Project report On

Chakan, unit-I pune- 411020036

Submitted by Piyush Gundecha Iccs (2009-10) s.y.b.b.a (Roll No. 54)

ACKNOWLEDGMENT

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Every work done needs to be followed by a deep sense of gratitude to those who made it through to success. I take this opportunity to thank all those who rendered their immense help & guidance for the completion of this report. Firstly, I would like to express my gratitude to Mr. B.P.Shiv Director (Business Development) of Auotline Industries Ltd, for his kind help and support by providing me with the necessary insights and information by taking a session after the visit. Secondly, I would like to express my sincere gratitude to my project guide Mr. Amol Shinde for his valuable guidance & support given to me endlessly from time to time. Finally, I would like to thank my friends for their cooperation and advice during the task of preparing this report .

Piyush Gundecha

INDEX
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SR.NO

TOPIC

PAGE NO.

1.

Introduction

4

2.

Industry Profile

5-7

3.

Company Profile

8-12

4.

Product Profile

13-15

5.

Management Structure

16-17

6.

Objective of the Project

18

7.

Manufacturing & Operation Details

19-20

8.

Suppliers & Customers

21-22

9.

Findings & Observations

23

10.

Suggestions

24

11.

Bibliography

25

INTRODUCTION

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Autoline Industries Ltd(AIL), is one of the auto-component manufacturers located
in Pune catering to the components & subassemblies requirements of leading automobile companies. Autoline Industries Ltd (AIL) (incorporated on December 16, 1996, as Autoline Stampings Private Ltd.) was initially set up in January 1995 as a partnership firm known as "Autoline Pressings" under Indian Partnership Act 1932. They are engaged in Manufacturing various auto parts / sheet metal components for Passenger cars, Sports Utility Vehicles (SUV), Commercial vehicles, Two wheelers, Three wheelers, Tractors, etc. They are one of the prime vendors to various Automobile Companies like, TATA MOTORS LTD. (earlier TELCO), BAJAJ AUTO LTD, KINETIC ENGINEERING LTD, MAHINDRA & MAHINDRA LTD., FIAT (INDIA) PVT. LTD., WALKER EXHAUST (INDIA) PVT LTD (a Subsidiary of Tenneco, a fortune 500 U.S. company), etc. AIL is also exporting auto parts i.e. brake shoes for Mercedes Benz Trailers to Saudi Arabia, Dubai etc. Autoline has grown by leaps and bounds from a single plant, a modest capital and a small staff to a company that can boast of 5 manufacturing units, over 1500 strong human resource and an almost 100 percent growth each year for seven years. Today, more than 400 products from Autoline fit into a range of SUVs, LCVs , HCVs and passenger cars besides 2 and 3 wheelers.

INDUSTRY PROFILE

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The auto-component industry is an important segment of the economy in any country as it links many industries and services. The Automotive Component Manufacturers Association of India (ACMA) is the nodal agency for the Indian Auto Component Industry, which includes Autoline Industries Ltd. The Indian auto component industry is one of India's sunrise industries with tremendous growth prospects. India is now a supplier of a range of high-value and critical automobile components to global auto makers such as General Motors, Toyota, Ford and Volkswagen, amongst others. Some leading manufacturers of auto components in India include Motor Industries Company of India, Bharat Forge, Sundaram Fasteners, Wheels India, Amtek Auto, Motherson Sumi, Rico Auto and Subros. There are presently 29 Vehicles Manufacturers (OEMs) in India located at Gurgaon, Pune and Chennai who together manufactured more than 5.2 million vehicles during 2005-06.

The regional base of auto component manufacturers is mostly concentrated in the West, North and South of India. This regional concentration of auto component manufacturers has been dictated by the emergence of automobile manufacturers in these regions. The set up of Tata Motors, Bajaj, Mahindra & Mahindra and TVS in the 1950s and 1960s laid the foundation for auto component manufacturers in the West and South, whilst the entry of Maruti during the 1980s created the base in the North.

