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1、11956 BonfiglioliisfoundedinBolognabyClementinoBonfiglioli,thecompanyscurrentChairman.1964 TheRAEseriesdual-stageplanetarygearunitisdesignedandpatented.1975AcquisitionofTrasmital,amanufacturerofplanetarygearunitsfordiggers,roadpaversandwindturbines.1982Bonfigliolistartsitsinternationalizationstrateg
2、y,leadingtotheopeningofbranchofficesworldwide.1999TheBonfiglioliTransmissionPvtLtd.factoryisopenedinChennai,India.2006Bonfigliolicelebratesits50thanniversary:confirmationofthecompanyssuccess.Bonfiglioli Milestones “Today the company has production plants and branches in 14 countries,with a global wo
3、rkforce of more than 2500 and a turnover in excess of Euro 610 million.”第1页/共32页BTPL Germany Italy Slovakia Vietnam Australia India Brazil Canada China England France New Zealand Singapore Greece South AfricaSweden USA Turkey Bonfiglioli Manufacturing Locations Bonfiglioli Sales OfficesSupply from B
4、TPL第2页/共32页3BTPL overviewTurn over51 millon euro Employees450 Built up area 17,000 sqmArea for expansion 19,892 sqmTotal investment 70 million euro 第3页/共32页4Quality Policy Bonfiglioli Transmissions pvt.Ltd.Quality Policy is to consistently and continually accomplish the strategic and improved goals
5、of“On Time Delivery”,Systematic Up gradation of Products,Quality,and Services,with the accent at all times on,One level of International Quality,the product reliability and a“Total Customer Satisfaction”.第4页/共32页5BTPL Products2000AS Inline Helical Gear Box Production-Industrial application2001TA Pro
6、duction/Indigenization-Industrial application2003&04300 series Production/Indigenization-Industrial application2005Industrial gear boxes and sub assemblies to planetary gear boxes 2006Planetary gear boxes for Windmill Application第5页/共32页6BTPL Manufactured products 2000AS Inline Helical Gear Box Prod
7、uction-Industrial application2001TA Production/Indigenization-Industrial application2008&09300 series planetary gear boxes for Industrial/Windmill application2006700 MT series gear boxes wind mill application.2009-2010Start up activities of mobile gear box production.第6页/共32页7About BTPL BTPL manufac
8、turing activity started in the year 2000 and has successfully completed 10 years of operations and sold over 1.8 million gearboxes/geared motors.BTPLs core competency is to make Geared Motors for Industrial,planetary Gear boxes for mobile and Wind Mill applications and export to parent company and c
9、ustomers outside India.BTPL has a strategic position in its Group in terms of Product Realization to meet customer requirements and operates on common SAP platform with parent company.BTPL has achieved Market Leadership in its domain of operations,in short span of Ten years and have won the confiden
10、ce of Domestic and International Customers.第7页/共32页8BTPLhasWorldClassManufacturingfacilitiessuchasMachiningcenters,GearManufacturingequipmentsforproductionofPinionShafts,Housings,PlanetCarriersSunGearsPlanetGearsetc,etc.,Thetechnologybehindthemanufacturingandinspection/testingareinlinewiththeInterna
11、tionalQualitystandardsestablishedbyTrasmitalBonfiglioli.BTPLs manufacturing Capabilities specific Mobile Gear Boxes 第8页/共32页9BTPLs Assembly Capabilities specific Mobile Gear Boxes BTPLassemblyhasgotthefollowingfacilitytoproducethemobileapplicationgearboxes.MainAssembly,OutputSubAssembly,ReductionSta
12、geAssemblyRuntestandAirLeakTestfacilitiesPaintShopfacilities.Assemblytesting,electricalmotor&hydraulicmotortestingfacilityIthasgotacapacitytoproduce&assemble2000mobileandplanetaryGearboxes/month第9页/共32页10Validations TheproductandtheprocessundergoestwotiervalidationsBTPL(Chennai)&TrasmitalBonfiglioli
13、(Italy)Training&verificationrequirementsofassemblyisprovidedbyTrasmitalBonfiglioli-Italy.PeriodicalauditsonpartsandtheassemblyalsoconductedbyTrasmitalBonfiglioliItaly.第10页/共32页11Manufacturing Capabilities 第11页/共32页12Production FacilitiesHMC第12页/共32页13Production machines 第13页/共32页14Production machine
