INDO SCHÖTTLE AUTO PARTS PVT. LTD. Business Overview
Location - Infrastructure PLANT 1 PLANT 2 PLANT 3 Location : Domestic Plant ISAP is located 20 kms West of Industrial city of Pune. ISAP has three plants located in close proximity ( in the vicinity of 2 km radius. Export Orienting Unit PUNE Head office Infrastructure Cold Forging Unit 3 locations totalling to 18 acres of carefully landscaped area. 13,000 sq.m. of built up shop floor. Express feeder line for power input.
About Indoschottle Autoparts Pvt. Ltd. - ISAP Indo Schottle Auto Parts Pvt Ltd ( ISAP ) is India s largest manufacturer of Engine Valve Collets, Rocker Arm Screws & Precision Turbocharger Components. In 1985, Mr Vijay Pusalkar partnered with Mr Wolfgang Schottle & formed the new Company. ISAP has its manufacturing operations in Pune, India & its products are sold globally. ISAP is a preferred supplier of precision machined components & assemblies to automotive & turbocharger industry. ISAP has Three state of the art manufacturing units ( including the one dedicated to export ) and highly skilled manufacturing team. Key products include Engine Valve Collets, Rocker Arm Screws, Turbocharger components & Fuel System Parts with a product range for all applications such as those used in : Commercial Vehicles Tractors Marine Engines Passenger Cars Two Wheelers
Tracing our History.. Some Milestones Indo Schottle is incorporated 1st product family (Engine Valve Collets) Single Customer, Sales US$ 5.6 k 2 nd product line (Rocker Arm Screws) 30 employees Sales US$ 0.22 million Established as a premier OEM supplier Development of Precision machined parts 3 rd Product line introduced (Turbocharger Parts) Sales US$ 0.71 million; Exports @ 10% 100% Export Unit (EOU) established QS 9000 certification Sales US$ 0.83 million
Tracing our History.. Some Milestones 4 th Product family started, Fuel System Parts and Assemblies Growth rate is at 40% Sales US$ 2.92 million 3 rd Manufacturing Plant Started in the EOU TS 16949 certification Sales USD 6.08 Million Domestic Unit moves to new premises 5th Product Family started (Hydraulics / Fluid power parts) Now manufacturing 100 mill. Stamped and 50 million machined parts / year Sales US$ 12.80 million Plant 3 built and commissioned 6 th product family introduced (Cold Forging line set up for near net shaped cold forged parts) Sales USD 23 million, Exports @ 55%
Indo Schottle Autoparts Pvt. Ltd...At a glance Financials Mill USD FY09 FY10 Turnover 20.32 22.22 EBITDA 5.27 6.67 Net assets 19.32 22.3 Summary Indo Schottle is Privately held company ; ownership of Chairman & MD Mr Vijay Pusalkar. Company Head quarter is in Pune, having three manufacturing plants. Two of manufacturing plants cater to domestic needs and third plant is export oriented unit. Infrastructure Indo Schottle caters to following: Commercial Vehicles Tractors Marine Engines Passenger cars Two wheelers Products, services, customers Indo Schottle - Sales FY 2009 Domestic $7.65M 38% Export $12.6M 62% Turbocharger Parts 17% 38% Precision Hydraulics 18 acres of landscaped area; 13000 sq.mt. Built-up Express power feeder line Within an hour distance from International airport and seaport Over 650 employees of which 350 nos. Are engineers and technicians Precision machines, gauging; Heat-treat facilities Indo Schottle is in the area of Precision Component Manufacturing of Auto Parts. Product ranges from: Valve train collets / Rocker arm Screw...near 100% reach in Indian Automotive with sizeable export. Fuel Injection parts...exports to Cummins Turbocharger components...export to Honeywell, Cummins, Borgwarner Precision Hydraulics components...export to Borgwarner, Bosch and Mitchel. Well integrated Cold forming and sheet forming facility. We export close to 60% of our business turn-over and even do Vendor Managed Inventory (VMI) to our prestigious customers at US and Europe. Export 3% 42% Fuel Injection System Engine Valve Screws Relevant technology / skills Highlights Business Location: Head Office Pune - India 25 years of experience producing parts for global MNC s in the area of Turbocharger, Fuel Injection System, Precision Hydraulics and Valve-train areas. Established and well recognised manufacturer of precision components and assemblies. Already catering to International and Indian market Financial and Technical Sound Financials with ability and desire to Grow Technical know-how of manufacturing precision components. Precision component manufacturing company having strong presence in domestic market and key suppliers to global MNC s
