a project report on high volume production trial

Deepak Sapra
Company Profile
Introduction to Plant
Heat Treatment
Paint Shop
Testing Lab
Steering System
Effective Project Mgt
Process Flow Charts
• Sona Group
In the automative component industry, Sona is a name that
stands for quality, dynamism, multifacated growth. With its
beginning as a small company in 1897, now Sona group comprises
company each of which are in joint venture partnership and
technical and financial collaboration with global leaders in their
specialist areas. The Sona group comprises five operating and two
services organizations.
• Sona is driving upon the strengths of its joint venture partners,
which includes Koyo Seiko co. Japan; Mondo Korea; Mitsubishi
Materials co. Japan; Somic Ishikawa, Japan; Fuji autotech,
France& Fuji autotech AB, Sweden and ZF Lemforder, Germany to
upgrade its systems, Skills, and Production values to offer its
customers contemporary and high quality products.
SONA KOYO-Patners of Choice
Sona koyo the flagship company of the Sona group is currently the largest
manufacturer of steering systems for the passenger car and utility vehicles market
in India, with a Market share of 45%. Its collaborator and partner Koyo Seiko
Company limited, Japan, is the market leader in Japan and has recently announced
a merger with Toyota Machine Works, making it number one steering systems
manufacturer in the world. The company also has a technological collaboration
with Ando Corporation, Korea.
The Deming Award, the world’s most coveted Honour for excellence in Total
Quality Management was awarded to Sona Koyo on 11th November 2003
Sona koyo steering system ltd. is a technique and financial joint venture company
of koyo Seiko Company, Japan—the global technology leader in steering systems.
The company is the largest manufacturer of steering gears in India and is the
leading supplier of—
Hydraulic power steering system
Manual rack and pinion steering system
Collapsible, tilt and rigid steering columns for passengers vans and MUVs
Tata Motors
Mahindra &Mahindra
Swaraj Mazda
Ashok Leyland
Honda Motors
Punjab Tractors
International Tractors
Bajaj Tempo
Koyo Seiko (Japan,US)
Mistibuishi Materials
Case New Holland
Maval Manufacturing
JCB Excavators Ltd.
Company Performance, History & Plan
• Sona Koyo Steering Systems Limited (SKSSL) is a technical and
financial joint venture company of Koyo Seiko Company, Japan. The
company is the largest manufacturer of steering gears in India. The
company’s product range also extends to Rear Axle Assemblies and
Propeller Shafts. The World Economic Forum named the company
as a Global Growth Company in 1997.
• SKSSL aims to achieve
• Zero accidents
• Zero defects
• Zero breakdowns
• “Commitment to defect prevention and continuous improvement
while meeting or exceeding customer requirements at all times.”
Future Plans
• The management of the company has chalked
out a plan known as Vision 2011. Salient features
of the plan are as follows:
– Vision 2011 looks ahead to maintain No. 1 position in
the long run.
– The present contribution of exports to the total
turnover is a mere 2%. The company plans to increase
it to as high as 45% of the total turnover by the year
• From being a Rs. 250 crores company presently,
the management wants to make it a Rs. 2000
crores by the end of the year 2011
Introduction to Plants
• SKSSL has a total of four plants, each of which manufactures
different products. Plant I manufactures RPS Assemblies, rigid
columns collapsible columns and tilt steering assembly. Apart from
the assemblies themselves, the various in-house parts like Rack,
Pinion, Case gear etc. that are used in the manufacturing of these
assemblies are made in Plant I. Apart from this, various other
brought out parts (BOP) are used such as Bellow, Rack cover, Rack
housing etc
• Plant II is slightly bigger and manufactures a larger number of items
than Plant I. The most important of the products manufactured
here are the RBS Assemblies for various models, Propeller Shaft
Assemblies and Axle Assemblies. In addition to these assemblies,
the sector shaft assemblies that are used in the RBS Assemblies, the
Slide Yoke and Flange Yoke Assemblies that are used in the
Propeller Shaft Assemblies.
Differential Assemblies that are used in the Axle
Assemblies are also made in this plant. Various
in-house products like the sector shaft, wormshaft, bevel gear, spider and ball-nut are made
in Plant II.
Plant III is also known as the Power Steering
Plant and it started in 1998. The plant makes
Power Steering Assemblies and has just an
assembly line currently.
