Sona Steering training report

8/14/2019 Sona Steering training report

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Sona Group beginning as a small company in ealiertimes now sona group comprises company each ofwhich are in joint venture partnership and technicaland financial collaboration with global leaders in theirspecialist areas.The sona group comprises 5 operating

and 2 service organisations.

Sona is driving upon its strengths of its joints venturepartners, which includes Koyo Seiko co. Japan;Mondo Korea; Mitsubishi materials co. Japan; SomicIshikawa; Fuji Autotech to upgrade its systems, Skills

and production values to offer its customerscotemporary and high quality products.


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Sona Koyo Steering Systems Ltd. With a market shareof 50% is the largest manufacturer of steering gears inindia and a leading supplier of hydraulic powersteering systems, manual rack and pinion steeringsystems, collapsible, tilt and rigid steering coloumnsfor passenger vans. In addition to this company also

includes real axle assemblies and propeller shafts.The company plants are located at Chengalpattu,Tamil Nadu, Gurgaon Haryana.

Sona Steering Systems incorporated in 1984,commenced business in 1985, as a key supplier to

maruti udyog ltd.

The company proposes to expand the capacity ofmanual steering gears to 1050000 units per annumand power steering capacity to 295000 units per

annum.


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Sona koyo the flagship company of the Sona group is currentlythe largest manufacturer of steering systems for the passenger

car and utility vehicles market in India, with a Market share of45%. Its collaborator and partner Koyo Seiko Company limited,

Japan, is the market leader in Japan and has recentlyannounced a merger with Toyota Machine Works, making it

number one steering systems manufacturer in the world. Thecompany also has a technological collaboration with AndoCorporation, Korea.

The Deming Award, the worlds most coveted Honour for

excellence in Total Quality Management was awarded to SonaKoyo on 11th November 2003

Sona koyo steering system ltd. is a technique and financial joint

venture company of koyo Seiko Company, Japan the globaltechnology leader in steering systems. The company is thelargest manufacturer of steering gears in India and is theleading supplier of

Hydraulic power steering system

Manual rack and pinion steering system


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Maruti-Suzuki Honda-Seil GM(India) Ford(India) Honda Motors Eicher-Mitsubuishi

Punjab Tractors International Tractors Bajaj Tempo Toyota(India) HM-Mitsublshi Tata Motors

Mahindra &Mahindra Swaraj Mazda Fiat Ashok Leyland


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Koyo Seiko (Japan, US) Lemforder (Germany) Mistibuishi Materials Arvin-Meritor

Continental (US) Maval Manufacturing EZGO JCB Excavators Ltd.

TMA Case New Holland


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SKSSL has a total of four plants, each of whichmanufactures different products. Plant I manufactures RPSAssemblies, rigid columns collapsible columns and tiltsteering assembly. Apart from the assemblies themselves,

the various in-house parts like Rack, Pinion, Case gear etc.that are used in the manufacturing of these assemblies are

made in Plant I. Apart from this, various other brought out

parts (BOP) are used such as Bellow, Rack cover, Rackhousing etc.

Plant II is slightly bigger and manufactures a larger numberof items than Plant I. The most important of the products

manufactured here are the RBS Assemblies for variousmodels, Propeller Shaft Assemblies and Axle Assemblies. Inaddition to these assemblies, the sector shaft assemblies

that are used in the RBS Assemblies, the Slide Yoke andFlange Yoke Assemblies that are used in the PropellerShaft Assemblies.


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Differential Assemblies that are used in the AxleAssemblies are also made in this plant. Various in-houseproducts like the sector shaft, worm-shaft, bevel gear,spider and ball-nut are made in Plant II.

Plant III is also known as the Power Steering Plant and itstarted in 1998. The plant makes Power Steering

Assemblies and has just an assembly line currently.

Quenching : This plant in SKSSL has three Sealed QuenchFurnaces. Two of them are hot oil quench furnaces while the

third one is cold oil one.

