KKR Metal Component

A 27 year old company established in A 27 year old company established in the year 1986 as ARUNA PUMPS PVT the year 1986 as ARUNA PUMPS PVT LTD to manufacture Liners for Tractor LTD to manufacture Liners for Tractor Engines and later on expanded and Engines and later on expanded and diversified by Mr. K.K.Ramesh, as KKR diversified by Mr. K.K.Ramesh, as KKR METAL COMPONENTS from the year METAL COMPONENTS from the year 1995 for manufacturing high precision 1995 for manufacturing high precision components for Automotive and other components for Automotive and other industries. industries.

KKR METAL COMPONEN

TS

PRESSURE DIE CASTING DIVISION

MACHINING DIVISION

INDUCTION HARDENING

DIVISION (ASSOCIATE COMPANY)

DIE AND MOULD MAKING DIVISION

(ASSOCIATE COMPANY)

CNC TRAINING INSTITUTE AND CAD /

CAM

KKR METAL COMPONENTS is located in Ambattur Industrial Estate of Chennai (Madras), one of the four metropolitancities in India and the so called“Detroit of India”.Address: Plant-I No.355, SIDCO Industrial Estate, Ambattur, Chennai- 600 098.

TamilnaduPlant -2 No. 368 SIDECO Industrial Estate

Ambattur,Chennai -600098Plant - 3 No 1, Vanagaram Road

Ambattur, Chennai 600058Tamilnadu

Tel: +91 44 26253567, +91 44 26257634Fax: 91 44 26247962E mail: marketing@kkrmetalcomponent.comEmail : kkrmetal@gmail.comWeb site: www.kkrmetalcomponents.com

Quality Certification Quality Certification Certified for TS 16949 in September 2007

by TUV NORD CERT

SCOPE Unit – 1 & 2SCOPE Unit – 1 & 2Manufacture of pressure die Casted and

Machined Precision Ferrous and Non

Ferrous Components and Sub assemblies

For Automobile and Engineering Industries

SCOPE -Unit - 3 SCOPE -Unit - 3 Manufacturing of Machined Component for auto motive application

DOMESTIC CUSTOMERS

•BRAKES INDIA : BRAKE PARTS

•DELPHI –TVS Plant 1 : FUEL INJECTION SYSTEM PARTS

• DELPHI –TVS Plant 3 : CR FUEL INJECTION SYSTEM PARTS

•LUCAS –TVS : AUTO ELECTRICALS PARTS

•MITSUBISHI DIESEL ENGINES : DIESEL ENGINES PARTS

•SUNDARAM CLAYTON : AUTOMOTIVE BRAKES PARTS

•MITUSUBA SICAL INDIA : AUTO ELETRICALS PARTS

•SAME TRACTORS : TRACTORS ENGINE PARTS

•SUNDARAM FASTENERS :TRANSMISSION PARTS

•BRIDGESTONE :SUSPENSION PARTS

•VST TILLERS& TRACTORS : OIL PUMP ASSY & ENGINE PARTS

•SONALICA TRACTORS : OIL PUMP ASSY AND ENGINE PARTS

OUR PARTS ARE USED BY

Hero Motors Ltd

Honda Motorcycle & Scooter India Ltd

Eicher Motors Ltd

GM India Ltd

Tata Motors Ltd

Honda Siel Cars India Ltd.

Mahindra & Mahindra Ltd

Maruti Udyog Ltd

Ford India.

Hyundai Motors India

Mitsubishi Diesel Engines

8

Target for the Year 2014- 2015Target for the Year 2014- 2015

Achieve ZEROCustomer Treat You Hero

9

Achieve Zero PPM by … Achieve Zero PPM by …

1. Implementing Producer Quality Concept (PQC)2. Utilized the core tool Effectively3. Ensure the Systems in place4. Eliminate incoming, internal, rejection

5. Ensure the First Time Quality

6. Kaizens-continual improvement.

7. Proactive Kaizens

8. Horizontal Deployment

Zero Rejection - Make Customer Delight

COLD CHAMBER PRESSURE DIE CASTING MACHINES– 100T, 150T 250 T CAPACITY INHOUSE UP TO 850T GROUP COMPANY

SALIENT FEATURES

• FULLY AUTOMATIC

•CLOSED LOOP

•HIGH SPEED

•HIGH ACCURACY

•CONSISTANT QUALITY

SHOT PARAMETERS CASTING PARAMETERS

SHOT PROFILEAUTO SPRAYER PARAMETERS

VMC- M/C’S

Appreciation & Recommendation Letter From Customer

Description Model Status Photo

Pump Housing GDC

2.2 LPPAP submitted and Delphi Diesel

System approval Received

Pump HousingPDC

1.4 LPPAP submitted and Delphi Diesel

System approval Received 

Pump Housing Common Rail Fuel injection pump –

1600 Bar Pressure generation

Pump housing Process Flow

Pump housing CNC 1 Operation

OD & Depth Tolerance 25 Micron

Concentricity 50 Micron

Pump housing CNC 2 Operation

Bore & Depth Tolerance 25 Micron

Concentricity 50 Micron

Pump housing Diameter Measurement

Electronic Probing 1 micron L.C Marposs Gauge for all Diameter measurement – Store data with Tractability

Pump housing VMC Drill Tap Operation

Thread Position Tolerance 75 Micron Squarness 25 Micron

Pump housing VMC - Cut SectionTransfer Pressure hole Operation

Bore & Depth Tolerance 25 Micron

Pump housing Vibro De burring Operation With German Make Plastic Media

Allowable De formation on bore After Vibro Deburring 10 micron

Pump housing 27 Jet High Pressure Cleaning

Millipore test spec.15 Mg

Achieved less than 5 Mg

CMM With Indexing Probe Head and Scanning

Pump housing Inspection With Automated Program

Pump housing Measurement on CMM With Indexing Probe Head

Pump housing Inspection With Automated Program

Pump Housing CMM Report –

Deviation in Red color – Visual alert

MAHR Surf Contour

Pump housing Inspection

Contour Report

Packing & Dispatch

Description Model Status Photo

Control Housing

PDC

JCB – Fuel Pump

Delphi approval Received - Production Running for last 4 years End Customer

Rejection Zero Customer Rejection Less than 10 PPM

Dent & Damages No Dimension Problems

Control Housing – JCB Fuel Pump Assembly

Control Housing – Pressure Die Casting at KKR

Control Housing – After Fettling & Shot blasting

Control Housing – After Machining

Critical Transfer Pressure Bore

Control Housing – Cut section Critical Transfer Pressure Bore

Tolerance Bore Dia 20 micron

Roundness 5 micron Straightness 10 Micron

Control Housing – Critical Transfer Pressure Bore

PCD Reaming Process Roundness Achieved

4.4 micron

PCD Reaming Process

Straightness Achieved 1.2 micron

Control Housing – After Anodizing Process -

Anodizing 5 micron – wear

Resistance

Other Critical Parts

Orifice

High Precision Brakes component – Supply to Four Wheeler Car

Wheel CylinderLSPV

Engine Oil pump Cover thermostat Pump Cover

Cover Rocker

High Precision Diesel Engine Parts – Supply to Mitsubishi Diesel Engine