CHAPTER-1

COMPANY PROFILE
GKN Driveline India LTD traces its origin back to 1986 when Invel Transmissions Ltd, as it was then
known, was established. Three years later the company became the first in India to manufacture side shafts
for front wheel drive vehicles when it was selected sole CVJ supplier for Maruti Suzuki at that time the
only front wheel drive car manufacturer of the country.
Later known as GKN Drive shafts (India) Ltd, the operation became a owned subsidiary of GKN Driveline
in 2002 and is today the side shaft market leader in India with an installed capacity to manufacture over one
million units (half a million vehicle sets) a year. Sales in 2003 stood at more than 23 million pound.
The companys growth in the 1990s was strongly linked with its supply of side shafts for the Government
of Indias joint venture with Japanese car maker Suzuki Motor Corporation to make front wheel drive cars.
Beginning with the Suzuki Maruti 800cc model in 1989, production rapidly expanded and GKN currently
supplies all front wheel drive cars for the company (800cc, Zen, Wagon-R. Gypsy, Esteem, Baleno and
Swift)
During the late 90s GKN Driveline India began supplying product for other major customers. In 1996 it
was selected sole supplier to Fiat (Uno, Siena and Palio models) and Ford (Escorts/Ikon) in India. Two
years later it became sole supplier to Korean manufacturer Hyundai Motors ( Santro , Accent, Sonata and
Getz) and began working with Tata Motors ( Indica ), one of the largest business house in India. In 2000
Honda (City) and General Motors (Corsa) were added to the customer base.
1.1 VISION & VALUES
THIS IS GKN

Technology and engineering from GKN is at the heart of the vehicles and
worlds leading automotive and aerospace manufacturers.

aircraft produced by the

More than 50,000 peoples work in GKN companies and joint ventures in more than 37 countries. Everyday
we harness our considerable technology and manufacturing resources to supply the highest quality systems,
structures, components and services
When we fulfill the trust of our customers place in us then we can enrich our Shareholders reward our
people and support our communities.
And because we respect the environment and the dignity and human rights of others we are building a
business, which can be sustained by future generations.
Everyone involved with a great company should expect nothing less. But those with a Stake in the
performance of GKN should expect more.
21st century global leadership in our four major businesses, when our
History spans more than 250 years, speaks for standards of agility, innovation and excellence, which would
be difficult to surpass.
Customer and quality
To provide excellent and continuously improving products and services to exceed our customers
expectations.
To be the best in class in terms of value through quality, technology, speed, performance and
innovation.
To treat our suppliers fairly as an integral part of our total capability to serve our customers.

1.2 Enterprise and Innovation

To foster the spirit of enterprise

To

using initiative

To move with speed in our business processes.

grow profitability by managing risk, being innovative and

To inspire outstanding performance from teams and individuals and to recognize and
appropriately reward achievement.

To encourage employees to fulfill the potential for the benefit of both themselves and the
organization.

To foster teamwork and individual achievement within a culture of empowerment and

accountability.

To share knowledge and best practice across our companies to stimulate the creation of new
business opportunities.

To provide equal opportunity irrespective of sex, sexual orientation, disability, Religion or ethnic
origin.

To provide a safe environment.

1.3 Community, environment and business ethics

To act with integrity at all times
To meet standards of good corporate governance.
To play our part in safeguarding the environment
To contribute positively to the communities in which we operate.

CHAPTER-2
PLANT

IN INDIA THERE ARE THREE PLANTS OF GKN WHICH ARE LOCATED AT DIFFERENT
SITES IN THE COUNTRY

FARIDABAD PLANT

DHARUHERA PLAN

ORAGADAM PLANT

2.1 FARIDABAD PLANT:

GKN Driveline India traces its origin back to 1986 when Invel Transmissions Ltd, as
It was known, was established. Three years later the company became the first in India
To manufacture side shafts for front wheel drive vehicles when it was selected sole CVJ
Supplier for Maruti Suzuki at that time the only front wheel drive car manufacturer in the
country
Faridabad plant is the mother plant in the country. Plant is situated in sector-24, Faridabad. This
plant is 30 km away from the national capital. This plant acquired a area about 40,000Sqm.
280peoples are working here. This plant is established in 1986 and the production starts from
April 1989. In all of the other three-plant Faridabad plant is the major plant. Faridabad plant is
the manufacturing plant. All the sub-parts are made here.

2.3 DHARUHERA PLANT:

This plant is set-up in14th January 1997. This plant acquired a area about 68,000Sqm.

The built up area is about 4,500Sqm.It is 75 km away from the national capital. There are over
150 employees at the plant which has responsibility for side shaft assembly and delivers to
customers Maruti Suzuki, Tata Motors, Honda, General Motors and Fiat.
In this plant GI joints are manufactured. Most of the assemblies like bell, tripod, pot, and shafts
are done here.

2.4 ORAGADAM PLANT:

Plant is established in 1st April, 1996.It is situated 60 kilometers from Chennai, and it has 22
employees and two assembly lines for JIT supply requirements for customers Hyundai and ford.
This plant acquired a area about 4000Sqm. In which built up area is 2000Sqm.

