AURANGABAD ELECTRICALS LTD

Sep 2015
1
ABOUT BAGLA GROUP

2
INTRODUCTION
Bagla Group was established in 1985. It is one of the leading auto component manufacturing companies in India
It has 8 manufacturing facilities across western and northern India
The group sales turnover is of INR 8.7 Billion for the year 2014-15
Industry Presence - Automotive

Manufacturing facilities / Capabilities:
o Die Designing & Manufacturing
o High Pressure & Gravity Die Casting
o Machining and Surface Treatments
o Sub-Assembly
o Steel Fabrication and Electro Plating
o High Tensile Fasteners
o Automotive electrical parts such as Ignition coil,
Magneto, Starter Motor, Sensor, Flasher, Relay etc
Joint Ventures:
o With Officine Meccaniche Rezzatesi (OMR), Italy for
HPDC
o With LI-IN Electricals, Taiwan for Electrical parts
o With Danielson Engineering, France for design,
engineering, development, prototyping,
manufacturing and testing of prototypes of
powertrain & components thereof
o With Fontana, Italy for High Tensile Steel Fasteners
Subsidiary:
o AE Deutschland GmbH, Germany: Machining of
Aluminium castings

Driven by 1150 qualified personnel

3
GROUP STRUCTURE

BAG LA GROUP

AE Danielson Performance
BGFEIPL* OBASIL** BG-LI-IN
Aurangabad Electricals Ltd. Deutschland
JV With JV With JV With Engineering Ltd
GmbH, LI-IN, Taiwan JV With DE, France
Fontana, Italy OMR, Italy
Germany

HPDC GDC HPDC

Design, Machining of Engineering, Prototyping &
Machining, Machining, Auto High Tensile Machining, Auto
Engg & Aluminium Testing of powertrain &
Painting, Electricals Steel Fasteners Painting, Electricals
Tool room Painting, castings components
Sub- Assy. Sub-Assy. Sub-Assy.

Note:
Danielson Performance Engineering Ltd is in the process of formation
* BG Fastening and Engineering Industries Private Limited
** OMR Bagla Automotive Systems India Limited

4
GROUP HISTORY

R&D Centre
Enters into JV
receives recognition
with OMR
Solution provider across a Holdings Spa
from DSIR2
wide range of automotive
products Establishes plant
Wind Power in Pantnagar for
Alu. Die Casting
components
GDC business Formed subsidiary
becomes part of company AE
AEL on back of Deutschland GmbH
Investment by
restructuring of
High Tensile Blue River Capital
AMML1
Fasteners

Commences Enters JV with

manufacturing of Fontana Finanziaria
high tensile S.P.A.
fasteners
Die Casting BG LI-IN
Shifts focus to be
Electricals Limited
complete solution
is incorporated
provider for die
casting comps.

Establishes die
casting unit
Auto Electricals Incorporation AEL
as a auto electrical
component supplier

1985-1994 1995-2004 2004-2005 2006-2008 2009-2010 2011-2013 2014 - 2015

Notes:
1 AMML - Aurangabad Motor Manufacturers Limited
2 DSIR: Department of Scientific and Industrial Research

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GROUP PRESENCE
Location: Pantnagar
1 HPDC Unit

Location: Aurangabad
2 HPDC Units
1 GDC Unit
2 Electrical Units
1 Fastener Unit

Corporate Office

Location: Pune
1 HPDC Unit

08 Plants across India

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QUALITY & ENVIRONMENTAL CERTIFICATIONS
We commit ourselves to satisfy our customers by manufacturing products synonymous with Quality & Reliability and
total dedication of all our members to achieve the goal.

We adopt continual improvement philosophy in products & processes and also work towards energy conservation &
environment protection & safety.

