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V-27.7.16~0 1
Mahindra Sona Ltd.
2
Highlights
ProductsPropeller Shafts, Steering Universal Joints, Steering Columns & Parts, Axle Shafts, Double CardanShafts, Clutch Driven Plates, Clutch Cover Assemblies
Promoting CompaniesMahindra & Mahindra Ltd., Mumbai (India)Sona Group, Delhi (India)
Gross Sales (FY 15-16)Rs. 4,638 million (Unaudited)(US$ 70 million / Euro 61.5 million)
Employees (perm) 278
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Mahindra Sona Ltd.
Propeller Shaft Balancing Standards Room 6 Station Transfer Line for Yokes
CNC Machining Main Plant Induction Hardening
Nasik Plant S.O.P. Nov 1979
Mahindra Sona formed Mar 1995
Investment Rs. 1.28 Bn
Site Area 45165 m2
Built-up Area 23370 m2
Production machines 350 +
Manpower (perm) 278
ISO / TS 16949 Certified
ISO 14001& OHSAS 18001 Certified
Capacity 2016-17 Nos./ Year
Propeller Shaft 900,000
Steering U-Joint 1200,000
Steering Sleeve-spindle 720,000
Clutch Driven Plate 720,000
Clutch Cover Assembly 720,000
Components & UJ Kits 1000,000
Axles & Drive Shafts 320,000
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Milestones
1968 Collaboration agreement between Mahindra Group and Dana Corp. USA for manufacturing of Clutches.
1976 Collaboration agreement between Mahindra Group and Dana Corp. for manufacturing of Propeller Shafts, Axle Shafts and Universal Joints, in a Joint Venture Company - Mahindra Spicer Ltd.
1979 Inauguration of Nashik Works.
1984 Merger of Mahindra Spicer Ltd. with Mahindra & Mahindra Ltd. Becomes MSL Division of Mahindra & Mahindra Ltd.
1986 Dana Collaboration ends.
1994 Formation of Mahindra Sona Limited. Restructure of MSL Division as Mahindra Sona Ltd.
1995 ISO 9001 Certification by TUV-CERT, Germany.
1996 Scientific work measurement technique (MOST) adopted. Cellular manufacturing and “Flow Production” introduced.
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Milestones Continued
1999 QS 9000 Certification by TUV-Cert, Germany.
1999 Exports to USA begin.
2002 Group Kaizen Activity launched.
2003 Exports to Indonesia, Egypt & U.K. begin. TPM Activities begin. (Total Productive Maintenance)
2004 TS 16949 Certification by TUV-Nord, Germany.
2009 ISO 14001 & OHSAS 18001 certified by TUV-Nord, Germany.
2009 Technical Collaboration with IFA-Rotorion, Germany, for high performance propeller shafts
2010 Technical Collaboration with Hyolim (Korea) for HCV Propeller Shafts
2012 Inauguration of R&D Centre.
2014 Expansion & shifting of R&D to new location.
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Customers and Sales Growth
Major CustomersArvin Meritor, USA
Ashok Leyland
Asia Motor Works Ltd
Axle Tech USA & France
Continental Engg, USA
Daimler India Commercial Vehicles
Escorts
Force Motors
Hindustan Motors
JCB India, UK
Kubota Mfg, USA
Mahindra & Mahindra
Rane TRW Steering
Sona Koyo Steering
Tata Motors
Terex, India & UK
TVSE - Kongsberg Automotive
Vehicle Factory, Jabalpur
Volvo Eicher Commercial Vehicles
Piaggio Vehicle Pvt. Ltd.
ZF Steering Year's
0
500
1000
1500
2000
2500
3000
3500
4000
4500
Ne
t Sa
les
(Rs
Mln
)
2010 - 11 2011 - 12 2013 - 14 2014 - 15 2015 - 16
Export Sales
Domestic Sales
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Sales Mix: Year 2015-16
Export, 17.6%
Domestic After Mkt,17.2%
Domestic OEM, 63.5%
Trading1.7%Stg. Column
component, 10.8%
Clutch, 22.6%
Trading,1.7 %
Prop shaft component, 25.7%
Prop shafts38.4%
Axles, 0.8
Product Mix Market Mix
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Current Product Range
Propeller Shaft Steering U. Joints Application
Torque carrying capacity 600 -17500 Nm. (10 Models). Single Piece, Two Piece outboard type with CB Kits.
Torque carrying capacity: 100 -600 Nm. (15 Models). Shafts Joint Articulation Angle : 15 - 90 Degrees.
Cars, Utility Vehicles, LCVs, Commercial Vehicles, Earth Moving Equipments/ Construction Machinery.
Product Capacity
Propeller Shafts 9,00,000 nos. p.a.
Steering U-Joints 12,00,000 nos. p.a.
