Ad­vik Pant­na­gar plant plumps for high-tech prod­ucts

Auto components India - - CONTENTS - Story & Photos: Sricha­ran R

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.

Raw ma­te­ri­als

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.

As­sem­bling

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

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