Sundram Fasteners Limited, Hosur

SUNDRAM FASTENERS LIMITED
Metal Forms Division
Sundram Fasteners Limited
GreenCo
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Sundram Fasteners Ltd

Established in 1966
Sales: US$ 555 million
Global manufacturing presence: India, China, UK and Germany
Comprising of 12 manufacturing plants
First Indian company to get ISO 9000
Winner of TPM special/ TPM excellence/ TPM consistency award

Global customer base
Unique IR record: not a single working day lost since inception
GreenCo
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SFL Metal Forms Division
Established in 1979
Sales: US$ 58 million `
Product range sintered and cold forged parts for automobile and
non-automobile application
State of the art in-house tooling
Vertically integrated - into iron powder
ISO 14001 & TS 16949 certified units
Pursuing TQM, targeting prestigious Deming award by 2017
GreenCo
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SFL Metal Forms Division
MFD TAPPET
MFD SINTERED PARTS
MFD POWDER METAL

MFD FORGING
SFL
1966
GreenCo
1979
1983
2007
2010
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Process Flow Chart

Cold Extrusion Plant
GreenCo
Powder Metallurgy Plant
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Cold Extruded Parts
GreenCo
Powder Metal Parts
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Journey to become a Greenco
Registration with CII and Training Mar14

Formation of CFTs - Apr14
Awareness and Training programmes - Apr14 to
May14
Handholding visits by CII -Jun14
Celebrating Greenco Month - Nov14
Document Submission Dec14
Final assessment Feb15
GreenCo
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Material Conservation, Recycling and Recyclability (MCR)

Frame work for material conservation and management:
MATERIALS
RAW MATERIALS
DESIGN
IMPROVEMENT
YIELD
IMPROVEMENT
GreenCo
SCRAP
REDUCTION
TOLERANCE
OPTIMIZATION
TOOL STEELS
PACKING
MATERIALS
MATERIAL
REDUCTION
RECYCLING
SLUG
RECYCLING
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Raw Materials
RM consumption reduction is emphasized using a two fold approach
Design Improvement
Scrap Reduction
Design Improvement focuses on projects like Yield Improvement, Tolerance
Optimization and Slug Recycling, Alternate Material
Yield improvement : Yield - Efficiency of a process by comparing the amount of output to the input
Yield can never be 100% in any manufacturing process, as there are some losses
Optimization of the process by reducing the losses leads to an improved yield %
Yield Improvement - Use fewer resources, less energy, processing facility and
obtain higher revenue for the same input
GreenCo
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COLD EXTRUSION (CE)
GreenCo
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Design Improvement
Some of the Yield Improvement Projects:
The projected yield improvement has been achieved through various
annual projects given below:
GreenCo
Sl. No:
Project
Theme
Period
Machining stock reduction
Hole backward extrusion introduced

to avoid slug machining.
2010-11
Weight reduction in sleeves
Peeling elimination and machining

stock optimisation
2011-12
Weight reduction in cams and

pinions
Process redesign and machining

stock optimisation
2012-13
Weight reduction in flanges
Counterbore and taperbore forming.

Combined extrusion introduced.
2013-14
Slugging loss reduction
Sawing to shearing change over
2014-15
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Yield Improvement :RM Yield Improvement in Flanges

SFL - MFD
Previous
Present
Weight Saved ( 2013-14) : 59.1 T

Estimated saving(2014-15) : 49.8 T
Engineering Cold Extrusion., Sundram Fasteners Limited, Hosur. INDIA
(2013-14) RM cost saved: 34.4 L

Benefit
Cost saved
Press strokes
15.6 L
Anneal + Coat'g
9.6 L
S/C Mach'g
6.4 L
A : Stem dia defined

B : Taper bore preformed
Yield: 53.3%
Yield: 57.5%
C : Counter bore preformed

D : Profile length optimized
* RM cost assumption: 65k/ton

Engineering Cold Extrusion., Sundram Fasteners Limited, Hosur. INDIA
GreenCo
4/9
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Cages has been developed through an alternate route..