Facilities
Facilities for Machining, Heat Treatment, Surface treatment, Assembly, Balancing, Painting and Testing.
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Technology Collaborators for Propeller Shafts
Vehicle Type Technology Partner
SUV/ LCV (Upto 7.5T)√ Technology Collaboration with IFA Rotorion GmbH, Germany
HCV (25T – 49T)√ Technology Collaboration with Hyolim Industrial Co., Korea
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Technical Collaboration with IFA Germany
Features offered for new generation of high performance drivelines
High strength swaged Tubing Submerged Arc welding of Tube with end parts
Crash featureCentre Bearing Kit with side crash feature
Monoblock CV Joint with plunge movementSGF Flexible Coupling for low NVH
Staked UJSubmerged Arc welding of Tube with end parts
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Technical Collaboration With Hyolim Industrial Company, Korea, For Heavy Duty Propeller Shafts
Propeller Shafts for Heavy Commercial Vehicles GVW from 25 MT to 49 MTTorque carrying capacity up to 17,500 Nm
HICL Customers
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Clutch Product Profile
Clutch Driven Plates Clutch Cover Assemblies
Size 160 Mm To 380 Mm (Single Disc, Regular & Pre-damper Type)
Size 160 Mm To 310 Mm (Diaphragm & Lever Type)
Driven plate Assembly 720,000 nos. Per year
Cover Assembly 720,000 nos. Per year
Facilities
Facilities for machining, heat treatment, surface treatment, assembly and testing. Component manufacturing is outsourced
Capacity
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Clutch Driven Plate & Cover Assembly
Clutch Driven Plate Features Clutch Cover Features
Size Range 160 mm to 380 mm diameterSingle Disc. Regular & Progressive/Pre-dampened Conventional Facings and Ceramic Buttons
Size Range 160 mm to 310 mm diameterDiaphragm and Conventional typesDiaphragm Spring Tagging and Rivetting types
160 mm dia Champion CA AL 14” DP 9.1/8” Prog DP M&M Bolero
9.1/8” DP M&M FC, FJ Tata 14” DP WF 350 mm dia DP (ceramic)
9.1/8 “ Conv. M&M CA 8.1/2” HM CA Tata 1210 Conv CA
180dia DST type CA 9” Diaphr M&M BA10 CA 9.1/2” M&M Savari CA
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Mahindra Sona Ltd : Nasik Plant Layout
Land Area : 45,165 sq. m. Built up Area incl. yards : 23,370 sq. m.M
IDC
Ro
adM
IDC
Ro
ad
Scrap Yard
Plant - 3 Vacant Land
Plant - 2
After MKT
Main Plant - 1
StorageFG Store
Canteen
Utilities
S.T.
RM Store
Material Yard
E. T. P. & S. T. P.
Off
ice New
Plant - 4
R & DLower
Ground Floor
Gate
Gate
N
VEH
PA
RK
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Quality Policy
We, at Mahindra Sona Limited,
are committed to satisfy ourcustomers by
designing, manufacturing &delivering products through a well
definedQuality management system
meeting ISO/TS 16949Standard and to continually improve
our products,processes and systems.
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Manufacturing Facility
• Over 350 machines.
• Turning - CNC Lathes
• PLC Hobbing Machines
• 3-Station Vertical Broaching Machines
• Induction Hardening CNC Controlled
• Vertical Machining Centers
• Horizontal Machining Center
• Yoke Manufacturing Machines CNC controlled
• UJ Cross & Bearing Grinding Machines
• MIG/MAG Welding Machines
• Dynamic Balancing Machines
• Conveyorised Paint Booths
• Assembly lines
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Quality Assurance
Metrology Laboratory Metallurgy Laboratory
CMM Room
Micro Hardness Tester OLYMPUS Microscope
B&S 3D CMM
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CMM & Profile Projector
Delta Profile Projector
Brown & sharpe 3D Coordinate Measuring Machine
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Well equipped Metallurgical Laboratory at MSL
SHIMADZU HMV-Fully AutomaticMicrohardness Tester
Rockwell Hardness Tester Olympus Microscope for checking microstructure
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e - Capability
Design Center
• Engineers: 18• Technicians: 2• Workstations: 19
Softwares
• I-DEAS 2D• Nx 3D• Pro-E 3D
Von Mises Stress AnalysisDesign Optimisation
• Altair Hyper works Analysis Software• Modal VIEW• NVH Geek
Business Software
Web enabled “Galaxy” (on Oracle 10g platform)
Computer Network
• 150+ Computers connected by Optic Fiber Network.
• Dedicated Business Apps, CAD & Mail Servers
• Emailing on Lotus Notes
EDI, CRM, SRM & Communication:
through Broadband Internet
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Mahindra Sona Ltd.
MAHINDRA SONA LTD - R&D CENTERInaugurated on 27th August 2012 by Dr. Pawan Goenka
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Design Software
Design Software
NX-I-Deas 6.1 : 16 seats.