Customers
Product Profile Part Families ENGINE COTTER VALVES Capacity : 225 million Process Patent received ROCKER ARM SCREWS Capacity : 40 million Precision machined part TURBOCHARGER PARTS Capacity : 10 million Micron level accuracies FUEL SYSTEM PARTS Capacity : 10 million Micron level accuracies, Match Assly HYDR / FLUID PWR ASSEMBLIES Capacity : 5 million State-of-the-art technology Match assly, micron accuracies COLD FORGED PARTS Capacity : 50 million 5 Station cold former Near Net Shaped parts
Infrastructure, Technology and Manufacturing SCREW MANUFACTURING LINES Turning, C less grinding, Induction hardening, Thread rolling machines VALVE COLLETS MANUFACTURING LINES High Speed cold forming machine
Cold Forming Infrastructure Cold Forging Machine - Nedschroef Belgium Capacity - 50 Million pieces per annum Stations - 5 Horizontal Tonnage 230 tons Toolings From Nedschroef (Using Eezee to Flow Software)
Cold Forming Capability Outer Forged Diameter maximum Length of forged component Maximum Weight of Component Input Raw material Diameter Input Cutoff Length max. Tonnage of the Machine 35 mm 145 mm 150 gm 8 mm to 18 mm 175 mm 230 Tons Material Steel - 16MnCr5, SCM 415H, SAE 52100 etc (Stainless Steel, Aluminium, Brass, Copper Feasibile)
Infrastructure, Technology and Manufacturing CNC turning centres, Turn-Mill centres, 12 spindle full CNC complex bar turning lathe (INDEX, Germany) 6 spindle full CNC complex bar turning lathe (TORNOS, Swiss) 5-Axis VMC (HASS, USA)
Infrastructure, Technology and Manufacturing High Precision CNC 5 station Honing machine (KADIA, Germany) CNC grinders - Internal, External, Centreless (NOVA, Cincinnati) CNC Internal grinders - (Micron, Japan) High Precision double disc grinders - (Peter Walters, Germany)
Infrastructure, Technology and Manufacturing In-House Heat Treatment Plant (Continuous Mesh Belt and Sealed Quench, Gas Carburizing Furnaces) as well as an Annealing Furnace Capable of meeting all current customer Heat treat requirements Fully equipped Metallurgical Lab with Metallurgists on staff Capable of doing Carburising, Hardening, Tempering, Carbo-Nitriding, Direct Hardening, Case Hardening & Annealing. Also equipped to do Sub-Zero tempering Current Capacity: 60 MT per month. Planned Capacity: 100 MT per month by 2009
Infrastructure, Technology and Manufacturing Fully equipped Metallurgy and Metrology laboratories with Roundness testers, CMM, Surface Roughness testers, Contour-o-graphs, Profil-o-graphs, Micro Hardness testers, Microscopes etc Makes: MAHR, TAYLOR HOBSON, MITUTOYO, BAKER, ZEISS etc
Quality Accreditations ISO 9001:2000 ISO 9001:2000 is the standard that provides a set of standardized requirements for a quality management system. The ISO 9001:2000 standard provides a tried and tested framework for taking a systematic approach to managing the organization's processes so that they consistently turn out product that satisfies customers' expectations. TS 16949 Written in line with ISO's Quality Management System standard, ISO/TS 16949 aligns many existing global automotive quality system requirements. This allows companies to take certification one step further. ISO/TS 16949 is not a standard but a Technical Specification. It applies to sites where production or service parts are manufactured. A site is defined as a location at which value added manufacturing processes occur. Manufacturing is defined as the process of making production materials, parts or assemblies, or heat treating, painting, plating services. ISO/TS 16949:2002 helps companies