Manufacturing

The company has 4 state-of-the art manufacturing plants – three locations in Ludhiana (Punjab), and one in Pune (Maharashtra).
  • Built over a gross of 25 Acres of land with a covered area exceeding 1 million square feet
  • Manufacturing plants equipped for crucial processes right from Design, Simulation, Prototypes, Dies to Final product
  • Systematic Workflow and Advanced Manufacturing & Processing Bays
  • Total Quality Management Procedures integrated from Industry-specific Procurement to Finished Product Quality checks
  • Customer Relationship Management (CRM)
  • Guided by Kaizen, 6 Sigma, and TQM principles
  • Accelerating progress with a focus on continuous improvement is the "Highway Mantra"

A panoptical view of our VALUE STREAM RESOURCES across plants and facilities:

  • 22 Forging Presses (check numbers & match with details below)
  • 09 Spline Rolling Machines
  • 27 Heat Treatment Furnaces
  • 500+ CNC and TMC Machines
  • 100+ VMCs with coolant
  • 07 Hobbing Machines.
  • 10 Broaching Machines

A detailed view of some allied tools and equipment:

  • CNC turning centers
  • VMC (Vertical Milling Centers)
  • Forging Presses 600-2500 Tons
  • CMM - Zeiss, Mitutoyo (6 nos)
  • Robotics on CNC Machines and Forging Preses
  • Induction Billet Heaters
  • Cold Forging 250 To 600 Tons
  • Warm Forging (up to 1600 Tons)
  • Spline Tester (KINGLENBURG P26)
  • Spectrometer (THERMO FISHER)
  • Sprint Cut Machine
  • Continuous Heat Treatment Furnaces
  • Sealed Quenched Furnaces (IPSEN)
  • Shot Blasting Normalizing Furnaces
  • Ultrasonic and Magnaflex Booths, and
  • Roboturn Automation.
  • GLEASON Angular roll tester
  • Casting through strategic sources.
  • INSPECTION LAB
    • CMM
    • Gear Tester
    • Gleason Bevel Gear Tester
    • Salt Spray Height Gauge
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Mangli, Ludhiana

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Pune Plant

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Sahnewal, Ludhiana

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Gill Chowk, Ludhiana

Facilities

  • Equipped with multi-station fully automatic Hot Forging shops
  • High-capacity press line range from 600 Tons to 2500 Tons.
  • Production capability of wide range of hot-forged high precision parts of varied sizes, specifications and complexities.
  • Forging proficiency across diverse materials, viz Alloy Steel, Micro Alloy, Stainless etc
  • Supported by automated facilities like Auto-transfer, Auto-lubrication, Quick die changer, etc.
  • Equipped with the best-of-breed QDC, Coil Changeover, Temp Poke Yoke and Scada
  • Specialization in Profile Components
hot-forging
  • Ideal methodology for difficult-to-cold-forge materials such as alloy steels for induction hardening applications, warm forging. Combines the benefits of both hot and cold forging.
  • Controlled temp to Warm Forging 850-900 Deg C
  • Near Net Shape Forged Parts
  • Followed with facilities of Cold Sizing
hot-forging
  • Leaders with decades of experience Experienced in Cold forging a wide spectrum of automotive components.
  • Forging of parts through methodologies that combine forward extrusion, backward extrusion, upsetting, trimming, flattening, and piercing.
  • Range from 250 Tons to 600 Tons
  • In-house integrated Phosphating and Annealing facility
hot-forging
  • Capability of delivering best precision Casting parts of diverse moudlings
  • Casting delivery capacity (Tons per month)
    • Green Sand Moulding – for CI, SG Iron, SiMo : 2300 Tons
    • Shell Moulding – for CI, SG Iron, SiMo : 2200 Tons
    • Investment Castings – for SS & other alloys : 200 Tons
hot-forging
  • Diverse range of forged components featuring Near-net shape, better grain structure, excellent surface quality, and greater accuracy.
  • High-volume automotive parts with reduced tooling and forging press loads, enhanced steel ductility
  • Elimination of the need to anneal before forging.
  • Our cutting-edge technology facilities:
    • CNC Turning , Turnmill Centres, VMC
    • Broaching, Gear Hobbing
    • Spline Rolling and Forming
    • Induction Hardening
    • Grinding
    • Polishing
    • Assembly
hot-forging