NX8.5 : 16 seats.
Pro-E WF4 : 9 seats.
Pro-Mechanica : 1 seat.
TEAM CENTER 10 : 16 seats.
MATLAB / Simulink : 1 seat.
Testing Software
LabVIEW based NVH Acquisition an analysis.
ModalVIEW
Altair Hyperworks
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Design Capability
Stress analysis
Thermal analysis
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Series No. Ø A (mm) B (mm) Dynamic Torque
Nm.
Short duration Torque
Nm.
Effective shock load
Nm.
Rated torque
capacity Nm.
Comparison
1310 27 81.7 479 1109 1630 2169 DANA Std.
1310 27 81.7 555 1293 1900 2807 MSL Std.
2015 27 74.5 530 1117 1642 2399 GWB Std.
1350 30.2 92 804 1797 2640 3064 DANA Std.
1350 30.2 92 966 2234 3282 4349 MSL Std.
2020 30.2 81.8 764 1767 2596 3440 GWB Std.
1410 30.2 106.3 885 1978 2906 3661 DANA Std.
1410 30.2 106.3 951 2114 3106 4924 MSL Std.
SPL55 34.9 106.3 1185 2939 4318 4515 DANA Std.
1480 34.9 106.3 1433 3018 4433 5757 MSL Std.
2025 34.9 92 1058 2129 3128 4979 GWB Std.
SPL70 34.9 126.1 1499 3739 5494 5966 DANA Std.
1550 34.9 126.1 1835 3866 5679 7352 MSL Std.
2030 34.9 106.4 1271 2557 3757 5981 GWB Std.
SPL100 41.3 126.1 2045 5096 7488 8678 DANA Std.
1650 41.3 126.1 2225 5096 7488 9919 MSL STd.
2035 42 119.4 1947 3998 5875 9640 GWB Std.
MSL UJ SeriesDeveloped at R&D Center
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Application:To conduct following tests :A] Static Torsion Test : Capacity : 30000 Nm.
B] Torsion fatigue Test : Capacity : 10000 Nm.
Torsional Fatigue testing in Uni-directional
or Bi-directional mode.
Capacity :Max. Shaft admit length 2500 mm.
Static Torsion & Torsional Fatigue Test Rig
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Application: To conduct Rotational durability test of
propeller shaft.
4 Prop shafts can be mounted in loop.
vehicle duty cycle at varying operating
Angle, Torque & Speed can be simulated.
Capacity : Speed : 3000 rpm max.
Torque : 3000 Nm. max.
Shaft Admit Length: 2000 mm max.
Rotational Durability Test Rig-3000 Nm. Capacity
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Application: To conduct Rotational durability test of
propeller shaft.
2 Prop shafts can be mounted in loop.
vehicle duty cycle at varying operating
Angle, Torque & Speed can be simulated.
Capacity : Speed : 3000 rpm max.
Torque : 10000 Nm. max.
Shaft Admit Length: 2000 mm max.
Rotational Durability TestRig-10000 Nm. Capacity
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Application: To conduct Rotational durability test of
propeller shaft.
2 Prop shafts can be mounted in loop.
vehicle duty cycle at varying operating
Angle, Torque & Speed can be simulated.
Capacity : Speed : 1500 rpm max.
Torque : 30000 Nm. max.
Shaft Admit Length: 2000 mm max.
Rotational Durability TestRig-30000 Nm. Capacity
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Application: To measure spline slide frictional force
during Pull & Push.
To check spline wear.
Capacity : Shaft admit length : 900mm max.
Torque : 100Nm~5000Nm.
Stroke : 100mm Max.
Spline Wear Test Rig
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Application: To check Backlash of steering joint
assembly, C.V. Joint.
Capacity : Torque : ±50 Nm.
Admit Length : 800 mm max.
Rotational Backlash Test Rig
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Application: To check sealing effectiveness of U.J. Kit &
C.B. Kit in Dry & Wet condition.
Capacity : Admit length : 600 mm max.
Angle : 10° Fixed.
Speed : 1000 rpm max.
Temperature range : 80 - 95˚C.
Mud bath Test Rig
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Application: To check salt spray life for surface protection
as per ASTM 117B.
Capacity : Chamber size : 55 cm X 80 cm X 55 cm.
Salt Spray Test
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Application:
Testing of Hysteresis characteristics
Capacity : Diameter : 160 mm to Dia 310 mm
Frequency : 50 Hz.
R&D Facility : Driven plate assy.
Hysteresis Test Rig
Application:
Testing of Cushion characteristics
Capacity : Diameter : 160 mm to Dia 310 mm
Load : 20kN max.
Deflection : 10mm Max.
Cushion Load & Deflection Test rig
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Application:
Burst test.
Capacity : Diameter : 160 mm to 310 mm.