Existing Process
Revised Process
Ring Rolling
Window
piercing
Heat Treatment
Input weight
(gm) sawing
route
Input weight
(gm) ring rolled
route
Weight
conserved (gm)
Qty in 2013-14
RM conserved in
2013-14 (T)
563
246
317
84938
26.9
392
189
203
34523
7.0
GreenCo
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Systematic Monitoring - Example

RM Savings Through various projects
Family
Turbine
shaft
Tripod
Sprocket
Sleeve
Gear
Flange
Cam
GreenCo
Theme
Peeling loss reduction
Counterbore and taperbore
formation in forging. Combined
extrsuion introduced
Total
Target / year
(MT)
Actual achieved
/Year (MT)
23.24
3.38
3.51
13.63
3.24
17.12
3.02
9.16
10.67
2.58
11.04
16.7
74.74
29.65
14.2
86.4
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Systematic Monitoring
Monitoring of RM saved due to implementation of projects
100
Target
90
Actual
86.4
86.4
80
70.4
74.7
70
Value in tonnes
60.8
66.4
60
49.9
58.1
50
33.3
30
25
10
0
39.3
30.5
16.8
20
GreenCo
49.0
41.6
40
0.8
3.1
1.2
0
BP 13-14 Apr'13 May'13
6.3
9.7
BETTER
19.0
13.5
10.2
3.7
Jun'13
July'13 Aug'13
Sep'13
Oct'13
Nov'13 Dec'13
Jan'14
Feb'14 Mar'14
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RM saved due to implementation of projects

120.00
100.00
80.00
MT
60.00
Target MT
40.00
Actual MT
20.00
0.00
Target MT
Actual MT
GreenCo
2010-11
107.80
106.80
2011-12
95.80
65.80
2012-13
76.10
51.40
2013-14
74.74
84.60
2014-15
71.60
75.80
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Improvements Axle & Hub Module (VW) CNC Machining 3
Before
Problem : Job not properly seated in the M/c

Chuck ( Improper clamping).
GreenCo
After
Action: M/c Program modified (During part

loading, turret will come and hold the part for
self alignment).
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Improvements - Cage Module Window Broaching
Before
1. Headstock and Tailstock component resting face is having

excess land which leads to deposition of broached burr.
2. Broached burr deposition in the tailstock ID leads to burr
damage.
GreenCo
After
1. Headstock and Tailstock excess land modified by Providing

the 45 degree angle for effective burr removal.
2. Tailstock ID is closed by using the LID to avoid the
broached burr deposition inside the ID.
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MCR Credit 3.2 :- Systematic Monitoring

RM yield improvement year on year
56.9
57
55
Yield %
53
52.3
51.6
51
50.8
49
47
Yield %
GreenCo
2011-12
50.8
2012-13
51.6
2013-14
52.3
2014-15
56.9
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POWDER METALLURGY (PM)
GreenCo
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Competitiveness of Powder Metallurgy
Cost
Strength
Weight Reduction
MATERIAL & ENERGY EFFICIENT.
MINIMIZE MACHINING
COST EFFECTIVE FOR COMPLEX SHAPES
PROVIDES PART TO PART REPRODUCIBILITY
PROVIDES CONTROLLED MICROPOROSITY FOR SELF LUBRICATION OR FILTRATION
SUITED TO MODERATE TO HIGH VOLUME PART PRODUCTION
GreenCo
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Design Improvement
PM - RAW MATERIAL IMPROVEMENT
PREMIX OPTIMIZATION
OPTIMIZE ADDITIVES
AGAINST CUSTOMER
SPECIFICATION
ALTERNATE POWDER /
SUPPLIER
SCRAP
MODIFY THE
POWDER GRADE /
CHOOSE ALTERNATE
SUPPLIER
REDUCE
INPROCESS SCRAP
ALTERNATE SOURCE
FOR POWDER/ALLOYS
CLASSIFY
PARTWISE SCRAP
IDENTIFY &
IMPLEMENT KAIZENS
GreenCo
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Design Improvement
Sl
Theme
Impact
no
Premix optimisation of Reduction in usage of materials like Copper,
1
material
Manganese Sulphide
2 Alternate powder
material
Machining stock
3 reduction - Near net
shape in compacting
Reduction in usage of materials like Copper,