Plant – I
1)Pinion Soft
2) Pinion Hard
3) Rack Bar
4) Case Gear
5) RPS Assembly
6) Universal Joint
a) Manual
b) Automatic
7) Collapsible Column
Plant ll
• Process
1. Ball Nut Soft Line & Hard line
2. Worm Shaft Soft Line
3. Sector Shaft Soft Line & Hard Line
4. RBS Housing
5. RBS Assembly
6. Bevel Gears
Manual and Automatic
7. Axle Assembly.
Plant lll
• Process
1. Cylinder Tube Machining
2. Rack Bar for Power Steering
3. Case gear for Power Steering
4. RPS Power Steering Assembly
Heat Treatment Plant
Quenching: This plant in SKSSL has three Sealed
Quench Furnaces. Two of them are hot oil
quench furnaces while the third one is cold oil
• Tempering: It is the process of heating the
components to be quenched at 160-170°C
proceeds quenching. The process softens the
material a bit so that it does not crack when
used due to over hardness
Central Lapping: This process is carried towards
the end of the heat treatment cycle. Here, the
preexisting holes are cleaned and chamfered.
Shot Blasting: Shot blasting is a process to improve
the surface finish of the components after heat
Engineering Testing Lab
• This lab is located in Plant II. The lab is operational all the
time and testing of various components is done here
periodically to make sure that the quality of the products
is of utmost quality. The various tests carried out in the lab
• Bellow Durability Test: To check for cracks, abrasions and
breakage in the bellow while operating under very hot or
very cold conditions.
• Column Durability Testing: Here input is a rectangular
waveform given from the handle side of the column.
• Steering Column Impact Testing: In this test, a body block
is attached to a linear actuator and through this system; a
thrust is given to the steering column. Sufficient thrust is
given to cause breakage of the column.
Steering Column: The steering column consists of the main
steering shaft, which transmits the steering wheel rotation to the
steering gear, and the column tube that fixes the steering main
shaft to body. The top end of the steering main shaft is tapered
and serrated, and a nut fits the steering wheel to it. The bottom
end of the steering main shaft is connected to the steering gear,
generally by way of a universal joint to minimize the transmission
of road shock from the steering gear to the steering wheel.
Steering Gear: The gears in the steering gears in
the steering gear assembly not only steer the
front wheels but, at the same time they act as
reduction gears, reducing steering wheel turning
effort by increasing the output torque. The
reduction ratio is called the steering gear ratio
and is normally between 18 and 20:1. A larger
ratio reduces the steering effort but makes it
necessary to turn the steering wheel more when
going around a curve.
There are various types of steering gear systems, but
the rack-and-pinion type (RPS) and the recirculatingball type (RBS) are most commonly used on current
(SKSSL) produces both types of steering systems
Re-circulating ball screw type manual
steering system
High Volume Production Trial
• Purpose of “High Volume Production Trial” (it is
called “HVPT” hereafter) is to communicate the
Product Quality Planning and Control Plan
requirements as well as defining the procedure
for conducting a High Volume Production Trial
(HVPT) and to judge whether or not the mass
production can be started for the line. This shall
be conducted before Start of Production (“SOP”)
for smoother launch of the new product.
2. Scope:
This procedure shall be applied to item (1),
however, for items (2) and (3) it can be applied
according as this procedure, too.
(1) The new product.
(2) The product in mass production but the
volume is greatly increased.
(3) The mass production product but there is a
quite big process change.
3. APQP:
The supplier shall perform the activities specified
in the Advanced Product Quality Planning and
Control Plan (APQP) and maintain documented
evidence of such activities.
4. Timing to implement:
The supplier shall perform the HVPT to reduce the
likelihood of any quality or quantity related problems
occurring at the Start of Production (SOP) by
simulating Mass Production conditions.
I.) Pre-conditions for conducting HVPT
II.) Check items to conduct the HVPT
5.Items to be checked during HVPT
•Standardized Work; Has Standardized Work
Chart (SWC) been provided?
And are operators working as per SWC?
6. Implementation of HVPT
6.1) The Role of Leader for HVPT
He must get together all people concerned,
operators, and supervisors, others who
concerned and must explain important points for
Give a signal for starting and finishing time for
6.2) The Role of Time Keeper
To keep record of the time and happenings those
are observed during HVPT.
7.Meeting after HVPT
After HVPT the Leader must hold a meeting with
concerned people, Time keeper, etc. and discuss
and/or confirm the followings
•Evaluate each items of No.5, above mentioned.
(2) Make summary sheet for Problems and Action
plan for countermeasures and/or improvement
against observations during HVPT. See attached
(Action plan shall be posted near the line and to
be followed-up.)
(3) In case of NG for HVPT judgment, decide the
date for re-HVPT.
•All countermeasures related to Quality and
Safety should be closed before start of mass
•HVPT should focus on meeting peak volume
requirement of the customer.