Presentation by Surinder Kapur September 14th, 2012 · PDF fileSales Profile F 2011 Sona BLW (Okgwa) 6.0% Others 2.0% Sona Somic 6.0% Sona BLW (Ger.) 39.5% ... involved employees.
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Presentation by Surinder Kapur
September 14th, 2012
The Sona Group
• 25 years ago the Sona Group started with :
» 25 employees
» 1 million € Sales
» 1 company in India
The Sona Group
• Today » 6000 Employees (4500 in India and 1500 outside India)
» Global Sales revenue cumulatively of € 680 million
» 8 manufacturing companies in India, 18 Plants.
» 1 overseas company with 3 plants in Germany and 1 plant in the US
» All Indian companies are with ISO 14000 and TS 16949 certification and practicing Japanese TQM and TPM methods.
» Sona Koyo is Deming Prize Winner and TPM Excellence Award winner
Sona
Autocomp
USA
SONA KOYO
STEERING
SYSTEMS
LTD.
MAHINDRA
SONA LTD.
SONA SOMIC
LEMFORDER
COMPONENTS
LTD.
SONA
OKEGAWA
PRECISION
FORGING LTD.
SONA
E-DESIGN &
Technology
Auto Components Services
Sona Holding
Support
Sona
Autocomp
France
JTEKT SONA
AUTOMOTIVE
INDIA LTD.
Fuji Autotech
Europe
.
SONA FUJI
KIKO INDIA
LTD.
Koyo- Sona
Electronics
Ltd.
SONA
MOBILITY
SERVICE
(SIXT)
SONA BLW
PRECISION
FORGING
GROUP
Germany
+
SONA
Plant Selma
USA
Sona
Stampings
PVT. LTD.
Structure
Sona BLW Precision Forge
1 plant in
North Carolina, USA
Fuji Autotech
Brazil
Sona BLW
Präzisionsschmiede
3 Plants in Germany
Sona Group India
18 Plants Fuji Koyo Czech
(FKC)
Fuji Autotech
France
Minority Stake Sona Group
Companies
Fuji Autotech
Sweden
Service Co
Global Footprint
Sona Marketing Offices
•USA
•Europe
•Japan
Chennai
• Sona Somic Lemforder
• Sona Koyo Steering Systems
• JSAI
DELHI
GURGAON
BAWAL DARUHERA
NASIK
PUNE
CHENNAI
Pantnagar
• Sona Somic Lemforder
Pune
• Sona Okegawa Precision Forgings
Nasik
• Mahindra Sona
Bawal
• JSAI
• SFAL
Gurgaon
• Sona Koyo Steering Systems
• Sona Okegawa Precision Forgings
• Sona Somic Lemforder
• Sona Stampings
Daruhera
• Sona Koyo Steering Systems (3 Plants)
SANAND
Sanand
• Sona Koyo Steering Systems
PANTNAGAR
Sona
Koyo
Sona
Somic
Sona
Okegawa
Mahindra
Sona
Cold
Forging
Production 1987 1995 1998 1980 1997
TS16949
ISO 14001
TPM
Excellence
Award
Deming CERTIFICATIONS
Presence in India
Sona Group is India’s largest manufacturer of Steering Systems
R&P Power Diff case Assembly Propeller Shaft CEPS Steering U Joints
Columns & shafts
Market Leaders in India
Sona Group is Worlds largest Precision Forged Bevel Gears Manufacturer
Bevel Gears Synchronizer Rings Speed Gears Axle Stubs Hatebur Flanges
Output Shaft
World’s Largest Precision Gear
Manufacturer
Steering column
Rear axle
Steering Gear
Propeller shaft
Clutch
Assembly
Control arm
Bevel Gear
Seat Recliner
Product Portfolio
Global Customers
India Customers
12
Sona Koyo Steering
System Ltd
Sona Okegawa Precision
Forgings Ltd
Sona Somic Lemforder
Components Ltd
Sona e-Design &
Technologies Ltd
S MIC
Mahindra Sona Ltd.
Overseas Technology Partnerships
Sales Profile F 2011
Sona BLW
(Okgwa)
6.0%
Others
2.0%
Sona Somic
6.0%
Sona BLW (Ger.)
39.5%
JTEKT Sona
7.0%
Mahindra Sona
7.0%
Sona Koyo
28.0%
Sona BLW (USA)
4.5%
Group Turnover – € 680 million
Sona Okegawa
Group 50%
INDIA
56%
Respect for the Individual
Service to the Customer
Excellence in the pursuit of our Goals
MOTTO
Think!
Create a Company That India is Proud of
To Make Sona A Partner Of Choice’ to Global Customers
MISSION
An organization of energized and involved employees.
Growing and achieving high profitability.
Supplying to major global OEMs directly or indirectly.
At least 50% of sales overseas,
Be #1 in every business line
VISION
Sona Vision 2020
The German Adventure Acquisation of ThyssenKrupp
Forging Company
Why the Acquisition
• Globalization
• Technology Leadership
• World No.1
17
1951 Fabrication of first forged differential gears world- Wide in BLW; Daimler -Benz is first customer for these parts.
1953
Straight bevel gear patent
1965 Start-up of the First automatic multi-stage Forging press “Hatebur” at Remscheid plant
1979/80 Remscheid produces first precision forged differential gears BLW files Production process And design of “Back Tapered coupling Teeth” as patent
1986/89 Wanheim plant is integrated into The Thyssen Business unit “Forming technologies” Acquires BLW And establishes The business Segment “gear parts”
1996 Business unit “forming Technologies” Acquires US- Precision forge SMB from Saurer AG (later renamed TK PF Inc.) and Integrated it into The business Segment “gear parts”
2002 Business Segment “gear Parts” is separated From the forming group and named ThyssenKrupp Prazision. (Plants Remscheid Munich, Wanheim And Selma (US)
Today Successful worldwide producer of precision forged power train parts e.g bevel -,speed gears and axle drive components
2008
Sona Okegawa acquired Thyssenkrupp Technologies and Sona BLW formed
1998
Start of Sona Okegawa Precision Forgings Ltd- Indian Operations
History- Sona Precision Forging Group
Remscheid Duisburg
Selma, USA
Munich Remscheid Duisburg Selma Gurgaon Pune
Foundation 1925 1773 1911 1996 1997 2005
ISO/TS16949
DIN EN ISO 14001
TPM Excellence Practicing Practicing Practicing Practicing Practicing
Munich
Locations- Sona Precision Forging Group
Post Acquisition Challenges
• Financial Crisis – Oct 2008
• Creating a ‘Mittelstand’ company with a ‘big
group’ mentality management
• Inefficient processes – low OEE, high Scrap
• Dealing with German Unions and high labour
cost
Competitiveness Strategy –
next 3 years, 2010 - 2013
Our Vision – Be Globally Competitive
To be globally competitive Precision Forge
Take an Active Part in our Customers‘ Globalization Strategies
To Offer World Class Supply and quality
Strategy developed with Employees
Improve
Productivity
Reduce
Scrap
Introduce
New Products
CAPEX
Education/Training
How ?
Introduce New Prod.
Strategy of HOW to become Globally
Competitive – 3 years
From Now to 2020
Become the #1 Global Independent Precision forging Group with sales of $1 billion .
Mission 2020 - Sona Precision Forging Group
No. 1 Precision Forging Company
Globally $ 1 billion
Globalization –
follow the customer
Strategic
Development Partner
Operational
Excellence R&D and Innovation
Geographical strategy Quality strategy Synergy strategy
Respect for the Individual Service to the Customer Excellence in the
pursuit of our goals
Governance excellence HR Excellence
2020
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