GDI LOCATIONS
Dharuhera

Fig. 2.1 GDI: Faridabad Plant

Commenced operation on 13th April, 1989
Land area 40,000sqm (Built-up 15,500sqm)
Manpower 339

Faridabad

GDI: Dharuhera Plant

Commenced operation on 14th January, 1997
Land Area 68,800sqm (Built-up 4,500sqm)
Manpower 150

GDI: Oragadam Plant

Commenced operation on 1st April, 1996

Land Area 4,000sqm (Built-up 2,000sqm)

Manpower 205

GKN HISTORY

GKN DRIVESHAFTS (INDIA) LTD formerly known as GKN INVEL TRANSMISSION LTD was formed in
the year 1986 was promoted in 1988 by GKN plc. and started commercial production in April 1989.
In November 1995 Invel became a subsidiary company of GKNADD (Automotive Driveline Division) who,
with facilities all over the world, fulfills a large proportion of the worlds demand for CV joints.
The company manufactures drive shafts assemblies made of constant velocity (CV) joints for front wheel
drive and four wheel drive vehicles, mainly passenger cars.
The sophisticated high precision GKN technology required by ball and tripod joint is supported by some of the
latest manufacturing and testing equipment to ensure the highest level of accuracy in every joint coming off
the assembly line from completely integrated production facilities.
The Faridabad plant has full range of facilities used for the manufacturing of bell assembly, Inner race and
DSA. This includes heat treatment and a testing facility available for the validation of the product from all of
the other facilities.
The Dharuhera plant has facilities for the manufacturing of Connecting Driveshaft, Tripod, Tulip and complete
assembly of CV joints with the exception of the tent house and heat treatment.
The Gummidipundi plant assembly facility is effectively an additional assembly cell of Dharuhera, assembling
product and shipping complete driveshaft to local customers.
All the three plants are 1SO9002/ QS9000 & ISO14001 Certified. The company is trying to get TS16949
Certification.
The company has got over 70% markets in the CV Joints in India & over 45% worldwide.
GKN PLC

GKN plc. is an international group of companies with a turnover of around 4.3 billion pounds. The
group designs, develops and manufactures automotive components as well aerospace and defense
products. The group provides a range of industrial services. GKNs operations are located in more
than 30 countries around the world and the group employs around 36,000 people.

The automotive and agricultural products business area is the largest within the group
accounting for over 60% of total turnover. Industrial services and aerospace and special vehicles
each generate approximately 20% of the groups total turnover.
The name GKN is derived from Guest, Keen and Nettlefolds. Its history dates back to 1759.
Starting in iron making and coal mining, the group progressed into steel and its many derivatives,
serving the railways, building and construction, automotive and other major industries. Although
once world renowned steel maker and producer of screws and fasteners, the group has been
through many changes over the last 25 years in response to fundamental shifts in these traditional
markets.

GKN DRIVELINE
GKN is a leading global supplier to the worlds automotive, off highway and aerospace
manufacturers. GKN provides technology-based, highly engineered products to virtually all of the
world's major manufacturers of light vehicles, agricultural and construction equipment, aircraft
and aero engines. Almost 38,000 people work in GKN companies and joint ventures in more than
30 countries
GKN is a multinational engineering company headquartered in Red ditch, United Kingdom. The
company was formerly known as Guest, Keen and Nettle folds and can trace its origins back to
1759 and the birth of the industrial revolution. In 2009 the company celebrated its 250th
anniversary.

GKN Driveline India LTD traces its origin back to 1986 when Invel Transmissions Ltd, as it was
then known, was established. Three years later the company became the first in India to
manufacture side shafts for front wheel drive vehicles when it was selected sole CVJ supplier for
Maruti Suzuki at that time the only front wheel drive car manufacturer of the country.

Later known as GKN Driveshaft (India) Ltd, the operation became a owned subsidiary of GKN
Driveline in 2002 and is today the sideshaft market leader in India with an installed capacity to
manufacture over one million units (half a million vehicle sets) a year. Sales in 2003 stood at
more than 23 million pound.
The companys growth in the 1990s was strongly linked with its supply of sideshafts for the
Government of Indias joint venture with Japanese car maker Suzuki Motor Corporation to make
front wheel drive cars. Beginning with the Suzuki Maruti 800cc model in 1989, production
rapidly expanded and GKN currently supplies all front wheel drive cars for the company (800cc,
Zen, Wagon-R. Gypsy, Esteem, Baleno and Swift)
During the late 90s GKN Driveline India began supplying product for other major customers. In
1996 it was selected sole supplier to Fiat (Uno, Siena and Palio models) and Ford (Escorts/Ikon)
in India. Two years later it became sole supplier to Korean manufacturer Hyundai Motors
(Santro, Accent, Sonata and Getz) and began working with Tata Motors (Indica), one of the
largest business house in India. In 2000 Honda (City) and General Motors (Corsa) were added to
the customer base.

