Aurangabad Electricals Ltd.

GROUP -2 ANSUMAN | ASHOK | GAURAV | RAJNEESH | SANDEEP | VATSAL

Bagla Group

The Bagla Group - Headquartered in Aurangabad, is one of the largest auto component manufacturing entities in Western India

The Bagla Group manufactures wide range of products from Aluminum Die Casting (PDC & GDC), Fasteners, complete Wheel rims for motor cycles including brake panel assembly for automotive industry and condensers for White good industry.

Today the group has crossed 100 million dollars turnover and caters to Domestic and European/American market.

Bagla Group Companies

Aurangabad Electricals Ltd.

Aurangabad Motor Manufacturers Ltd

BG Appliances Ltd.

BG-LI-IN Pvt Ltd.

• Flagship company of Bagla Group

• Four principle business units • Auto Electricals, High

Pressure Die Casting,  Wheels & Rims and Fasteners

• BG LI-IN is a joint venture between Bagla Group and LI-IN Electricals of Taiwan

• One of the largest manufacturers of magnetos in India

• One of India’s leading Electronics Manufacturing Services (EMS) Company

• Catering to the needs of consumer appliances, lighting, automotive and telecommunication industries

• Services include Product Design, PCBA Sub Contracting, Testing and value-added Assembly Services

• A division of Bagla Group• Commenced- Shafts for

domestic appliances• Diversified- rolled bond

evaporators, wire on tube condensers, skin condensers and driers for the refrigerator industry and aluminium gravity die casting parts

Customers

Aurangabad Electricals Ltd.

Principal Business

Units

Die Casting

Wheels and Brakes

High Tensile Fasteners

Auto Electricals

Auto Electricals

Aurangabad Electricals is in a relationship with Taigene Electronics, Taiwan for Magnetos, Shihlin, Taiwan for HT coils and LI-IN Electronics for relays and flashers.

Magnetos : Magneto is an electro mechanical device that produces electrical energy through mechanical movements from a magnetic field. Presently we manufacture magnetos of 60 W to 200 W, single phase and three phase.

Ignition Coil : An Ignition coil is an induction coil which is working as a step-up pulse transformer and giving high voltage output to the spark plug. We manufacture ignition coils for 2 and 3 wheeler vehicles (Iron core as well as soft ferrite core)

Relays : A relay is a Electronics / Electro mechanical switch, which protects and control the operation of headlight, starter motor etc. with a small capacity switch. We make relays for various applications  required for 2,3 and 4-wheeler vehicles.

Die Casting Die Casting is wherein molten metal is poured in a mould cavity to take

the desired shape After solidification the mould is opened and base casting is retrieved

along with metal feeding paths All these process are mapped with graphic simulation depicting absolute

reality, sequence of operations in the die with respect to temperature, time, air gaps etc.

This is done to ensure high quality and consistent reliability.

Brakes and Wheels

Manufacture the entire wheel rim assembly along with the brake

drum

Completely assembled with

brake panel, brake shoe, spring

etc.

The wheel rim is manufactured by

cold forming, TIG(Tungsten Inert Gas) welding and

electroplating surface treatment

(nickel chrome plating)

Fasteners Bagla group has been diversifying according to customer requirements High Tensile Fastener manufacturing is one of the integral part of the

above process Manufacture  Bolts, Screws, Studs and Nuts in various sizes and grades

from Cold Forging Process

Scope

•This mini project is taken to draw and study the current value stream of the processes at Aurangabad Electricals Ltd. This will help the management to identify the area of waste, higher lead time and scope of improvement in the current process

App

roach

•2 Plant visits•Studied the current process•Selected one component (Magneto cover) to study the VSM•Collected data pertaining to :• Process flow• Cycle time• Changeover• time• Batch size•Studied the best practices

Deliverables

•Identification of problem areas•Identification of areas of waste, higher lead time & scope of improvement in the current process•Improved VSM

PROCESS FLOWFOR

MAGNETO COVER

Raw Material - InwardTruck Capacity 9 and 12 ton (mostly 9)Unloading time 90 minNo of suppliers 9

Raw MaterialAlSi9MnMg and AlSi132MnMg

Pallet storage capacity 1000 kg

Melting Shop (Furnace)Loading time 10 min

Melting time 30 min

Pouring of molten material 5 min

Dross removal 5 min

Checking of chemical composition 5 min

Transfer of molten material 10 min

Total Cycle Time 65 min

Lift Capacity 120 kgFurnace Capaicty 1.5 ton

Casting Shop

Cycle Time 52 sec

Die Change 45 min

Batch Size 105 pcs

Transportation for next operation 2 min

No of pieces in a die 2

Shot BlastingCycle Time 2 minChangeover time 12 minRa Rz value check once in a dayReliability 100%Transfer lot size 60 pcs

Inventory 0%

Steel Shots used for blasting

Paint ShopConveyer Belt length 225 m

Belt speed 1 m/min

No of pcs in one hanger 12

Cleaning and Drying Painting (Manual spray)

Degreasing 5 minAir Spray (to remove dust)

25 minWater rinse 2 min Primer Paint

Chromotizing Tank 5 min Flash off zone

Water Tank 2 min Final Paint

DM Water Tank (Spray) 30 min Flash off zone

Water Dry over 30 minVacuum Oven (paint dry) 90 min

Normal Atmospheric Cooling 45 min

Machining, Assembly and TestingTapping and Drilling (one piece) 35 secLoading/unloading 14 secFacing and Reaming (two pieces) 66 secLeakage testing 14 secBush threading (D Kaal Box) 60 sec

Quality Check 18 sec

DispatchNo packaging, direct dispatch in bins

1 bin contains 12 pieces

Current VSM

Best Practices5S implemented in the offices

Even for keeping chairs around the table, lines of demarcation have been set-up

Also for keeping record files 5S have been implemented

Best Practices5S implemented on the shop floor

Best Practices5S & TPM implemented on the shop floor

Best Practices

For quality awareness among workers and officers they have customers’ mail’s snapshot on the shop floor near the concerned department / machine

Best Practices

Q - Alert

Q – Alert is a quality alert system used for the operator to spot some common defects occurring in the recent pastThis makes it easy for him to ensure that these defect do not get repeated

Best PracticesTPM Activity Boards in the offices

Best PracticesKaizen Boards in the offices

Best PracticesTPM Policy at Aurangabad Electricals

Thank You