The turnover of the auto component industry was estimated at over US$ 18 billion in 2007-08, a compunded increase of 27.2 per cent since 2002. It is likely to touch US$ 40 billion by 2015-16

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The six broad product categories according to Automotive Components Manufacturers Association (ACMA) are: 1. Engine Parts 2. Electrical Parts 3. Drive Transmission & Steering Parts 4. Suspension & Braking Parts 5. Equipments 6. Others

1. COMPONENT PRODUCTION (IN US $ MLN.)

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2. COMPONENT EXPORT (IN US $ MLN.)

COMPANY PROFILE
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Incorporated as Autoline Stampings Private Limited on 16th December 1996. We changed the name to Autoline Industries Private Limited on January 10, 2006 and converted into a public limited company on January 13, 2006 and name changed to Autoline Industries Limited.

NAME REGISTERED OFFICE

AUTOLINE INDUSTRIES LTD T-135, MIDC, Bhosari, Pune 411026, Maharashtra

Telephone Fax Registration No ROC Address

+91-20-27128961 +91-20-27110540 11-104510 Registrar of Companies, Maharashtra, Pune PMT Commercial Building, 3rd Floor, Deccan Gymkhana, Pune - 411004

Company¶s Vision: ³To be an innovation driven, Global Leader in the Design, Engineering and Manufacturing of Automotive Mechanical Systems.´ Company¶s Mission: ³To migrate into the fast lane without speed limits.´ Quality Policy: "We, at Autoline Dimensions, are committed to constantly strive for customer satisfaction, by consistently exceeding customer's expectations for product/Service quality with the help of continual improvements in our processes."
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BACKGROUND
Autoline Industriesis an auto-component manufacturer located in Pune catering to the components and subassembly requirements of leading automobile manufacturers. Three of our promoters Mr. Shivaji Akhade, Mr. Sudhir Mungase, and Mrs. Rema Radhakrishnan promoted a partnership firm in the name of Autoline Pressings in 1995. They started contract manufacturing of sheet metal components in January 1995 from a 3000 sq.ft rented premises at Survey No.825 Kudalwadi, near MIDC, Chinchwad Area, Pune. Subsequently, a Company in the name and style of Autoline Stampings Private Limited was incorporated on December 16, 1996. This company took over the partnership business. Autoline Stampings Pvt.Ltd was converted to a public limited company and renamed Autoline Industries Limited w.e.f. January 13, 2006. Another factory was setup in 1997-98 at Chakan, Pune with a built up area of 104,000 sq. ft. on a plot of land measuring 114,000 sq. ft. This factory is presently the largest manufacturing facility. They set up the 3rd manufacturing unit at MIDC, Bhosari in 1999-2000 on a 54,000 sq. ft. plot of land located near Tata Motors. All the three factories have obtained ISO/TS 16949: 2002 quality certifications. In November 2005 the company acquired Western Pressing Private Limited, with facilities for manufacturing Silencers and Exhaust Systems.

CURRENT OPERATIONS
Autoline Industries is one of the very few companies in India, which have capability to go from complete Design to manufacture (or ³Art to Part´) in very short time. Company has a strong team of 300 designers and engineers and prosperity software¶s( Morpher 4.0) which
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provides the company capability to to lower the new product designing process by 80-90%. Inorganic expansion has led to company having strong presence across 3 key markets of western Europe(Zagato, Italy), South Asia(India, Dimensions Engineering, Pune ) and US( Detroit Engineering Products, US). Besides company has 5 manufacturing mainly in Pune(Chakan) and Uttaranchal( Haridwar).

COMPETITIVE STRENGTHS 1. Integrated design engineering, prototyping, tooling and mass manufacturing capabilities.

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2. Strength to proactively seek opportunities for offering customized products for manufacturers in niche sectors. 3. One of the top five prime vendors of auto components with capability to provide high quality products in large volumes at competitive costs. 4. Ranked No.1 in terms of adherence to quality standards 5. Competent Management Team 6. Single Source Supplier: The single source supplier of more than 100 components for the Tata Indica, Indigo & Marino Cars. They are also the single source supplier for load bodies for the Tata Mini 1-Ton truck Ace.