GKN DRIVELINE PRODUCTS

Products
GKN Driveline is the world leader in the design and production of driveline components.
Producing systems and components for small front wheel drive to the most sophisticated four
wheel drive vehicles, GKN Driveline has the products to achieve the optimum driveline solution.
With these products comes technical expertise and an understanding of all aspects that affect
vehicle dynamics and how these can be optimized for weight and performance improvement.

CVJ Side shaft

Premium Prop shafts

Geared Power Transmission Products

Torque Management Devices

Replacement Parts

Motorsport Products

Solution Finder
GKN Driveline has a wide range of products across the vehicle driveline to meet most vehicle
configurations.
With torque products for every axle, front and rear sideshafts and propshafts from one piece to
three pieces - we are sure to have a solution for you.
Select the vehicle configuration you need from the list below to see what solutions GKN
Driveline can offer:
Premium Propshafts
GKN Driveline offers an entire portfolio of propshaft solutions for passenger cars and light
commercial vehicles. They are tailored, tuned and harmonized to suit the characteristics and
performance requirements of each application. Each propshaft is a unique, engineered product.
Configuration Examples

High Speed Fixed Constant Velocity Joints (CVJ)

High Speed Plunging Constant Velocity Joints (CVJ)

Cardan Joints

Other Components

Configuration Examples

High Speed Joints

Other Components

CVJ Sideshafts
GKN Driveline CVJ sideshafts transfer the engine power transversely from the gearbox to the
wheel ends on front wheel, rear wheel and four wheel drive applications. They are optimized for
weight, noise, vibration, harshness (NVH), steering and suspension performance.
GKN Driveline has a unique range of CVJ sideshaft configurations to meet the needs of all types
of vehicle.

Sideshaft CV Joints

Interconnecting Shafts and Boots

Configuration Examples

Sideshaft
A sideshaft is a system that transfers torque from a differential to the driven wheels allowing
wheel movement due to steering or suspension movement. This system has three major elements:

Inboard Constant Velocity Joint (CVJ)

Interconnecting shaft

Outboard Constant Velocity Joint (CVJ)

In most applications, the inboard CV Joint is a plunge joint that allows the effective length of the
sideshaft to change due to suspension travel. In front (or steer) axle applications, the outboard

joint must transfer torque effectively through a wide angle (up to 52 degrees). In rear axle
applications, joint operating angles are much lower.
Geared Power Transmission Products
GKN Drivelines range of power transmission products ensure that driving torque is constantly
transmitted to driving wheels at maximum efficiency, to provide unsurpassed levels of responsiveness
and reliability.
The range of geared products includes final drive units, which transfer torque from propshaft to wheels
in rear- and all-wheel drive (AWD) vehicles, and power transfer units, which distribute torque between
front and rear axles in AWD configurations.

Power Transfer Unit

Final Drive Unit

Differentials

Dual Differential

Drive Module for Motor Assisted 4WD

Power Transfer Unit

GKN Drivelines robust and versatile Power Transfer Units provide full-time or on-demand
AWD torque distribution for front wheel-drive based AWD systems. Tailored designs provided
compact and cost effective AWD driveline solutions.
Benefits

Aluminum construction

Compact designs

Used in front-wheel drive based vehicles with transverse engine mount

Available in part-time, full-time and on-demand AWD configurations

Available installation of various differential or coupling

Final Drive Unit

GKN Drivelines proven and reliable Final Drive Units (FDU) for front and rear
independent axle applications, offer robust performance and versatility for all-wheeldrive and real-wheel-drive drivelines.

Differentials

GKN Driveline offers a wide range of open bevel gear differentials for use in passenger cars,
sport utility vehicles (SUVs) and light truck transmissions of final drive units.
Design Features

Available in eight sizes ranging from 3.000 to 20.000 Nm differential input torque

Available in both 2-pinion and 4-pinion design

Bevel gears are either cut or cold formed

Compact and cost competitive designs

SUPPLIER NETWORK
Company has 17 local direct material suppliers, 21 overseas direct material suppliers, 15 local
sub contractors & over 300 suppliers for In-direct materials. In indirect material suppliers there
are 238 local suppliers, 42 technical service providers & 19 general service providers.

Figure 2.2 : Supplier network at GKN

Direct Material-Local

Direct Material-Ov erseas

Sub Contractors

12%

68%

5%
5%

4%
6%
Serv ice-Technical

Serv ice-General

IDM - Local

Budget for direct material is made every year based on the customer forecast & based on the
budget for direct material Purchase planning is made.

xFigure 2.3 : Budget for Direct Material

Pforging

Jt Parts

Forgings

Rubber Boots

Steel

Bearings

2%

7%
7%
8%

2%

3%

4%

32%
3%
15%

Sheet Metal

Grease

Steel Balls

ORP

16%

Plastic Boots

 BRIEF DESCRIPTION OF MAJOR COMPONENTS

Major components required for manufacturing of Driveshafts are Outer Race (Bell), Inner Race,
Cage, Tulip, Shaft, Male & Female pot. Besides these other components are Tripod, Rubber boot,
Clamps, Steel Balls, Damper, needle roller Bearings,

GDI- Organization Chart

GKN Customers In INDIA