All plants are certified for ISO 9001 and Plant-3, Plant-6,Plant-9,Plant-N1 & GDC
TS 16949 Certified for OHSAS & ISO 14001

ISO 9001: 2008 ISO/TS 16949: 2009 BS OHSAS 18001: 2007 ISO 14001: 2004

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DOMESTIC & OVERSEAS CUSTOMERS
Two Wheeler OEM Four Wheeler OEM Tier 1 & Non Auto

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GLOBAL CUSTOMERS

Canada Germany Austria (Rotax,

(Magna) (Behr, GPM) Scooter Tech)

Netherlands
(MHIL)

Italy (Aprilia, Thailand

OMR, Piaggio) (MHIL)
USA (Behr,
Chrysler)
Vietnam
India (Bagla (Piaggio)
Group)

Representatives Offices at France, Germany, UK & Italy

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CAPABILITY OVERVIEW
Design & Analysis
Die Design Die Mfg M/C
Unigraphics Tool & Die
NX 8 VA / VE CNC Milling
Manufacturing
Suggestions
Catia V5
R 21 CNC EDM

Proe-Creo-2 NC EDM

Surface
Grinder
Engineering & Process Design &
Design Inputs Development Cylindrical
Die Mfg Grinder

Unigraphics Lathe
NX 8

Work NC Radial
V 21 Drilling

Manufacturing of
Surface Treatment & Casting
Painting
Simulation Inspection
Flow 3D Mitutoyo
V10.1 CMM
Machining & Assembly

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ALUMINIUM CASTING BUSINESS

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FACILITIES: ALUMINIUM CASTING BUSINESS

Plant 3 Plant 6 Plant N1

Plant GDC OBASIL Engineering & Tool Room

Engineering
Description Plant 3 Plant 6 OBASIL Plant N1 Plant GDC
& Tool room
Open Area (Sq. Mt.) 48,969 12,000 24,417 39,000 10,500 6,375

Buildup Area (Sq. Mt.) 12,000 6,000 14,028 11,000 5,000 1,646

Location Aurangabad Pune Aurangabad Pant Nagar Aurangabad Aurangabad

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FACILITIES HPDC & GDC

HPDC Facilities

GDC Facilities

13
FACILITIES: HPDC

14
FACILITIES: GDC
GDC Machine Mounting size No. Of
type (mm) machines
Tilting Type 950 x 520 2
Tilting Type 900 x 450 2
Tilting Type 525 x 300 3
Tilting Type 750 x 600 4
Stationary Type 525 x 300 5
Stationary Type 700 x 600 3

Total 19

Core Machine type Mounting size (mm) No. Of machines

Stationary 600 x 750 2
Stationary 600 x 400 2
Stationary 500 x 500 1
Roll Over 600 x 450 1
Roll Over 820 x 500 1
Roll Over 900 x 500 1
Roll Over 650 x 380 1
Roll Over 400X400 1
Swing Door 800X400 1
Total 9

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FACILITIES: MACHINING , SUB-ASSEMBLY AND SURFACE TREATMENT

Machining Facility

Sub assembly & Painting Facility

16
FACILITIES: MACHINING
Plant 3 Plant 6 OBASIL Plant N1 Plant GDC
Machine Total
Aurangabad Pune Aurangabad Pantnagar Aurangabad

CNC Turning Centre 30 0 19 15 3 67

Turno Mill Centre 0 0 2 0 0 2

Special Purpose Machines 8 2 2 16 0 28

Vertical Machining Centre 50 0 23 14 11 98

Horizontal Machining
Centre
0 2 10 0 0 12

Cylindrical Grinding SPM 7 0 0 4 0 11

Broaching Machine 1 0 1 0 0 2

Total 96 4 57 49 14 220

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FACILITIES: SUB-ASSEMBLY AND SURFACE TREATMENT

Plant 3 Plant 6 OBASIL Plant N1 Plant GDC

Machine / Plant Total
Aurangabad Pune Aurangabad Pantnagar Aurangabad
Assembly Lines for
various components
3 3 2 6 0 14
Automated Pre
Treatment & Painting 1 1 0 1 0 3
Line
Automated Pre
Treatment & Powder 0 1 0 0 0 1
coating Line 3D MODEL RPT MACHINE

Nickel Chrome Plating

Plant
0 0 0 1 0 1

Washing Machine 3 0 4 1 1 9

Leak Testing Machines 8 1 18 5 5 37

Vacuum Impregnation 0 0 2 0 0 2

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FACILITIES: QA INSTRUMENTS

19
FACILITIES: QA INSTRUMENTS
Plant 3 Plant 6 OBASIL Plant N1 Plant GDC
MACHINE Total
Aurangabad Pune Aurangabad Pantnagar Aurangabad