CAPITAL STRUCTURE

AGGREGATE AMOUNT AT NOMINAL VALUE

AGGREGATE AMOUNT AT ISSUE PRICE

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A) Authorized Capital
15,000,000 equity shares of 10 Each
150.00 150.00

B) Issued, Subscribed and Paid up Equity Share Capital
70,33,511 equity shares of Rs. 10 each
70.33 139.74

C) Present Issue to the public in terms of this Red Herring Prospectus
[*] Equity Shares of Rs. 10 each fully paid up
[*] (*)

D) Paid Up Equity Capital After the Issue
[*] Equity Shares of Rs. 10 each fully paid up
[*] [*]

E) Share Premium account
Before the issue After the issue
69.41 [*] 69.41 [*]

PRODUCT PROFILE
Autoline Industries Ltd., is a major supplier of sheet metal components, sub assemblies and assemblies. Also manufacturing "A" class sheet metal dies, we supply about 130 components to Tata Motor's prestigious INDICA, Car Project and its mid-sized sedan INDIGO
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& MARINA mostly as single source supplier, and about 400 components to its Auto Division for LCVs, MCVs and HCVs, besides components for SUVs like Safari, Sumo and their variants. Various other components numbering more than 150 are being supplied to Bajaj Auto Limited & Kinetic Engineering Limited for 2 wheelers & 3 wheelers. Critical and prestigious components are regularly supplied to Walker Exhaust (India) Pvt Ltd, a wholly owned subsidiary of a Fortune 500 company. Besides these, we also supply Tractor components to Mahindra & Mahindra Limited, Mumbai, and Fiat, Mumbai, for their prestigious Palio Project. Exports of Brake shoes meant as spares for Mercedes Trailers to Germany, Singapore, UAE, Saudi Arabia, etc. A joint venture by the name of Union Autoline Spare Parts LLC, UAE has been set up to promote exports of Auto Components for the Gulf and African Markets.

PRODUCTS 1. 2. 3. 4. 5. 6. 7. Assembly Panel Inn Front Door RH & LH Assembly Panel Inn Rear Door RH & LH Panel Inn. Engine Hood RH & LH Panel Tunnel Panel Wind Shield Outer Panel Engine Hood Top Assembly Rear Quarter Inn. RH & AH
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8. Panel Tail Gate Sill Inner 9. Cross Member Front Bump Mounting Rear 10. Side Sill Reinforcement Front LH 11. Reinforcement Waist Outer Front Door 12. Reinforcement Waist Inner Front Door 13. Safari Door Hinge 14. Reinforcement Hand Brake 15. Tail Lamp Cover 16. D Pillar Top 17. Side Sill Reinforcement Rear LH 18. Panel Sill Truck Lid Outer 19. Frame Front Floor 20. Member Parcel Shelf Supp Side 21. Suspension Tower 22. Assembly Foot Control Modules 23. Exhaust Systems 24. Switch Gears 25. Assembly Cross Members & Assembly Brackets 26. Assembly Foot Control Modules.

Some of the products that the company deals with are as follows:-

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MANAGEMENT STRUCTURE The Management Structure of Autoline Industries Pvt Ltd. is given below:

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BOARD OF DIRECTORS
In all there are 10 Board of Directors. The day-to-day affairs of the company are being managed by Mr. Shivaji Akhade, Managing Director. The Board of Directors comprises of the following:
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Name
Mr. Vilas Lande Mr. Gopal Patwardhan Mr. Shivaji Tukaram Akhade Mr. M. Radhakrishnan Mr. Sudhir Vitthal Mungase Mr. Prakash B. Nimbalkar Mr. Vijay K. Thanawala Mr. Abraham Koshy Mr. Ajit B. Karnik Mr. Stanton Dodson

Status
Chairman Executive Chairman Managing Director and Chief Executive Officer (CEO) Joint Managing Director Wholetime Director Independent Director (Non-Executive) Independent Director (Non-Executive) Independent Director (Non-Executive) Independent Director (Non-Executive) Director (Non-Executive)

OBJECTIVE OF THE PROJECT
The project is prepared to fulfil various objectives. The objective to prepare this project is: I. II. III. To understand the working of an automotive industry. To understand how the company works in real sense. To understand the different ways by which the different parts of an automotive is made.
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IV.

To realize the importance and the role played by the company in the economy.