Tempering : It is the process of heating the components tobe quenched at 160-170C proceeds quenching. The processsoftens the material a bit so that it does not crack when used

due to over hardness


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Process

1)Pinion Soft 6) Universal Joint

2) Pinion Hard a) Manual

3) Rack Bar b) Automatic

4) Case Gear 7) Collapsible Column Assembly

5) RPS Assembly

Process Ball Nut Soft Line & Hard line Worm Shaft Soft Line


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Sector Shaft Soft Line & Hard Line RBS Housing RBS Assembly Bevel Gears

o Manual and Automatic 7. Axle Assembly.

Process

Cylinder Tube Machining Rack Bar for Power Steering Case gear for Power Steering RPS Power Steering Assembly


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This lab is located in Plant II. The lab is operational all thetime and testing of various components is done hereperiodically to make sure that the quality of the productsis of utmost quality. The various tests carried out in the lab

are: Bellow Durability Test: To check for cracks, abrasions and

breakage in the bellow while operating under very hot or

very cold conditions. Column Durability Testing: Here input is a rectangular

waveform given from the handle side of the column.

Steering Column Impact Testing: In this test, a body blockis attached to a linear actuator and through this system; athrust is given to the steering column. Sufficient thrust is

given to cause breakage of the column.


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TESTING FACILITIES 2

Coloumn and tilt lock endurance testing Forward wear test - r&p

Endurance testing- actuator Fatigue test- Propeller Shaft Performance test bench Column durability test Column torsional durability of forward input Universal joint articulating angle test arrangement

Column steering lock endurance testing. Linear actuator.


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Steering Column:

The steering column consists of the main steering shaft,which transmits the steering wheel rotation to the

steering gear, and the column tube that fixes the steeringmain shaft to body. The top end of the steering main shaftis tapered and serrated, and a nut fits the steering wheel

to it. The bottom end of the steering main shaft isconnected to the steering gear, generally by way of auniversal joint to minimize the transmission of road shock

from the steering gear to the steering wheel.


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Steering Gear:

The gears in the steering gears in the steering gearassembly not only steer the front wheels but, at the sametime they act as reduction gears, reducing steering wheelturning effort by increasing the output torque. The

reduction ratio is called the steering gear ratio and is

normally between 18 and 20:1. A larger ratio reduces thesteering effort but makes it necessary to turn the steeringwheel more when going around a curve.

There are various types of steering gear systems, but therack-and-pinion type (RPS) and the recirculating-ball type(RBS) are most commonly used on current vehicles. SONA

KOYO STEERING SYSTEMS LIMITED (SKSSL) produces bothtypes of steering systems.


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Re-Circulating ball screw type:


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Purpose of High Volume Production Trial (it is called HVPThereafter) is to communicate the Product Quality Planning and

Control Plan requirements as well as defining the procedure forconducting a High Volume Production Trial (HVPT) and to judge

whether or not the mass production can be started for the line.This shall be conducted before Start of Production (SOP) forsmoother launch of the new product.

. Implementation of HVPT:The Role of Leader for HVPT

He must get together all people concerned, operators, andsupervisors, others who concerned and must explain importantpoints for HVPT.

Give a signal for starting and finishing time for HVPT

The Role of Time Keeper

To keep record of the time and happenings those are observed

during HVPT.


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Sona Steering is committed to safety and health of employeesand others who may be affected by its operations. We believe

that the safe work practices lead to better businessperformance, motivated workforce and higher productivity.

We shall create safety culture by:-

Integrating safety and health mattering all otheractivities.

Ensuring compliance with all applicable legislativerequirements.

Empowering employees to ensure safety in theirrespective workplaces.


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Promoting safety and health awareness amongst theemployees and suppliers.

To satisfy the customer.

To meet customers requirements all the time.

To implement quality policy all the time.

To involve all the employees in overall development ofcompany.

Quality check at all stages.


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The management of the company has chalked out a planknown as Vision 2011. Salient features of the plan are as

follows: Vision 2011 looks ahead to maintain No. 1 position in the

long run. The present contribution of exports to the total turnover isa mere 2%. The company plans to increase it to as high as45% of the total turnover by the year 2012.

From being a Rs. 250 crores company presently, themanagement wants to make it a Rs. 2000 crores by the

end of the year 2014.


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Sona Steering training report

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