PUNJAB BEVEL GEARS
INTRODUCTION
Sahibabad
Sitarganj
Sahibabad
INTRODUCTION
GROUP COMPANIES
SAHIBABAD
UTTAR PRADESH
4 PLANTS*
Differential &
Transmission
Gears and Shafts
LUDHIANA
PUNJAB
2 PLANTS
Forging
Machining
Axle Shaft
SITARGANJ
UTTARAKHAND
3 PLANTS
Differential &
Transmission
Gears, Differential cage
and Drive line parts
*There are 4 manufacturing units all located within 500 metres in Sahibabad.
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
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
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
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
PRODUCT RANGE
Crown Wheel & Pinion
(Face Mill and Face Hob Wet Cutting process)
Crown Teeth Cutting
Pinion Teeth Cutting
Crown & Pinion Testing
PRODUCT RANGE
St. Bevel Gears & Pinions
(Gleason Coniflex System)
Teeth Cutting
Gear & Pinion Testing
Teeth Cutting
PRODUCT RANGE
Transmission Gears and Shafts (Spur, Helical)
CNC Blanking
CNC Hobbing
Spline Hobbing
Stack Hobbing
PRODUCT RANGE
Transmission Gears and Shafts
(Products)
PRODUCT RANGE
Differential Cages
CNC Machining
CMM
PRODUCT RANGE
Axle Shafts
GROUP TURN OVER (Mio Rs)
GROUP TURN OVER (Mio $)
SEGMENT WISE SALES FY13-14
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%
6.
Differential Cage
48,000 Nos.
40%
7.
Drive Line Parts
200,000 Nos.
* On 2 Shift Basis
---
CAPABILITIES - GEARS
TYPE
SPIRAL/
HYPOIDS
STRAIGHT
BEVEL
SPEED
GEAR
MAX. SIZE (DIA) MM
600
216(10:1)
152(1:1)
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
TRANS.
SHAFT
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
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
MANPOWER
Sahibabad
Ludhiana
Sitarganj
Hourly
335
165
100
Supervisory
47
07
12
Manager
13
01
02
Total
395
173
114
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
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
CUTTING EQUIPMENT INSTALLED
AT SAHIBABAD/LUDHIANA
CNC Turning Lathes
39 Nos.
Vertical Machining Center
10 Nos.
Gleason Crown Wheel
(608/609, 606/607, No. 22, No.11 & No.112)
9 Sets
Gleason Pinion
(No.116)
7 Sets
Oerlikon
(SM3, S17, SKM1)
9 Nos.
CUTTING EQUIPMENT INSTALLED
AT SAHIBABAD
Transmission Gears
Hobbers
CNC Hobbers
3 nos
CNC Shaper
1 no.
Shapers
34 nos
Shavers
14 nos
Shobbers
Straight Bevel Gears
30 nos
1 no
Gleason Coniflex114
02 nos
Gleason Coniflex104
02 nos
Coniflex WMW
34 nos
HEAT TREATMENT FACILITIES
Sealed Quench Furnace
Sealed Quench Furnace
Continuous Gas Carburising Furnace
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
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
(503/506/119/516)
- 12 Nos.
•Gear Testers-Gleason
(502/511/17-A)
- 18 Nos.
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
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
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.
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.
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
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
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
CUSTOMER PROFILE–DOMESTIC OEMs
AUTOMOTIVE
•Tata Motors
•Mahindra & Mahindra
•American Axle &
Manufacturing
•Scooters India
CUSTOMER PROFILE–DOMESTIC OEMs
AGRICULTURE
•Tractors and Farm Equipment
•International Tractors
•John Deere Equipment
•Dana India
•Indo Farm Equipment
•Sicma India
CUSTOMER PROFILE–EXPORT OEMs
•Meritor, Brazil
•Dana, USA
• Hema Endustri A.S.,Turkey
•Mega Motors Company, Iran
•Iran Tractor Mfg Company, Iran
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.
FORGING FACILITIES AT LUDHIANA
Steel Yard
Friction Belt Drop Hammer
Annealing Furnace
Up Setter
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
FACILITIES AT SITARGANJ
Latest Generation
Gleason Phoenix
CNC Dry/Wet
Cutting
System
FACILITIES AT SITARGANJ
Pinion Teeth Cutting Line
Sealed Quench Furnace
Forging Press
Crown Teeth Cutting Line
Phosphating Plant
Forging Press
Lapping & Testing Line
Metallurgical Lab
Annealing Furnace
FACILITIES AT SITARGANJ
•
Green Field Plant Production started from March 2010.
•
Equipment at the Plant:
Gleason Phoenix CNC Cutting(600 HC)
Gleason Phoenix CNC Cutting(275 HC)
CNC Blade Profile Grinder
CNC Cutter Build Machine
CNC Gear Measuring Machine
Gleason Pinion Generator(No.116)
Gleason Crown Wheel(606/607, No.22)
Hobber
Shaper
Shaver
Milling
External Grinder
Internal Grinder
CNC Lathe
-- 1 No.
-- 1 No.
-- 1 No.
-- 1 No.
-- 1 No.
-- 5 sets
-- 5 sets
-- 15 nos.
-- 9 nos.
-- 5 nos.
-- 4 nos.
-- 6 nos.
-- 6 nos.
-- 4 nos.
FACILITIES AT SITARGANJ
Gleason Lapper(503, 506, 514)
Oerlikon Lapper SKL 1
Gleason Tester(511, 512, 17A)
Continuous Gas Carburising Furnace
Sealed Quench Furnace
Gas Carburising Furnace
Rotary Furnace
Gleason Quenching Press
(537)
Shot Blasting Equipment
-- 4 nos.
-- 1 no.
-- 6 nos.
-- 1 no.
-- 1 no.
-- 2 nos.
-- 1 no.
-- 2 nos.
-- 1 no.
•
Fully Equipped Metrology and Metallurgical Laboratory
•
100% captive power back up
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@pbgl.in URL: www.pbgl.in
Unit-II :
B-174, Phase –I, Eldeco Sidcul Industrial Park,
Sitarganj -261453, Udhamsingh Nagar ,
(Uttarakhand), INDIA
Email: sitarganj@pbgl.in
Unit-III:
V&PO: Bhama Kalan,
Kohara-Machiwara Road,
Ludhiana- 141115(Punjab), INDIA
E-mail: ldh@pbgl.in