Spectrometer for Al Alloy and Steel

material composition
1 1 1 1 1 5

X-Ray Machine 0 0 1 0 1 2
Co-ordinate Measuring (3D) 2 1 2 1 1 8
Universal Load Testing 1 1 1 1 0 4
Hardness Tester 2 1 1 1 1 6
Mechanical Testing Lab 1 1 1 0 0 3
Techno Scope (porosity) 1 0 0 1 0 2
Surface Finish Tester 1 0 1 1 0 3
Full fledged Room for calibration 1 0 1 0 0 2
Optima Height Tester 0 0 1 6 0 7
Contour Tester 0 0 1 0 0 1
Profile Projector 1 0 0 0 0 1
Roundness Tester 0 0 1 0 0 1
Particle count measurement 1 0 0 0 0 1

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PRODUCTS

Brake Drum
Cylinder Head Suspension Arm
(M/ced & sub Assy)

21
PRODUCTS

Bed Plate Bed Plate Oil Pan

------------------ ------------------ Support Brackets ------------------- ------------------

------------------ ------- Gear Box Covers ------------------ -------- ---Support Brackets ----
-
22
PRODUCTS

---------------------------------------------------------------------------------- Pump Housings ------------------------------------------------------------------------

----------------------------------------------------- Support Brackets ------------------------------------------------------------

23
PRODUCTS

Charge Air Pipes

--------------------------------------- Housings Power take off -----------------------------------------------

------------------------------------------------------------------- Charge Air Housing -----------------------------------------------------------------

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PRODUCTS

Gear Housings RH Gear Housings Center Gear Housings LH

25
PRODUCTS

---------------------------------------------------------------------------- Oil & Water Pump Housings -------------------------------------------------------------------

Rear Hgs. Front Hsg Front Bracket Heat sink

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PRODUCTS

------------------------------------------------------------------------------ Compressor Housings -------------------------------------------------------------------

------------------------------------------------------------------------------ ECU Cover -------------------------------------------------------------------

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PRODUCTS

------- Front/ Rear Brake Panel ---------- Clutch Cover Cover Magneto
(5 million pcs pa) (3.0 million pcs pa)

------ -- Front/ Rear Brake Drum ------ Grip Frame Coupling

(1.5 million pcs pa) (0.85 mil pcs pa) (0.85 mil pcs pa)

---------- Step Holder LH/RH ----------- Master Cylinder Cylinder Block

(3 million pcs pa) (0.5 mil pcs pa) (0.25 mil pcs pa)

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PRODUCTS
-------------------------- Intake Pipes ------------------------
(3.8 million pcs pa)

Pulsur-180 Avenger Discover

RE2S Platina CT-100

Upper Bracket Handle Holder

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PRODUCTS

Water Pump Head Cover Clutch Cover Command

Cover Support Support

Assembly

Suspension Arm Support Shock Absorber

Head Cover Magneto Cover Support

Assembly
30
PRODUCTS

Compressor Filter Housing As Cast

Compressor Filter
Housing Machined &
Painted
Compressor Filter Head Machined &
Painted

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ENGINEERING & TOOL ROOM

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CAPABILITIES: DESIGN & ENGINEERING
Co-design & simultaneous engineering

o Weight reduction

o Material substitution

o Improvement in mechanical properties

o Enhancement of performance

o Value Engineering: Reduction in

Part count
Subsequent manufacturing operations
Manufacturing cycle time
Robustness in manufacturing process
Ease of manufacturing

3D modelling

Flow, fill and solidification simulation and validation

33
CAPABILITIES: DESIGN & ENGINEERING

Finite element analysis (S/c)

Design & development of dies and core boxes

Design of gating system

Selection of material, heat treatment cycle

Location, shape and size of rest pad, ejection pin etc.

Design, development and local manufacturing (S/c) of key foundry equipment

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CAPABILITIES:
Objectives of R & D:
Create, evaluate & validate concepts and specifications Improvements & innovation in design, process and
through design, simulation, manufacturing & testing of product
prototypes
Improvement in efficiency of utilisation of resources
Design, development of new Product such as equipment, energy, material etc.

