PUNJAB BEVEL GEARS

INTRODUCTION

Sahibabad

Sitarganj Sahibabad

INTRODUCTION

SAHIBABADUTTAR PRADESH

4 PLANTS*

LUDHIANAPUNJAB

2 PLANTS

SITARGANJUTTARAKHAND

3 PLANTS

GROUP COMPANIES

Differential & TransmissionGears and Shafts

Forging MachiningAxle Shaft

Differential & TransmissionGears, Differential cage and Drive line parts

*There are 4 manufacturing units all located within 500 metres in Sahibabad.

• Started operations in 1979

• Manufactures more than 2000 different type of gears

• Leading manufacturer, supplier and exporter of automotive and tractor parts

• Caters to industries like commercial vehicles, agricultural tractors, passenger cars, three wheelers & construction equipments

INTRODUCTION

Our competitiveness lies in the fact that we are:

• Cost Competitive,

• Quality Conscious,

• Having track record of on time delivery

• Having capability to develop new products in a comparatively shorter period

INTRODUCTION

• Financially sound having credit rating of ‘care BBB-’ (Triple B Minus) For long term bank facilities for 2014 • Having assurances from financial institutions for support in the on going and future expansions

• Having very sound HR policies with almost nil employee turnover

• The average age of employees is 40 years

•Having 100% captive power back up at all plants

• An ISO/TS 16949: 2009 Certified Company

INTRODUCTION

PRODUCT RANGECrown Wheel & Pinion

(Face Mill, Face Mill Completing and Face Hob in both Dry and Wet cutting)

ST. Bevel Gear & Pinions (Gleason Coniflex System)Transmission Gears(Spur,Helical)Differential CagesAxle Shafts

Forgings/Machined Forgings

Drive Line Parts

PRODUCT RANGE

Crown Teeth Cutting Pinion Teeth Cutting Crown & Pinion Testing

Crown Wheel & Pinion (Face Mill and Face Hob Wet Cutting process)

PRODUCT RANGE

St. Bevel Gears & Pinions (Gleason Coniflex System)

Teeth Cutting

Teeth Cutting Gear & Pinion Testing

PRODUCT RANGE

Transmission Gears and Shafts (Spur, Helical)

CNC Blanking

CNC Hobbing Spline Hobbing Stack Hobbing

PRODUCT RANGETransmission Gears and Shafts

(Products)

PRODUCT RANGEDifferential Cages

CMM CNC Machining

PRODUCT RANGE

Axle Shafts

GROUP TURN OVER (Mio Rs)

GROUP TURN OVER (Mio $)

SEGMENT WISE SALES FY13-14

CAPACITY INSTALLED

Sl.No. Product Annual* Utilization

Capacity of

capacity

1. Crown Wheel & Pinion 720,000 Sets 60%

2. Straight Bevel Gears 1,500,000 Nos. 80%

3. Transmission Gears 1,600,000 Nos. 60%

4. Axle Shafts 100,000 Nos. 25%

5. Forgings 12,000 MT 70%

6. Differential Cage 48,000 Nos. 40%

7. Drive Line Parts 200,000 Nos. ---

* On 2 Shift Basis

TYPE SPIRAL/

HYPOIDS

STRAIGHT

BEVEL

SPEED

GEAR TRANS. SHAFT

MAX. SIZE (DIA) MM 600216(10:1)

152(1:1) 400 80

MAX. FACE WIDTH/L 70 50.80 135mm Shaving

1000mm

MAX. MODULE (mm) 13.00 8.50 8.00 8.00

ACCURACY

DIN

CLASS 6-7 in Dry Cutting &

8-9 in Conventional

DIN

CLASS 8-9

DIN

CLASS 8-9

DIN

CLASS 8-9

CAPABILITIES - GEARS

CAPABILITIES - FORGINGS

• Weight 0.5 Kg to 50 Kgs

• Round Forging Min. Dia 80 mmMax. Dia 500 mm

• Shaft Forgings Length 1200 mmFlange Dia 325 mm

Sahibabad Ludhiana Sitarganj

Total Area 500,600 152,500 183,140

Covered Area 179,390 46,000 95,200

General Office Area

5,420 5,000 11,600

PLANT AREA IN SQ. FT

Sahibabad Ludhiana Sitarganj

Hourly 335 165 100

Supervisory 47 07 12

Manager 13 01 02

Total 395 173 114

MANPOWER

QUALITY SYSTEMS:

• Plants at Sahibabad and Sitarganj are ISO/TS 16949: 2009 certified

• Forging plant at Ludhiana is ISO 9001: 2008 certified

• Differential gear plant is ISO 9001, ISO 14000 & ISO 18000 certified

EXPORT PROMOTION:

• Recognized star export house

• Awarded silver shield for export performance during 2005-06,

2007-08, 2008-09, 2009-10, 2010-11 & 2011-2012 by Engineering Export Promotion Council, India

CERTIFICATION / AWARD

CUSTOMER AWARDS:

• Best supplier award for new product development by TAFE in 2010

• Best supplier award for consistent delivery performance through pull system-KANBAN by TAFE in 2013

• Supplier recognition award by American Axle in 2010

• Direct on line supplier award by TAFE & International Tractors Limited

CERTIFICATION / AWARD

CNC Turning Lathes 39 Nos.