Die Design & Manufacturing

Our capabilities in the tool room are attributed to the following:

  • Ultra-modern, well-interfaced CAD/CAM center
  • 2Drafting, 3D Modeling & Simulation, and CNC programming 
  • Deckel Maho (Die Sinking) – 2 Nos.
  • VMC – 4 Nos. 
  • CNC Lathe – 4 Nos.
  • EDM and Wire cut.
  • Ability to bring in high quality in all tools and dies including consistency and repeatability
  • Detailed value analysis during the tool making
  • New-age facilities for adaptive post-processing
  • Reduced programming time, and optimization of the machining feed-rate
  • Maximum accuracy, reliability, and reproducibility with zero need for rework.  
  • We are achieving din class 2 for hot forging , coining dies and Din class 8 for components
  • We are capable for master sample manufacturing through the milling process before proto sample.

Heat Treatment

We have an advanced in-house heat treatment shop equipped with fully automated facilities to carry out the following processes:

  • Continuous Mesh Furnace
  • Sealed Quenching
  • Normalizing
  • Tempering
  • Annealing
  • Precipitation Strengthening
  • Induction Hardening

Sealed Quench Furnace (SQF) - 10 Nos.

Normalizing Furnace - 3 Nos.

Machining-Centres

Precision Machining

In the machining section, we are backed by technologically advanced VMCs, CNCs, Horizontal Milling, and Broaching machines sourced from the world's best manufacturers

Be it conventional or complex geometries, we always remain particular about optimal product quality and precision. Some of the major operations performed in the machining area include Honing, Grinding, Spline rolling, Broaching, Induction hardening, Turning, Boring, Tapping, Grooving, and Drilling.

  • CNC Turning, Turnmill Centres, VMC
  • Broaching, Gear Hobbing
  • Spline Rolling and Forming
  • Induction Hardening
  • Grinding
  • Polishing
  • Assembly

Automation

  • Robotics on Machines / Forging Press
  • Pick & place on Spline Rolling Machine
  • Gantry / Carousal Machines
  • Industry 4.0 on Heat Treatment Furnaces
  • SCADA on Furnaces
  • Poke Yokes on Furnaces
  • Digital input of Reports on Gemba

The ultramodern tools and machines that support our MACHINING EXCELLENCE Include:

  • 200+ CNC Machines TALLY & CHECK REPEAT
  • 40 Vertical Machining Center
  • 20 Turn-mill Centers
  • 100+ SPMs
  • 20 CNC Grinding Machines
  • 80+ General Purpose Machines

Spline / Thread Rack

  • Profiroll (Germany) 2 Nos.
  • Nachi (Japan) 3 Nos.
  • NHK (Japan) 1 No.
  • Waitai (Taiwan) 2 Nos.
  • MTE (India) 4 Nos.

Gear Hobbing

  • Liebherr (Germany) 2 Nos.
  • Nimble (Local) 2 Nos.

Testing

All forged deliverables that we supply to our valued customers undergo rigid and stringent testing procedures to obtain the prescribed quality parameters. Our sophisticated inspection and testing facility enables us to deliver cutting-edge forging solutions with quality, durability, and reliability par excellence. The tools and equipment used in the testing and inspection area include the following:

Facilities for Inspection

Metrology Lab

  • 2D Height Gauge
  • Profile Projector
  • Micro Vicker Hardness Tester
  • Millipore Testing
  • SPECTRO 28 Elements
  • Contracer
  • Roughness Tester
  • Carl Zeiss
  • Olympus Microscope & Mitutoyo CMM
  • MPI
  • Klinger berg P 26 Gear Tester.

Metallurgy Lab

  • Magnetic Crack Detector - 15 Nos.
  • Spectrometer (Steel chemistry) - 1 No.
  • Ultrasonic Detector - 6 Nos.
  • Micro Hardness Testers - 3 Nos.
  • Salt Spray - 1 No.
  • UTM - 2 Nos.
Machining-Centres

Finishing

For finishing, we have an ultra-advanced setup that houses all the latest facilities including chrome plating, anodizing, shot blasting, laser engraving, and ultrasonic cleaning among others. 

  • Heat Treatment – Continuous, SQF, Normalising
  • Plasma Nitriding
  • Shot Blasting and
  • Coating – E-Coat, Powder, Plating, Geomat etc