14、s第14页/共32页15BTPL ManufacturingBTPL manufacturing facilities have been well integrated with the capability to produce Geared parts,(including pinion shaft manufacturing Housing ,complete Heat treatment&assembly and testing.It has its key personnel trained at Bonfiglioli-Italy Product design,manufactu
15、ring concept are received from Head Quarters.BTPLs manufacturing facilities are flexible in nature and provide adequate back-up resources.The product manufacturing plan is integrated with Bonfiglioli,both for process and conformance.It has two tier approval process for the parts and assembly prior t
16、o usage.BTPL,has a two tier approach to its manufacturing and supplier base development.第15页/共32页16World Class Manufacturing FacilitiesEquipmentMakeTo produce Turn Mill CentersMazak IntegrexHorizontal/Vertical/Turning CentersMazakInternal/External GrindersStuders/VoumardGear Manufacturing gear cutti
17、ng,shaving,gear grinding Gleason/Pfauter/Reishauer第16页/共32页17BTPL Production FacilitiesEquipment GroupNo.ofMachinesNew ExpectedBroaching31GearGrinding41GearShaping21HeatTreatment61HMC5-Hobbing92IDGrinding3-ODGrinding6-VTL1-VMC2-TurningCentres6-TurnMillCentres-Mazak/Integrex41Gearshaving41第17页/共32页18
18、Mobile equipment Components Manufactured in BTPL第18页/共32页19Assembly and paint shop capabilities第19页/共32页20Assembly&Paint Shop第20页/共32页21Assembly of mobile Gear Box 第21页/共32页22BTPL Assembly FacilitiesEquipment GroupNo.of MachinesInputSubAssy2OutputSubAssy4PlanetarySubAssy4MainAssy&Testing4TestBench1P
19、aintShop1第22页/共32页23Mobile Application JCB(India)-700 T-slew drives Codes already under development 2T 261608090 7T 09 2 F*LE 1 S 009 A 17 T BR TS 2T 709 T 20 16 A 01 7T 09 2 FXLE S 022 A 16.9 Y 10 T VJ U 22C第23页/共32页24BTPL Production volumes第24页/共32页QUALITY ISO 9001 Certified since Dec 2001(ISO 900
20、1:2008 from Jun09)第25页/共32页26Quality Equipments MICRO SCOPESPECTROGEAR TESTER第26页/共32页27Some of the Quality Equipments CMM2GearTester2DigitalHeightGage3Microvickers1Microscope2MagneticParticleInspection2RoundnessTester1Profileprojector1Linearmeasuringinstrument1Profilometer(Expectedshortly)1第27页/共32
21、页28Quality Assurance(including metallurgy)IncomingInspectionMetallurgyInprocess(M/c)AssemblyCalibrationQualitySystemsAuditCertificateDimensionalInspectionforRegularProductsNewProductsSupplierEvaluationSupplierVisitsNewProductInspectionGRNClosureVendorNotificationsInspectionofBar/Casting/Forging/Exte
22、rnalHeatTreatmentInspectionofInhouseHeatTreatmentInspectionofNewComponentsSupplierEvaluationSupplierVisitsFirstOffInspectionforEverySetup/MachinePatrolinspectionNewSamplesInspection/BRI/TB/InternalFeedbackProcessCapabilityStudiesandfeedbackFinalInspectionGearboxapproval1stoffandperiodicalapprovalBat
23、chapprovalforthepaintedgearbox.auditofthegearboxCustomerComplaintAnalysis&ActionsCalibrationofMeasuringEquipment(Internal)CoordinationforExternalCalibrationofMeasuringEquipmentPlanningforNewGageProcurementInternalAuditPlanning&ExecutionMRMPlanningCoordinateforExternalAuditsFocusonImprovementofQMSIss
24、ue&ControlofStandardsComponentAuditTorqueAuditLubricationAuditGearBoxAuditTestCertificatecumWarrantyCertificateProduct/CustomerspecificInspectionReports第28页/共32页Quality Assurance Plan第29页/共32页30Raw material used PartsRaw material usedHousing,motor flangeSG Iron(500/7)600/10&700/2 Gears 20 MnCr5Shaft
25、s 17Ni CrMo6-4,EN24,第30页/共32页31Customer Satisfaction SurveyInter company Rating by Bonfiglioli on BTPL2008Quality Overall Ridutori(BRI)99.4%98.1%Trasmital (TB)98.3%97.0%for 2008*RatingSatisfied DelightedTotal Product Reliability 28.4%65.2%94%Product performance 19%76%94%*Note:Survey conducted by BDB Q-SAMM OEM RatingCustomer Complaints-PPM YearPPM2008 864 PPM2009(YTD)600 PPM2010 target 500 PPM 第31页/共32页32感谢您的观看。第32页/共32页