PUNJAB BEVEL GEARS

INTRODUCTION

Sahibabad

Sitarganj Sahibabad
 INTRODUCTION

GROUP COMPANIES

SAHIBABAD LUDHIANA SITARGANJ

UTTAR PRADESH PUNJAB UTTARAKHAND
4 PLANTS* 2 PLANTS 3 PLANTS

Differential & Forging Differential &

Transmission Machining Transmission
Gears and Shafts Axle Shaft Gears, Differential cage
and Drive line parts
*There are 4 manufacturing units all located within 500 metres in Sahibabad.
 INTRODUCTION

• 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

 PRODUCT RANGE
Crown 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 Cages
Axle Shafts
Forgings/Machined Forgings
Drive Line Parts
 PRODUCT RANGE
Crown Wheel & Pinion
(Face Mill and Face Hob Wet Cutting process)

Crown Teeth Cutting Pinion Teeth Cutting Crown & Pinion Testing
 PRODUCT RANGE
St. Bevel Gears & Pinions
(Gleason Coniflex System)

Teeth Cutting Gear & Pinion Testing

Teeth Cutting
 PRODUCT RANGE
Transmission Gears and Shafts (Spur, Helical)

CNC Blanking

CNC Hobbing Spline Hobbing Stack Hobbing

 PRODUCT RANGE
Transmission Gears and Shafts
(Products)
 PRODUCT RANGE
Differential Cages

CNC Machining CMM

 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
 CAPABILITIES - GEARS

SPIRAL/ STRAIGHT SPEED TRANS.

TYPE
HYPOIDS BEVEL GEAR SHAFT

216(10:1)
MAX. SIZE (DIA) MM 600 400 80
152(1:1)
135mm
MAX. FACE WIDTH/L 70 50.80 1000mm
Shaving

MAX. MODULE (mm) 13.00 8.50 8.00 8.00

DIN
CLASS 6-7 in DIN DIN DIN
ACCURACY Dry Cutting &
CLASS 8-9 CLASS 8-9 CLASS 8-9
8-9 in
Conventional
 CAPABILITIES - FORGINGS

• Weight 0.5 Kg to 50 Kgs

• Round Forging Min. Dia 80 mm

Max. Dia 500 mm

• Shaft Forgings Length 1200 mm

Flange Dia 325 mm
 PLANT AREA IN SQ. FT

Sahibabad Ludhiana Sitarganj

Total Area 500,600 152,500 183,140

Covered Area 179,390 46,000 95,200

General Office
5,420 5,000 11,600
Area
 MANPOWER

Sahibabad Ludhiana Sitarganj

Hourly 335 165 100

Supervisory 47 07 12

Manager 13 01 02

Total 395 173 114

 CERTIFICATION / AWARD

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
 CUTTING EQUIPMENT INSTALLED
AT SAHIBABAD/LUDHIANA

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 INSTALLED
AT SAHIBABAD
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
 HEAT TREATMENT FACILITIES

Sealed Quench Furnace Sealed Quench Furnace

Continuous Gas Carburising 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
 FINISHING EQUIPMENTS

•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)
 METALLURGICAL LAB FACILITIES

• 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
 METROLOGY 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
 QUALITY SYSTEMS
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
 TRACEABILITY

•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
 INVESTMENT COMMITTED
• 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
 CUSTOMER PROFILE–DOMESTIC OEMs
AUTOMOTIVE
•Tata Motors

•Mahindra & Mahindra

•American Axle &

Manufacturing

•Scooters India
 CUSTOMER PROFILE–DOMESTIC OEMs
AGRICULTURE
•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

 CUSTOMER PROFILE-EXPORTS

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.
 FORGING FACILITIES AT LUDHIANA

Steel Yard Friction Belt Drop Hammer Up Setter

Annealing Furnace
 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 Phoenix
CNC Dry/Wet
Cutting
System
 FACILITIES AT SITARGANJ

Pinion Teeth Cutting Line Crown Teeth Cutting Line Lapping & Testing Line

Sealed Quench Furnace Phosphating Plant Metallurgical Lab

Forging Press Forging Press Annealing Furnace

 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 sets
Gleason Crown Wheel(606/607, No.22) -- 5 sets
Hobber -- 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

 PLANT ADDRESS
PUNJAB BEVEL GEARS LIMITED
Unit-I &Address for communications:
B-44/1 & 52/2, Site-IV, Industrial Area,
Sahibabad-201010, Ghaziabad (U.P) INDIA
Tel.: +91-120-4505100-129, Fax: +91-120-4505104/4505105
Email: [email protected] URL: www.pbgl.in

Unit-II :
B-174, Phase –I, Eldeco Sidcul Industrial Park,
Sitarganj -261453, Udhamsingh Nagar ,
(Uttarakhand), INDIA
Email: [email protected]
Unit-III:
V&PO: Bhama Kalan,
Kohara-Machiwara Road,
Ludhiana- 141115(Punjab), INDIA
E-mail: [email protected]