Sansera to make sin­gle piece crankshafts for two-wheel­ers

Sansera En­gi­neer­ing is set­ting up a new plant in Bi­dadi near Ban­ga­lore to meet the grow­ing de­mand.

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The Ban­ga­lore-based Sansera En­gi­neer­ing Pri­vate Lim­ited, man­u­fac­turer of high-pre­ci­sion ma­chined en­gine parts, is all set to make sin­gle piece crank­shaft for two-wheel­ers. As it is a main part of the en­gine of the premium bikes, the com­pany feels that the new prod­uct has huge growth po­ten­tial. Sansera is man­u­fac­tur­ing en­gine parts such as con­nect­ing rods, rocker arms, gearshift forks, crankshafts for four- and two-wheel­ers. Since in­cep­tion in 1987, Sansera has been adding new prod­ucts and cus­tomers ev­ery year. Now it has 25 cus­tomers and more than 20 prod­ucts. “In In­dia, premium bikes are on the in­crease and high­per­for­mance bikes are in big de­mand. It is to serve these seg­ments that we are go­ing to man­u­fac­ture sin­gle piece crankshafts. The first sam­ples will be de­liv­ered in the first week of Au­gust,” S Sekhar Vasan, Chair­man and Man­ag­ing Di­rec­tor,

Sansera En­gi­neer­ing, told Auto

Com­po­nents In­dia. “Sin­gle piece crankshafts are more suit­able for higher per­for­mance en­gines. We have cre­ated a ded­i­cated line in­vest­ing Rs 20 crore to make 180,000 to 200,000 sin­gle piece crankshafts a year. Special ma­chines are needed to make them. There­fore we are buy­ing Or­bital grind­ing ma­chines to grind the pins. We have pur­chased the first set and placed orders for more,” he said.

Sansera will be look­ing at the do­mes­tic mar­ket for the sin­gle piece crank­shaft but will grad­u­ally en­ter the ex­port mar­kets. Vasan said that they are in talks with their global cus­tomers for ex­ports. In the do­mes­tic mar­ket it has al­ready bagged orders for sin­gle piece crankshafts worth Rs 10 crore a year.

In­stead of be­ing a built-toprint man­u­fac­ture, Sansera has started work­ing on the de­sign of the com­po­nents. The com­pany now re­ceives state­ment of re­quire­ments and from that it de­signs and man­u­fac­tures the com­po­nents. It elim­i­nates the prac­ti­cal is­sues that arise dur­ing man­u­fac­tur­ing and re­duces the over­all cost of the com­po­nents.

To be­come a one-stop so­lu­tion to its cus­tomers, it is set­ting up a ded­i­cated test fa­cil­ity. The test­ing cen­tre for fa­tigue test­ing will come up in its Bom­masan­dra plant in Ban­ga­lore at an in­vest­ment of Rs 2.5 crore. Once it de­cides on the ma­chiner­ies, the cen­tre will be ready in a year. Vasan said, “we are look­ing at set­ting up a test­ing cen­tre for ac­cel­er­ated test­ing of con­nect­ing rods. We will have cou­ple of other test­ings also in the same fa­cil­ity in the near fu­ture. We want to be a one-stop so­lu­tion to our cus­tomers from de­sign­ing the com­po­nents, man­u­fac­tur­ing them and fi­nally val­i­dat­ing them.” Once the fa­tigue test­ing fa­cil­ity is in place, Sansera will go into x-ray die-frac­tion for some met­al­lur­gi­cal test­ing. All these tests will be done ini­tially as per de­sign ver­i­fi­ca­tion and for the fi­nal test it will be fitted in the en­gine.

The com­po­nent man­u­fac­turer also de­signs and man­u­fac­tures the ma­chines used in the shopfloor. Over 80% of the ma­chines de­ployed in its man­u­fac­tur­ing facilities are built in-house. The com­pany de­signs and man­u­fac­tures CNC ma­chines ac­cord­ing to its prod­uct re­quire­ments. Sansera has also de­vel­oped soft­ware for pe­ri­od­i­cal cal­i­bra­tion of jigs and fix­tures.

Car­burised con­nect­ing rod

As the OEMs are work­ing on lightweight­ing the en­gine, com­po­nents sup­pli­ers like Sansera also are part of that ini­tia­tive. The com­pany gives in­put to the OEMs for us­ing higher strength ma­te­ri­als, which cut down the weight of the con­nect­ing rod by hav­ing less cross sec­tion. Re­cently, Sansera de­vel­oped con­nect­ing rods with low-car­bon steel, which is car­burised and frac­tured for higher per­for­mance en­gines. By us­ing this ma­te­rial Sansera can re­duce weight of the com­po­nents it man­u­fac­tures by around 10%. Now the car­burised con­nect­ing rods are ex­ported and used in the high per­for­mance two-wheel­ers.