RPM : 15000 Max.
Temperature : At 250°C and at room temperature.
R&D Facility : Driven plate Assy.
Burst testing machine for Clutch facing
Application:
Drag torque measurement.
Capacity : Diameter : 160 mm to 310 mm.
Displacement range : 5 -15 mm.
Load : 30kN Max.
Torque : 20Nm Max.
Drag Test Rig
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Application: Torsion durability test.
Capacity : Diameter : 160 mm to 310 mm.
Angle : 25° Max.
Frequency : 6 -10 Hz.
R&D Facility : Driven plate Assy.
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Application:
Pressure Plate Lift, Load and Release load testing
Capacity : Diameter : 160 mm to 310 mm
P.P. Load : 15kN max.
Release Load : 5kN Max.
R&D Facility : Cover assy.
Comprehensive Load Test Rig
Application:
Load v/s Deflection measurement
Capacity : Diameter : 160 mm to 310 mm Diaphragm spring
Load : 30kN Max.
Deflection : 25mm Max.
Load V/s Deflection Test Rig for Diaphragm Spring
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Application:
Dynamic durability test.
Capacity : Diameter : 160 mm to 310 mm.
Release travel : 5 -15 mm.
Release Frequency : 2Hz Max.
RPM : 3000 Max.
R&D Facility : Cover assy.
Dynamic release durability testing machine
Application:
Static release durability test.
Capacity : Diameter : 160 mm to 310 mm.
Frequency : 50Hz Max.
Static release durability testing machine
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Application: Burst test.
Capacity : Diameter : 160 mm to 310 mm.
RPM : 17000 Max.
Weight : 15 kg Max.
Temperature : At 250°C and at room
temperature.
R&D Facility : Clutch Assy.
Burst testing machine for Clutch Assembly
Application:
Moment of inertia measurement
Principle : Tri-filler suspension
Moment of inertia measurement set up for Clutch Assembly
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R&D Facility : Clutch Assy.
Application:
1. Comprehensive performance test. 2. Clutch thermal load determination test.
3. Clutch lining wear test. 4. Clutch frictional moment determination test.
Capacity : Diameter : 160mm to 310mm. Max Speed 3000
Comprehensive Performance Testing Machine for Clutch Assembly.
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R&D Facility : NVH
Application :Torsional vibrations Measurement
In-Vehicle NVH Measurement
Modal Analysis
Equipment specification,
Hardware : 20 channel data acquisition platform. (cDAQ)
Uniaxial & Triaxial accelerometers.
High Frequency Proximity sensors.
Microphones.
Software : ABSignal Modal VIEW.
Lab VIEW based NVH Acquisition and analysis.
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Clutch Testing Facilities Recently Added
Sr. No.
Description of Equipment TestClutch product
Range
1 Comprehensive Performance Testing machine for Clutch assembly. 310mm - 450mm Dia
2 Torsion Durability testing machine for Driven plate assy. 310mm - 450mm Dia
3 Comprehensive Load Test Rig for Cover Assembly. 310mm - 450mm Dia
4 Burst Testing machine for Clutch assembly 310mm - 450mm Dia
5 Dynamic Release Durability Testing machine for Cover Assembly . 310mm - 450mm Dia
6 Cushion Load and Deflection Test Rig for Driven Plate assy. 310mm - 450mm Dia
7 Hysteresis Test rig for Driven plate assy. 310mm - 450mm Dia
8 Clutch Drag testing machine for Driven plate assy. 310mm - 450mm Dia
9 Load v/s Deflection Test Rig for Diaphragm Spring 310mm - 450mm Dia
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Mahindra Sona – Geographical Presence in India
•NASIK
23 Aftermarket Product Distributors &
2000+ Retail Outlets covering all States
KOLKOTA
MUMBAI
ManufacturingPlant at Nashik
Mumbai office and Sales office West Zone
Sales Office South Zone
Sales Office East Zone
Sales Office North Zone
•CHENNAI
•DELHI
•Pune
Manufacturing Location•INDORE (u/construction)
Regional Offices for Customer Support
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Mahindra Sona Ltd.
Addresses & Contacts
Mumbai Office :
Mahindra Sona Limited
31, 3rd Floor, Maker Chambers VI, Nariman Point,
Mumbai - 400 021
Phone : +(91)-022-67432885
Fax : +(91)-022-67432880
Email : [email protected]
Contact Person :
G. G. Motwane – Managing Director
R. V. Vadhavkar – Sr. VP (Marketing, Business Development)
Plant Office :
Mahindra Sona Limited
89/1/A, M.I.D.C. Industrial Area,
Satpur, Nashik - 422 007, India.
Phone : 91-253-6610500
Fax : 91-253-6610504
Email : [email protected]
Contact Person :
B S Patwardhan – General Manager
V-27.7.16~0 45
Thank You !