Manganese Sulphide,Nickel, Molybdenum
Yield improvement
Conversion form Cold

4 extrusion to Powder Yield improvement, Reduced consumption of
Metallurgy
resources
GreenCo
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Machining Stock Reduction

Existing route
New route
Compaction
weight
220g
190g
RM Yield
80%
93%
Compaction
Savings
Green Part
Photo
Machining
area
GreenCo
Cycle time per part :

220s
Cycle time per part :

180s
RM Cost
: 271/kg
Saving per part : 8.13
Machining hourly rate :

140
Saving per part
:
1.56
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Conversion from CE Process to PM Process
Details
GreenCo
Before
After
Powder Metallurgy
Cold Extrusion (CE) (PM)
No. of operations
Slug weight kg /
piece
16
2.3
0.95
RM yield %
40
86
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Advantages of PM Process over CE Process

1. RM Yield improvement from 40% to 86%
2. Zero Water consumption for the Process in PM whereas CE involves
Phosphate coating, which consumes water.
3. Reduced energy consumption in the manufacturing process due to
lesser number of operations.
4. Less fuel consumption of the vehicle after assembly due to
lesser weight of the product.
5. Lower Emission levels due to lesser weight of the product.
GreenCo
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Cam Re-designed
Abrupt Movement over Cam
GreenCo
Smooth Transition Cam
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Pocket type foam trays

BEFORE
Separator type trays used

GreenCo
AFTER
Pocket type Foam trays

used
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Tools
(for both Cold Extrusion and Powder Metallurgy)
GreenCo
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Tool Materials
Tooling materials receive maximum attention for conservation and recycling as
They are very expensive

They are difficult to manufacture due to intricate design
The tooling materials could be either carbides or tool steels
Both tool steel and carbides are reworked and used multiple times till all
avenues are exhausted for any further usage
IMPACT
IMPLEMENTATI
ON
FRAMEWOR
K FOR
ANALYSIS MATERIAL
CONSERVAT
ION
OBJECTIVE
GreenCo
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Tool Materials
TOOL STEEL (RM )

SIZE OPTIMISATION
RECYCLING
IMPROVEMENT OF
TOOL LIFE
TOOL DESIGN
GreenCo
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Tool Materials
SL
NO
THEMES
IMPLEMENTATION
Reduction of Carbide tools

consumption
Re sharpening and recoating of the used cutters

Re using the shrink fitted die cases
Re using the shrink fitted die cases
Reduction of Tool steel

consumption
Reforming piercing punch holders

Re sharpening and reusing the blunt / damaged punches
and anvils
RATIO OF TOOL STEEL CONSUMED PER TON OF PRODUCT

DESPATCHED
WEIGHT (kg)
6
4
2
0
2011-2012
GreenCo
ratio of ce
5.17
ratio of pm
2.62
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Tools recycling trend Chart :HSS Recycle %

70
59.15
60
63.03
53.33
50
40
30
2012-13
53.33
HSS Recycle %
2013-14
59.15
2014-15
63.03
Carbides recycling trend Chart :Carbide Recycle %

70
65
60
55
50
45
40
35
30
Carbide Recycle %
GreenCo
54.39
55.90
57.03
2012-13
54.39
2013-14
55.90
2014-15
57.03
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Material Conservation - Tools
Quantity of tool steel procured has declined at a rate of 72.5 % in CE and 44.8% in PM from
period 2011-2014.
GreenCo
34 of 49