Sansera keeps adding 2 to 3 new cus­tomers and new prod­ucts ev­ery year. Re­cently it has started pro­duc­tion of drive line parts like pro­pel­ler shaft ends, yokes and uni­ver­sal joints for pas­sen­ger cars. It is plan­ning to man­u­fac­ture au­to­mated man­ual trans­mis­sion (AMT) also. “We are ac­tively

look­ing at AMT tech­nol­ogy. Now we don’t have the tech­nol­ogy, there­fore we will ei­ther de­sign or ac­quire some com­pany to get the tech­nol­ogy. Ini­tially we are look­ing at man­u­fac­tur­ing some sub­sys­tems and we are talking to a few AMT man­u­fac­tur­ers,” said F R Singhvi, Joint Man­ag­ing Di­rec­tor of Sansera En­gi­neer­ing.

New plant at Bi­dadi

In or­der to meet the grow­ing mar­ket de­mand, the South-based com­pany is set­ting up a green field plant at Bi­dadi in Ban­ga­lore. “We have new cus­tomers and prod­ucts ev­ery year and all our plants are reach­ing full ca­pac­ity. There­fore we have de­cided to set up a new fa­cil­ity at Bi­dadi near Ban­ga­lore. We have a 15-acre land and we will be build­ing the plant in 150,000 sq.mt area. It will be ready in 18 months and all our new orders will be ex­e­cuted there. We be­lieve that by 2020 we should be do­ing around 20 mil­lion con­nect­ing rods,” Singhvi said.

The com­po­nent man­u­fac­turer is also sup­ply­ing trans­mis­sion parts to Toyota and Honda Cars In­dia. In­ter­est­ingly, Sansera is the first com­pany to man­u­fac­ture gear shifters out of forg­ings. It is ex­port­ing them to 3 coun­tries. Two years ago Sansera for­ayed into heavy com­mer­cial ve­hi­cle busi­ness by bag­ging an or­der from Daim­ler In­dia Com­mer­cial Ve­hi­cles to sup­ply in­ter­me­di­ate ring for their wide range of trucks. Soon it will start man­u­fac­tur­ing com­mer­cial ve­hi­cle con­nect­ing rods for its cus­tomer in Ja­pan.

Aero­space com­po­nents

Sansera has di­ver­si­fied into man­u­fac­tur­ing aero­space parts. The divi­sion that is en­ter­ing its 5th year of op­er­a­tion is hop­ing to cross Rs 50-crore turnover. “We have taken the leap much ahead of oth­ers and are dou­bling our turnover al­most ev­ery year. We are re­ceiv­ing a lot of en­quiries and work­ing hard to turn it into fruit­ful busi­nesses. Cur­rently we are sup­ply­ing parts for cargo, seat­ing and light­ing systems and we in­tend to grow much faster in this divi­sion,” Vasan said.

Fu­ture plans

Last year Sansera recorded a turnover over of Rs 878 crore and this year it is tar­get­ing Rs 1100 crore. The com­pany, which started its jour­ney in 1987 by man­u­fac­tur­ing rocker arms, has plants in Ban­ga­lore, Pune, Mane­sar and Pant­na­gar. In 2005, Sansera be­gan man­u­fac­tur­ing in­te­gral con­rod and from 2008 it com­menced man­u­fac­tur­ing wide range of con­nect­ing rods like split con­rod, frac­tured con­rod and pis­ton con­rod as­sem­bly.

In the last 3 years Sansera has in­vested more than Rs 300 crore and this year it is in­vest­ing another Rs 150 crore. Sansera is buy­ing land in Gu­jarat but the plan for set­ting up a fa­cil­ity is still in the nascent stage.

Glob­ally it sup­plies rocker arms to Honda Mo­tor­cy­cles, Yamaha, Maruti Suzuki and Gen­eral Motors, and con­nect­ing rods to FPT Pow­er­train Tech­nolo­gies. It is plan­ning to grow its ex­ports busi­ness from the cur­rent 20% to 28%. Since the con­nect­ing rod is a niche part, Vasan feels that there will be more de­mand for it across the globe.

S Sekhar Vasan, CMD and FR Singhvi, JMD, Sansera En­gi­neer­ing

In­te­gral Type con­nect­ing rod

Crank­shaft as­sem­bly

Frac­tured Tyre con­nect­ing rod

Split Type con­nect­ing rod

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