Presentation on Summer Training at SONA KOYO STEERING SYSTEMS LTD, SANAND,GUJARAT

by Ashutosh Prakash(1021130074)

Under the guidance of Vinod Kumar(Training officer) Department of Mechanical Engineering SRM University Delhi NCR Campus April -2013

CONTANTS
Introduction to SONA Products Departments in the company Customers Assembly lines Differential case assembly Kaizen References

INTRODUCTION ON SONA

Company was established in 1987 Now SONA group comprises of many companies each of which are in joint venture partnerships SONA KOYO Steering Systems Limited (SKSSL) is a technical and financial joint venture company of Koyo Seiko Company, Japan largest manufacturer of steering gears in India With a Market share of 50%

PLANT LOCATIONS

GURGAON PLANT

CHENNAI PLANT

DHARUHERA PLANT

SANAND PLANT

PRODUCTS
Case Differential (Fiat Punto) Collapsible Column (Tata Nano) Column Assembly (Mahindra ltv) IMV Column (Mahindra ltv) Column Assembly (Tata Nano)

DEPARTMENTS IN THE COMPANY

Production planning department Human resource department Production department Quality control department Packaging and dispatching unit

Customers

ASSEMBLY LINES IN COMPANY

Plant have three assembly lines:1. Differential case line 2. Column line 3. RPS line

DIFFERENTIAL ASSEMBLY

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DIFFERENTIAL HAS THREE JOBS

To aim the engine power at the wheels To act as the final gear reduction in the vehicle, slowing the rotational speed of the transmission one final time before it hits the wheels To transmit the power to the wheels while allowing them to rotate at different speeds (This is the one that earned the differential its name.)

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WORKING
When a car is driving straight down the road, both drive wheels are spinning at the same speed. The input pinion is turning the ring gear and cage, and none of the pinions within the cage are rotating -- both side gears are effectively locked to the cage When a car makes a turn, the wheels must spin at different speeds the pinions in the cage start to spin as the car begins to turn, allowing the wheels to move at different speeds

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MANUFACTURING OF DIFFERENTIAL CASE

Rough turning (CNC) Semi finish turning(CNC) Finish turning(CNC) Milling ,drilling, reaming ,tapping(VMC) Washing of the case Pinion gears and yoke gears are assembled with washer inside the case
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CNC USED FOR ROUGH,SEMI ,&FINISH TURNING

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BEFOR CNC OPERATION

AFTER CNC OPERATION

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VMC USED FOR MILLING,DRILLING,REAMING

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AFTER VMC OPERATION

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SPM FOR WASHING PURPOSE

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PTM
Later the differential assembly is tested on PTM (Performance testing machine) for torque transmitted to the wheel Graph of the case plotted first finished case is then checked by the quality department.

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AFTER TESTED IN PTM

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STACKED FOR PACKAGING

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KAIZEN
KAIZEN is a Japanese word meaning gradual and orderly, continuous improvement KAIZEN is a business strategy involves everyone in an organization working together to make improvements without large capital investments.

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REFERENCES
Google images Wikipedia Howstuffworks.com

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Thank you

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