Advik Pantnagar plant plumps for high-tech products
Looking from outside, all one can see is an internal combustion engine. But, it needs a lot of small in-built components to run. The invisible components are very important for a bike or a car. The most important parts of an engine are tensioner, oil pump, drum gear shifter, fuel cork body, body centrifugal oil filter, and starter gear reduction. Advik Hi-Tech Private Limited (AHPL), a leading Indian and global automotive components manufacturer, produces these critical parts in its plants in Chakan and Pantnagar.
Advik has been catering to the needs of a number of domestic and overseas customers in the two-wheeler, stationary engine and transmission system segment for the past 18 years. Its customer base includes leading automotive OEMs in India, Europe, the UK the US and ASEAN region. A visit to the Pantnagar facility of Advik Hi-Tech revealed its unique facilities for heat treatment and surface treatment and an advanced paint shop which are unsurpassed and available only in this facility. Tensioner and oil pumps, drum gear shifter, fuel cork body and Body Centrif- ugal Oil (BCO) filter are the components being produced here.
Next to its Pune plant in size and capacity, the Pantnagar facility employs 510 people, of whom 90 are staff members and the rest work in machining and assembly section. “The plant works in
Total Productive Maintenance (TPM) way and focuses on safety and quality. Safety of the workers is a priority and there has not been any accident in the past 4-5 months. The firm also ensures total quality and allows no defective product to leave the factory,” Aditya Bhartia, Managing Director, ADVIK Group, said.
The customers of Advik include Bajaj, Hero MotoCorp, Honda Motorcycles and Scooters India (HMSI), Maruthi Suzuki, and Yamaha. From this plant, parts are sent to 11 other locations. The components for Hero is sent to Haridwar, Gurgaon, Baroda, and Neemrana. Being a major manufacturer of oil pumps, Advik supplies around 70-80% to all major companies. Though there is no direct export, products from Pantnagar and Pune plants are exported by Yamaha.
The Pantnagar facility has incorporated the highest technology and modular assembly lines. For making the components perfect, it employs poka-yoke technique and makes sure that no defect passes through. If some imperfection is made in the first station, the parts will not pass through the second as the machine will detect it. There is a buzzer system and mechanical poka-yoke. Using this, the components will not get processed further if there is any problem and this ensures 100% quality. The plant also has the highest accuracy in the machining section, by using the polycrystalline diamond tool.
The raw materials for the components are sourced locally and only very few materials are imported. Die-cast aluminium is the main raw material for tensioners. It is purchased from local suppliers and is taken to the blasting area to increase the roughness on its surface.
A tensioner is a device that applies a force to create or maintain tension. The force may be applied parallel to, as in the case of a hydraulic bolt tensioner, or perpendicular to, as in the case of a spring-loaded bicycle chain tensioner, the tension it creates. The next step is the paint shop. These tensioners need a coat of paint as this will be visible. After this, it goes to the machining section and gets moulded. Its cycle time is around 30-35 minutes and in a single run, it makes 4 pieces, that is approximately 140 seconds each. Then it moves to the assembly section. The tensioners and oil pumps made in this facility are mainly for Bajaj, Hero, Yamaha, and Maruti.
While some parts are assembled and fitted here, others are being sent directly to the customers. Oil pump and tensioners are the major components that are being assembled in the facility. Fuel cork is also being done here. A single tensioner will take approximately 10 seconds to be assembled. There are 6 different lines for it and in each line 7 people work to assemble. On an average, 25,000 tensioners are made daily.
For oil pumps, there are 10 lines to make 30,000 daily. The average time to assemble an oil pump is 15 seconds. Different types of pumps are done at the assembly station. In the plate assembly fixture, they place the components together and send them for the flushing operation.
Drum gear shifter
The raw material for the drum gear shifter is carbon. These basic substances are sent to the machining section at first and then to the fitting centre, where the drill is made. The product goes to the first set-up where they clamp it to the machine, clean it and remove a little. In the second stage, it is checked for defects, cut a little more and then taken to the profile grooving section. This is where the component gets its shape for the gear levers to move. When a gear shifting lever is moved, it rotates the drum.
Heat treatment and surface treatment facility