Development of new processes, technologies, methods Reduce impact on environment due to the activities of
of analysis and testing the company

Substitution of imported material, machine, tooling,

Acquire know how to manufacture light metal castings
technology etc.
that are required for
o Light weighting
o Environmental compliance
o Performance enhancement

Our Engineering center has been recognised as

In-house Research and Development Centre by
Government of Indias Department of Science & Industrial
Research

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CAPABILITIES: RECENT DEVELOPMENT

Danielson Engineering (DE) is engaged in contract research and engineering, having proprietary know-
how in design, engineering, development, prototyping, manufacturing and testing of prototypes of
powertrain including propulsion system for aircraft & UAV, its sub-systems & critical parts, for
application in various areas including automotive, aeronautics, aerospace, defense and engineering
industries.

DE is unique in its ability to offer fully integrated state of the art facilities for
o Research & development
o Design, engineering & simulation
o Rapid prototyping
o Manufacturing and testing of Powertrain, its subsystem & critical parts

Joint venture with Danielson Engineering, France: AEL has

set up a joint venture company in India with Danielson Engineering, France,
namely Danielson Performance Engineering Ltd.

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INNOVATION: CO-DESIGN, SIMULTANEOUS ENGINEERING, VA/VE

37
INNOVATION: CO-DESIGN, SIMULTANEOUS ENGINEERING, VA/VE
Before After

4 Cavity die to 12
Cavity die

Before: 104 gm After: 72 gm

Core weight
reduction

38
INNOVATION: CO-DESIGN, SIMULTANEOUS ENGINEERING, VA/VE

Yield Improvement

Before: 35 % After: 60 %

Core weight
reduction
Core height reduced
by 20 mm, 0.7 Kg
Before After sand saved

39
INNOVATION: PRODUCT DESIGN IMPROVEMENT (REDUCTION IN WEIGHT)

Before:
Weight = 2.94 Kg

runner

After:
Weight = 2.76 Kg
Die was redesigned with a
weight reduction pocket
to tackle the problem of
solidification shrinkage.

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FACILITIES: ENGINEERING AND TOOL ROOM
Facility Numbers
Unigraphics NX6 8
Catia V5 R17 1
Pro-E 2
Solid Edge 1
Work NC 2
Simulation Software 2
Feed Design Software 1
Vertical Machining Center 9
EDM Machine (Spark Erosion) 2
Wire cut EDM Machine 4
Die Spotting Press 1
Surface Grinding Machine 3
Cylindrical Grinding Machine 2
Coordinate Measuring Machine 1
Tempering Furnace 1

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AE DEUTSCHLAND GmbH, GERMANY
(GREENFIELD PROJECT)

42
AE DEUTSCHLAND GmbH, GERMANY

The company formed & registered

Land measuring 18,968 sq meters, located at Bachschleife, in the industrial area of Arnstadt,
Thringen (30 km from Erfurt) is acquired for setting up the facility
Current status (Sep 2015) : Planning stage

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HIGH TENSILE STEEL FASTENER DIVISION
(BG FASTENING AND ENGINEERING INDUSTRIES PRIVATE LIMITED)

44
FACILITIES: FASTENER DIVISION (BG FASTENING AND ENGINEERING INDUSTRIES PRIVATE LIMITED)

Description Fastener Division (BGFEIPL)

Open Area (Sq. Mt.) 78,307

Buildup Area (Sq. Mt.) 10,683
Location (Sq. Mt.) Aurangabad

45
FACILITIES: FASTENER DIVISION
Sr. No. Capacity Type MT / Month

1 Wire Drawing Capacity 1000

Single roof operation for wire processing
2 Forging Capacity 750
Cold forging
3 Heat Treatment Capacity 1000 Thread rolling
4 Alkaline Zinc Plating Capacity 1000 Machining

