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Sandhar Automotive Gurgaon: Plant Visit - 1

SAG is a mother plant of Sandhar Automotive that produces ignition locks, fuel caps, and latches for two and four-wheelers. Key processes include milling and bitting ignition keys, moulding plastic keys, and assembling lock and latch components on production lines. Extensive testing is conducted in-house and components are inspected against strict quality standards. The plant aims to deliver high quality parts to major automotive customers through efficient operations and reliable suppliers.

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Ankush Sood
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72 views5 pages

Sandhar Automotive Gurgaon: Plant Visit - 1

SAG is a mother plant of Sandhar Automotive that produces ignition locks, fuel caps, and latches for two and four-wheelers. Key processes include milling and bitting ignition keys, moulding plastic keys, and assembling lock and latch components on production lines. Extensive testing is conducted in-house and components are inspected against strict quality standards. The plant aims to deliver high quality parts to major automotive customers through efficient operations and reliable suppliers.

Uploaded by

Ankush Sood
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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SANDHAR AUTOMOTIVE GURGAON

Plant visit - 1

Report submitted by :- Ankush Sood


SANDHAR AUTOMOTIVE GURGAON
We had a visit on 4th March 2019 in SAG (Sandhar Automotive Gurgaon), It’s
basically a mother plant of SANDHAR. Mr Sunil Kumar Pipil is the Unit head of
SAG. It’s a production plant of Sandhar mainly deals with Ignition lock, Fuel filler
Cap, Fuel Cock assembly & latches for both two & four wheelers. SAG main
Customer are: - HERO, TVS, HONDA, MAHINDRA, TATA, NEW HOLLAND &
PIAGGIO. Our visit was held under the supervision of Mr Rakesh Sidhana (Quality
assurance manager)

Department we visited:-

1. INCOMING & STORE


2. KEY MILLING & BITTING SECTION
3. KEY MOULDING SECTION
4. PRODUCTION LINE OF TWO & FOUR WHEELERS IGNITION LOCKS AND
LATCHES
5. TESTING LAB
6. JEM DIVISION
Firstly material received at inspection department where lot wise material is inspected
by quality team members. For inspection they have develop the standard which is
known as Sandhar Inspection Standard (SIS). In SIS they mentioned the critical
parameters of parts which must be checked during inspection. For Export items there
is 100 % inspection of parts in their respective lots. Once it’s verified by quality team
material will be send to Store. There is also a Bought out part (BOP) area where
only BOP parts are inspected.

To improvement the supply chain SAG developed their Supplier Quality Assurance
(SQA) team. They will define the:-
1. Product's quality requirements.
2. Identify and evaluate available suppliers
3. Choose the most reliable suppliers that fit the productions' needs

The best thing about SAG is that there is one day inventory.

STORE:-

After inspection of material, it will place into the bins and sent to the store. Store
members placed it in their particular sections, which are mentioned in Material
Location chart, Material Location chart helps to find the location of different parts in
the store. There is also a FIFO system for material i.e. First in First out.

KEY MILLING & BITTING SECTION:-

Lock key is made from brass sheet i.e. C2801 as per JIS H: 3100 having copper
59-62%. For manufacturing of key there are four processes:-

1. Blanking and Punching (from the brass sheet, working piece is removed through
punch and die)
2. Milling (Unwanted material is removed through blanking piece of key)
3. Bitting (also a metal removal process but more critical process in which key is
bitting according to their particular code and engage the lock mechanism)
4. Plating (Ni plating just to improve the appearance of key)

In SAG blanking process will be done by some other unit of Sandhar i.e. Sandhar
Component Manesar.

After receiving key blank there is In-house milling machining.


In milling machine there is two type of Key cutting i.e.

Type-A Type-C
These two type of key cutting increase the combination of key.
After milling process these key blanks goes to Vibro dryer where all moisture is
absorbed by small vibro granules. Capacity of Vibro dryer is 2000 pieces in 5 min.

Then it goes to another process i.e. bitting. Bitting of key depend upon the
Combination of key required for Customers, based on that they start the process.
Combination of key increased by the number of tumbler used in lock assembly.
Maximum number of Combination obtain is 4500 A type and 4500 C type key with
eight tumbler disc.

Last process of plating is done by outsource i.e JMD Noida.

KEY MOULDING AREA :-

There are five vertical moulding machines (range from 50 to 65 ton) in which three
are with rotary table and rest two are double sliding table vertical injection moulding
machine(used for increasing the productivity) .

Polypropylene and Nylon-6 + 15%GF are generally used for key moulding. Raw
material is first pre heated then it goes to their respective moulding machining hopper.

We also saw the eight cavity injection tool used for Hero Key in vertical injection
moulding machine with rotary table.

Before key moulding there is Vision based auto tag punching machine used to
identify the key number of particular bitting sequence and to punch the number of
key.

PRODUCTION LINE OF TWO & FOUR WHEELERS IGNITION LOCKS


AND LATCHES :-

In two wheeler production line there is total 18 production line but at that time only
12 lines are in work-flow. We saw the:-

 Fuel cock assembly


 Ignition lock with Fuel filler cap assembly
 Latch assembly for TATA 407 in four wheeler production line

Eight to twelve persons are in one line to complete the process of assembly.
According to the process flow chart, Assembly is done on each section. After
assembly there is Leakage testing, Continuity testing and Movement testing of each
final product. Then finished product placed into a coloured cloth bag and send to pre
dispatch inspection area through conveyor belt. Colour coding for cloth bag is used
for to identify the same product having supply for various customers.
TESTING LAB:-

Basically there is three type of testing:- Performance test, Endurance test and Strength
test. According to customer requirement they will perform test on the product.
One of the Hero ignition lock is testing on endurance testing machine and requirement
of lock to get passed is:- 30000 cycle at 10 ampere load

There is also a vibration testing machine having :-


Frequency range up to :- 3500 Hz
Acceleration :- 75G
Force :- 1000 kgf
Some of testing machine are written below which is used by SAG:-

High voltage test ,Over current test , Ni & Cr plating layer test, Flow rate tester,
Rockwell hardness tester, Spring load tester(Compression as well as torsion spring),
Water bath chamber, Dust cum Evaporation chamber, Hot and Cold chamber & Salt
spray test chamber.

JEM DIVISION :-

It’s a technical collaboration between Sandhar and Korean company Jinyoung Electro
– Mechanics. Here highly precision parts i.e. Electronic relays are manufactured by
using full automatic special purpose machines. The JEM Division major customers
are Mahindra and Honda.

Relay:- A relay is a switching device which is operated by a relatively small electric


current that can turn on or off a much larger electric current.
Relay rated voltage – 12V to 24V
For Long life 99.9% Copper is used for Electrical conductivity.
Life cycle of relay is 2 lakh cycle.

Application in Automotive Industry:- Head light, High-Low beam, ACC, wiper motor,
Blower fan etc.

Key Learnings after visiting SAG

1. Know about SQA and their benefits towards organization.


2. Know about Vibro dryer
3. How relay manufacturing by fully-automatic machines.

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