MANUFACTURING & OPERATIONS DETAILS
Metal Stamping manufacturing is the process of creating metal parts by applying extreme pressure to a blank piece on metal and forming the metal into a desired shape. The stamping machine incorporates a specially made form or die which gives the stamped part shape.

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Most metals may manufactured using the stamped process these include:

y y y y y y y y y

Aluminum (most alloys) Brass Steel, Cold rolled Copper Steel, Galvanized Steel, Hot Rolled, Cold Rolled Stainless Steel Titanium Zinc

Machines used in stamped manufacturing range from a simple hand press or hydraulic press, to the much larger machines referred to as drop hammers. All stamping machines incorporate a form or die to give the stamped metal the desired shape.

Stamping manufacturing processes include the following specific manufacturing processes or techniques:

y y y y y

Fine Blanking Deep Drawing Multislide Stamping Fourslide Stamping Wire forming
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y

Progressive Stamping

Depending on the complexity of the part, additional manufacturing steps required for the final part, will drive the effective cost-per-part of stamping manufacturing. Typical stamping speeds do vary, however many high production stamping manufacturers are capable of 30 to 80 stamping stokes per minute.

Besides, wielding & piercing is also done in the company.

SUPPLIERS & CUSTOMERS
SUPPLIERS: The main raw material for manufacturing operations is mild steel and alloy steel which is sourced directly from manufacturers such as Tata Steel Ltd, Bhushan Steel Ltd, Ispat Ltd, Essar Steel Ltd. The following grades of steel in our manufacturing processes:

THICKNESS ( in mm)

GRADE

CONSUMPTION (MT)
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0.7

D513 D513 EDD513 D513 DD1079 DD1079 -

3000 2520 2436 2268 1200 1368 7632 20424

1.2 1.0 1.0 1.6 2.0 Other Grades

Total Consumption per Annum

The required raw material is available in large quantities and according to our qualitative requirements.

CUSTOMERS:

Following are the customers of the company:
2004-05 Rs. In millions 684.82 % of Contribution in total sales 1113.26 2005-06 Rs. In millions

Name Gross Sales

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Tata Motors Bajaj Auto Ltd. Ganage Pressings Pvt. Ltd. Fiat India Pvt. Ltd. Kailash Vahan Udyog Ltd.
Mahindra & Mahindra Ltd. Other sundry customers

81.09 7.25 0.73 0.48 0.29 10.16

84.39 2.75 0.97 0.48 0.26 11.12

Company has advantage of being a single source supplier to Tata Motors, which provides it huge potential for not just TataMotors but also Fiat India. The company supplies about 86% of its products to Tata Motors Ltd and Bajaj Auto Limited. The single source supplier of more than 100 components for the Tata Indica, Indigo & Marino Cars. They are also the single source supplier for load bodies for the Tata Mini 1-Ton truck Ace.

FINDINGS & OBSERVATIONS
During our visit to Autoline Industries Ltd and while preparing this report, I observed various things. They are:

1.

They have adopted the technique of water harvesting to avoid pollution of water .

2. The company has adopted high standards of safety.

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3. They also give a lot of importance to time management i.e they have proper shift timings so that the workers get enough rest. 4. The industry is equipped with fully automatic machinery.

SUGGESTIONS
After the visit and while preparing this report I think there are certain things that the company should take care of. 1. The workers working near or with the welding machines should be provided with special material of clothes that does not burn with the sparks when the welding is done. 2. Fire extinguishers should be installed in and around the manufacturing unit.

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3. The working area should be more lighted. 4. There should be more ventilation.

BIBLIOGRAPHY
I took certain references and various help while preparing the project. The internet was the main source from where we found the information. The list of URLs used for the reference is listed below: 1. http://www.ibef.org/industry/autocomponents.aspx 2. http://www.autolineind.com/ 3. http://www.stampritemachine.com/hot_stamping.htm
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4. http://metals.about.com/gi/dynamic/offsite.htm?zi=1/XJ/Ya&sdn=metals&cdn=money&t m=7&f=00&tt=14&bt=0&bts=0&zu=http%3A//www.cauffiel.com/ 5. http://www.engineersedge.com/manufacturing/hot_stamping.htm 6. http://www.neptuneparts.com/ 7. http://www.searchindia.com/search/Autos/Auto_Components/index.shtml

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