5 Dacro / Geomet Coating Capacity 50 Heat Treatment

Zinc Plating to Dacro Coating
6 Precoating / Patch Coating Capacity 50

7 Phosphating Capacity 600

46
PRODUCTS: FASTENER DIVISION (BOLTS)

Types : Engine Studs, Con rod bolts, Axles, Flange bolts,

Socket head bolts
Size Range : M6 to M16
Length : Upto 300mm
Grade : 6.8, 8.8, 9.8, 10.9, 12.9
Thread Type : Metric

47
PRODUCTS: FASTENER DIVISION (NUTS)

Types :Nylock, Domed, Wheel and Serrated Flange Nuts

Size Range : M6 to M16
Grade : 4, 6, 8, 10
Thread Type : Metric

48
PRODUCTS: FASTENER DIVISION (SPECIAL FASTENERS)

Size Range : M6 to M16

Length : Upto 300mm
Grade : 6.8, 8.8, 9.8, 10.9, 12.9
Thread Type : Metric

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AUTO ELECTRICALS DIVISION

50
FACILITIES: AUTO ELECTRICALS

Description Auto Electricals Division (Plant 4) BG LI IN Electricals

Open Area (Sq. Mt.) 10,000 4500

Buildup Area (Sq. Mt.) 1,500 3239
Location Aurangabad Aurangabad

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FACILITIES AUTO ELECTRICALS
Production :
Conveyorised, Temperature & Dust Control environment
CNC multi spindle & twister for secondary coil winding.
Vacuum potting machine from Huebers, Germany.
On-line burning & Open voltage circuit tester
Testing in actual operating condition with Magneto
Performance Test Machine (Chuyi, Taiwan)
Capacity to produce 16 Million Relays Per Annum
In-house Research and Development Centre recognised by
Government of Indias Department of Science & Industrial Research

Quality Control :
Endurance testing for HT coil, Jig for life cycle test
Vibration testing, Hot water & Salt spray test chamber
Hot & cold chamber
X-ray testing machine

52
FACILITIES AUTO ELECTRICALS

Assembly Lines

Online Relay Testing Facilities

53
PRODUCTS: AUTO ELECTRICALS

Product Range:
Magnetos
Regulators
Ignition Coils (HT Coil)
Relays
Flashers
CUSTOMER SUPPORT

55
CUSTOMER SUPPORT

NPD Status update

Conference call

Schedule visibility
E - Mail

Delivery performance
Internet portal

Periodic visits
Stock monitoring

Local office
Quality status

56
LOGISTICS

Export
AEL Aurangabad
Port of Mumbai Ocean Freight
Clearance at Port.

Local CCL at Port at

warehousing Destination Destination

Delivery at
Customer Location

57
MANAGEMENT FOCUS

58
MANAGEMENT FOCUS

Process re-
engineering

Continuous
improvement Employee
& innovation development
&
involvement

Customer
satisfaction

Supplier Result
partnership Orientation

Social
responsibility

59
SHOP FLOOR MANAGEMENT

Kaizens (small improvements)

Focused improvements

1S - 2S

Housekeeping

Abnormality elimination

Why why analysis

60
RECOGNITIONS

61
AWARDS

BAL Q - Gold Award - AEL Plant N1

General Motor "Best Quality Supply Award - OBASIL
Excellent performance award at QCFI Convention in Sept 2014 Plant 9
Appreciation award in state level Kaizen competition by QCFI Plant 9
Suzuki Motor Best Supply Performance Award. BG LI-IN Electricals

Silver Award at Quality Circle Forum of India - AEL Plant 9

BAL TPM Award - AEL Plant N1
BAL Q - Gold Award - AEL Plant 3
BAL TPM Award - AEL GDC division
BAL Q - Gold Award - AEL GDC division

Tata Toyo Best Supplier AEL GDC division

Atlas Copco Best New Supplier AEL GDC division
BAVA Kaizen Competition (2nd Runner-up Award)
BAL "Q - Silver Award"- AEL Plant 3
BAL "Q - Silver Award"- AEL Plant 4

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CONTACTS

Mr. Kundan K Jha

Group CEO (AEL)
E-mail: kundan.jha@baglagroup.com
Mobile No: +91 9372848930

Mr. Deepak Mahajan

Executive Vice President (Business Development and Sales, AEL)
E-mail: mahajan.deepak@baglagroup.com
Mobile No: +91 9096993655

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