use of Robotic in operations & Material Handling systems at Foundry as • well as Machine Shop. • Diversification : Establish Aluminum HPDC foundry. • Advance Training to Employees

  36. Thank You

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