to: Improve automotive supply chain product and process quality. Apply common and consistent international quality system requirements for the automotive industry. Gain confidence in global supplier quality. Implement policies and procedures for a common third party registration scheme to ensure consistency worldwide. Introduce process-based audits focusing on customer satisfaction. Gain global acceptance of the standard in place of national standards. ISO 14001 The ISO 14000 family addresses "environmental management". This means what the organization does to: minimize harmful effects on the environment caused by its activities, and to achieve continual improvement of its environmental performance. CERTIFIED BY:
Project Management Process DECISION MAKING PROCESS Receive RFQ s from Customer Review of RFQ in line with Business Policy and Focus Initial feasibility & Risk Analysis from Enquiry Business Feasible? No Regret Yes Technical and Financial Feasibility Study (APQP) Cross Functional Inputs (CFT) on the process & equipments needed for the project. Team signoff. Preparation of primary process flow and time line. Quote to Customer with project report and time line Award of Business from Customer ( LOI / PO ) PROJECT EXECUTION PROCESS Resolve with customer? Contract Review & Re-visit of Feasibility Customer Feedback Start of production (SOP). Three bulk lot monitoring. Study of TGR / TGW Report Closure of APQP Receipt of Equipments & Final Prove out at our location. PPAP Limited production run. Identification, Finalization & Ordering of New Equipments /Tooling/Instruments. Weekly Project reviews & seek top management help if required. New technology project- Training plan for employees. Initial prove out of equipments at suppliers end Send Order Acceptance. Identification of Project Leader & Team. Prepare & Freeze Time plan with micro level activities and Milestones. Responsibility assignment for individual activities
Logistics VMI process (Export & Domestic) CUSTOMER PO s / Schedules ISCM/ Supply on Releases ISAP Material Request Manufacturing Plant-I and II Delivery Machined / Stamped Inspection and Packaging Customer Assembly line VMI Stocks to warehouses in UK USA, Germany And Mexico Notice to Customer ASN ISAP Shipping Dock
Key Achievements ZERO labour issues since inception PREFERRED SUPPLIER status with customers 100% Customer Retention and Consistent Growth CONSISTENT Quality record ON-TIME delivery via warehousing, worldwide HIGH LEVEL of Manufacturing Technology Integration
Corporate Social Responsibility (CSR) Donated School Buildings: Indo Schottle has built three schools out of which one is already open and functional at Anavatti in Karnataka State. The other two are scheduled to open in 2008. These two are at the villages Urawade and Ambegaon, within the vicinity of our factory. Free Immunisation for Children: Indo Schottle has conducted free immunization programs at a nearby village to protect the children against Hepatitis B infection, Typhoid and MMR. Medical check-up camps have also been conducted for the school children of the nearby villages for eye checkups, dental check-up and blood group determination. Local Employment: 40% of our employees are from nearby villages. Our Educational programs have empowered them to become better skilled citizens. Staff Welfare Activities include: Training Programs for Personality Development and Technical Skills Transport facility Medical insurance for the entire family Indo Schottle Training center: This is a major and important activity under taken by us. Our training center conducts a free six month duration course comprising Theory, Practice and on the job training. Candidates successfully completing training have the option of seeking permanent employment within Indo Schottle. The candidates are paid a stipend Support to Fine Arts: Indo Schottle provides financial assistance to the Sawai Gandharv Smarak a local Fine Arts Society engaged in the promotion of Indian classical music.
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