Material Conservation Tools steel

As per the product dimension
minimum stock is fixed and RM
is maintained
Designing tool in
correspondence with part
parameters
Optimizing length and diameter
as per functionality
SAVINGS IN RM WEIGHT
30
WEIGHT
25
20
15
10
5
0
RM WEIGHT(KG)
GreenCo
BEFORE
26.3
AFTER
5.8
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Tool Life Improvement

Nitriding of die inserts done to avoid
chip off and pick up issues.
tool
steel
grade
change
tool
handling
/usage
TOOL LIFE
IMPROVEMENT
enhanced
coating
techniques
Die life
before
after
%
increase
in life
Quantity
in no.s
500
4000
87.5
DIE LIFE OF TOOL
tool
manufac
turing
4500
4000
No of pieces
3500
3000
2500
2000
1500
1000
500
0
die life
GreenCo
before
500
after
4000
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Tool Design
Standardization of
common tools
Optimization of tool
size(Dia & length)
Split design
RM USED(in kg)
2.5
qty
1.5
0.5
0
RM USED(in kg)
GreenCo
BEFORE
2.15
AFTER
0.68
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Results of tools conservation

RATIO OF TOOL STEEL CONSUMED PER TON OF
PRODUCT DESPATCHED
5.50
5.00
4.50
WEIGHT(kg)
4.00
3.50
3.00
2.50
2.00
1.50
1.00
ratio of ce
ratio of pm
GreenCo
2011-2012
5.17
2.62
2012-2013
4.89
2.42
2013-2014
4.53
1.82
2014-PRESENT
4.01
1.31
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SUNDRAM FASTENERS LIMITED

Metal Forms Division

Sundram Fasteners Limited

Sundram Fasteners Ltd

Winner of TPM special/ TPM excellence/ TPM consistency award

Sundram Fasteners Limited

SFL Metal Forms Division

Sundram Fasteners Limited

SFL Metal Forms Division

MFD SINTERED PARTS

MFD POWDER METAL

Process Flow Chart

Cold Extrusion Plant

Powder Metallurgy Plant

Sundram Fasteners Limited

Cold Extruded Parts

Powder Metal Parts

Journey to become a Greenco

Sundram Fasteners Limited

Registration with CII and Training Mar14

Material Conservation, Recycling and Recyclability (MCR)

Frame work for material conservation and management:

Material Conservation, Recycling and Recyclability (MCR)

Optimization and Slug Recycling, Alternate Material

Material Conservation, Recycling and Recyclability (MCR)

COLD EXTRUSION (CE)

Material Conservation, Recycling and Recyclability (MCR)

Machining stock reduction

Hole backward extrusion introduced

Weight reduction in sleeves

Peeling elimination and machining

Weight reduction in cams and

Process redesign and machining

Weight reduction in flanges

Counterbore and taperbore forming.

Slugging loss reduction

Sawing to shearing change over

Material Conservation, Recycling and Recyclability (MCR)

Yield Improvement :RM Yield Improvement in Flanges

Weight Saved ( 2013-14) : 59.1 T

Engineering Cold Extrusion., Sundram Fasteners Limited, Hosur. INDIA

(2013-14) RM cost saved: 34.4 L

A : Stem dia defined

C : Counter bore preformed

* RM cost assumption: 65k/ton

Material Conservation, Recycling and Recyclability (MCR)

Cages has been developed through an alternate route..

Material Conservation, Recycling and Recyclability (MCR)

Systematic Monitoring - Example

Material Conservation, Recycling and Recyclability (MCR)

Material Conservation, Recycling and Recyclability (MCR)

RM saved due to implementation of projects

Material Conservation, Recycling and Recyclability (MCR)

Improvements Axle & Hub Module (VW) CNC Machining 3

Problem : Job not properly seated in the M/c

Action: M/c Program modified (During part

Material Conservation, Recycling and Recyclability (MCR)

Improvements - Cage Module Window Broaching