Vertical Machining Center 10 Nos.

Gleason Crown Wheel 9 Sets(608/609, 606/607, No. 22, No.11 & No.112)

Gleason Pinion 7 Sets(No.116)

Oerlikon 9 Nos. (SM3, S17, SKM1)

CUTTING EQUIPMENT INSTALLEDAT SAHIBABAD/LUDHIANA

Transmission Gears Hobbers 30 nos

CNC Hobbers 3 nos

CNC Shaper 1 no.

Shapers 34 nos

Shavers 14 nos

Shobbers 1 no

Straight Bevel Gears Gleason Coniflex114 02 nos

Gleason Coniflex104 02 nos

Coniflex WMW 34 nos

CUTTING EQUIPMENT INSTALLED

AT SAHIBABAD

HEAT TREATMENT FACILITIES

Sealed Quench Furnace

Continuous Gas Carburising Furnace

Sealed Quench Furnace

HEAT TREATMENT FACILITIES

• Sealed Quench Furnaces

• Continuous Gas Carburizing Furnace

• Rotary Hearth Furnaces

• Induction Hardening / Softening

• Quench Presses – Gleason

• Tempering Furnaces

• Manganese Phosphating Facilities

• Shot Peening Equipment

• Shot Blasting Equipments

• Straightening Presses

•Cylindrical Grinding Machines -15 Nos.

•CNC Internal Grinder - 1 No.

•CNC Lathe for Hard - 2 Nos.

•Internal Grinding Machines - 8 Nos.

•Spline Grinding Machines - 3 Nos.

•Lapping Machine•Gleason - 12 Nos.(503/506/119/516)

•Gear Testers-Gleason - 18 Nos.(502/511/17-A)

FINISHING EQUIPMENTS

• Full range of Hardness Testers

•( Rockwell, Brinell, Micro Vickers)

• Hardenability (Jominy) Apparatus

• Microscope with camera and image analyzer

• Magnetic Particle Inspection

• Macro Etching

• Muffle Furnaces

•Manganese Phosphating Solution Analyzer

METALLURGICAL LAB FACILITIES

• CMM with Gear Analyzer

• Lead and Profile Testers

• Surface Roughness Tester

• Contouro Graph

• Profile Projectors

•Gear Roll Testers

• Digital Temperature Calibrator

• dB Meter

METROLOGY LAB FACILITIES

RAW MATERIAL Forgings are received Heat Code wise duly

Isothermally Annealed/ Normalised from approved Forge shops.

Checks carried out before processing are:

•     Visual Inspection for cracks and folds.

•   Check of chemical composition by Spectro Analysis at forging plant.

•     Hardness.

•     Jominy Hardenability.

•     Micro structure and Inclusions.

•     Grain Size.

• Inclusion Rating.

• Macro etching/Grain flow.

QUALITY SYSTEMS

IN-PROCESS

•      First off inspection as per control plan.

•   Patrol inspection at defined interval as per control plan.

• For Bevel Gears check tooth contacts in soft Gears.

• Before Heat Treatment inspection for all parts.

ensuring removal of any sharp edges and burrs.

• For Bevel Gears Final Testing to ensure backlash at

correct mounting distance, tooth contact, run out and

marking mounting distance variations.  

QUALITY SYSTEMS

HEAT TREATMENT

Batches are subjected to checks on:

•Effective Case Depth

•Core and Surface Hardness

•Microstructure- Case & Core

•Flatness & ovality of bore for Crown Wheels

•Straightness for Shaft items

•Magnetic particle inspection

QUALITY SYSTEMS

•RAW MATERIAL TRACEABILITY

- Unique TR No. Identifying steel mill, grade & forge

shop punched on parts wherever possible

• HEAT TREATMENT TRACEABILITY

- Unique charge No. identifying furnace, month &

process parameters punched on parts wherever possible

• CWP SET TRACEABILITY

- Unique set no. etched on both the members

• LOGO MARKING

- Customer / PBG logo punched / Laser marked / Bar Code as

per customer requirements

TRACEABILITY

• Additional Continuous Gas Carburizing Furnace

• Additional Sealed Quench Furnaces

• Shaving Cutter Sharpening- Gleason

• Additional CNC Hobbers

• Additional CNC Shapers

• CNC Shavers

• Additional CNC Internal Grinder

• CNC External Grinders

• Additional Vertical Machining Center

INVESTMENT COMMITTED

CUSTOMER PROFILE–DOMESTIC OEMsAUTOMOTIVE

•Tata Motors

•Mahindra & Mahindra

•American Axle &Manufacturing

•Scooters India

CUSTOMER PROFILE–DOMESTIC OEMsAGRICULTURE

•Tractors and Farm Equipment

•International Tractors

•John Deere Equipment

•Dana India

•Indo Farm Equipment

•Sicma India

CUSTOMER PROFILE–EXPORT OEMs

•Meritor, Brazil

•Dana, USA

• Hema Endustri A.S.,Turkey

•Mega Motors Company, Iran

•Iran Tractor Mfg Company, Iran

We also Export our products to Importers, Gear Makers & After Markets in:

USA , U.K., France, S. Africa, Indonesia, Malaysia, Thailand, Singapore, Myanmar, Syria, Egypt, Turkey, Bangladesh, Sri Lanka, Iran, Dubai, Italy, Argentina, Australia, Hungary, Germany, Brazil.

CUSTOMER PROFILE-EXPORTS

FORGING FACILITIES AT LUDHIANA

Steel Yard

Annealing Furnace

Friction Belt Drop Hammer Up Setter

FORGING FACILITIES AT LUDHIANA

• Friction Belt Drop Hammer (1.00, 1.50, 2.00, 2.50, 3.00, 6.00, 8.00 M.T. and a 25T Counter Blow hammer)

• Up Setter - 3 Inches & 7 Inches

• Furnaces for Isothermal annealing & normalizing

• Fully equipped die making facilities

• Material testing facilities includes Spectro Meter & Universal Testing Machine along with Izol Impact & Charpy Testing Machines

• 100% back up with Captive Power

• An ISO 9001: 2008 certified

FACILITIES AT SITARGANJ

Latest Generation Gleason PhoenixCNC Dry/Wet CuttingSystem

FACILITIES AT SITARGANJ

Crown Teeth Cutting LinePinion Teeth Cutting Line Lapping & Testing Line

Sealed Quench Furnace Phosphating Plant Metallurgical Lab

Annealing FurnaceForging PressForging Press

FACILITIES AT SITARGANJ

• Green Field Plant Production started from March 2010.

• Equipment at the Plant:Gleason Phoenix CNC Cutting(600 HC) -- 1 No.Gleason Phoenix CNC Cutting(275 HC) -- 1 No.CNC Blade Profile Grinder -- 1 No.CNC Cutter Build Machine -- 1 No.CNC Gear Measuring Machine -- 1 No. Gleason Pinion Generator(No.116) -- 5 setsGleason Crown Wheel(606/607, No.22) -- 5 setsHobber -- 15 nos.Shaper -- 9 nos.Shaver -- 5 nos.Milling -- 4 nos.External Grinder -- 6 nos.Internal Grinder -- 6 nos.CNC Lathe -- 4 nos.

FACILITIES AT SITARGANJ

Gleason Lapper(503, 506, 514) -- 4 nos. Oerlikon Lapper SKL 1 -- 1 no.

Gleason Tester(511, 512, 17A) -- 6 nos.Continuous Gas Carburising Furnace -- 1 no.Sealed Quench Furnace -- 1 no.Gas Carburising Furnace -- 2 nos.Rotary Furnace -- 1 no.Gleason Quenching Press (537) -- 2 nos.Shot Blasting Equipment -- 1 no.

• Fully Equipped Metrology and Metallurgical Laboratory

• 100% captive power back up

PUNJAB BEVEL GEARS LIMITED

Unit-I &Address for communications:B-44/1 & 52/2, Site-IV, Industrial Area,Sahibabad-201010, Ghaziabad (U.P) INDIATel.: +91-120-4505100-129, Fax: +91-120-4505104/4505105Email: mktg@pbgl.in URL: www.pbgl.in

Unit-II :B-174, Phase –I, Eldeco Sidcul Industrial Park,Sitarganj -261453, Udhamsingh Nagar , (Uttarakhand), INDIAEmail: sitarganj@pbgl.in

PLANT ADDRESS

Unit-III:V&PO: Bhama Kalan, Kohara-Machiwara Road, Ludhiana- 141115(Punjab), INDIAE-mail: ldh@pbgl.in