Summers Project Report

On New Product Development and Logistics Management

For RMP Bearings Ltd. 1007, Kirti Shikhar, Janak Puri, District Centre New Delhi 110058

In partial fulfillment of Post graduate MBA programme (20010-2012)

Industry Guide: Mr. Naveen Sharma Deputy Manager Marketing and Business Development RMP Bearings Ltd.

Faculty Guide: Dr. M. Mallikarjun Institute of Management, Nirma University

Submitted by: Manpreet Singh (101324) MBA (Full Time) Institute of Management, Nirma University

TITLE PAGE

Author of the Project

Manpreet Singh

Organization Name

RMP Bearings Ltd. 1007, Kirti Shikhar Janak Puri, District Center New Delhi - 110058

Address

Date of Report

June 30, 2010

Purpose of Report

Summer Internship Report

Project Name

New Product Development and Logistics Management

Prepared for

Institute of Management, Nirma University

Acknowledgement

At the completion of my project I take great pleasure of acknowledging the management of RMP BEARINGS LIMITED for giving me the golden opportunity to do my summer project in their esteemed organization. I offer my profound gratitude to the management for giving me this opportunity of amalgamating my theoretical knowledge with my practical experience in a professional environment I am indeed very happy to acknowledge the numerous personalities involved in lending their help to make my summer project a successful one. I would like to thank the CEO & ED Mr. Parveen Kumar, Deputy Manager Marketing and Business Development at RMP Bearings Ltd. Mr. Naveen Sharma and all other staff of RMP Bearings Ltd. for their guidance and motivation throughout the project. Above all I am deeply grateful to Mr. M.Malikarjun, my project mentor for helping me and giving the opportunity to complete this project successfully This acknowledgement would not be complete without extending my thanks to my colleagues, who did their summer internship with me at RMP Bearings Ltd.

INDEX
PART A -Introduction..07 Automobile Industry in India........07

RMP Bearings Ltd..13 Introduction........13 R&D at RMP......13 Infrastructure..13 Clientele..13 Quality Control at RMP..13 About Ball Bearings19 How Ball Bearings Manufactured30 About Universal joints.36 7 S Framework for RMP Bearings Ltd..40 Porters five force analysis...47

PART B Projects done at RMP...51 NPD for ITL... ...52 NPD for NHIL...58 NPD for Yamaha....60 Vendor Development for RMP..69

Logistics Management.78

PART C Learning from Internship...75 REFRENCES78 ANNEXURE80

PART A INTRODUCTION OF THE ORGANIZATION

INTRODUCTION
Automotive Industry in India

The Automotive industry in India is one of the largest in the world and one of the fastest growing globally. India manufactures over 17.5 million vehicles (including 2 wheeled and 4 wheeled) and exports about 2.33 million every year.[1] It is the world's second largest manufacturer of motorcycles, with annual sales exceeding 8.5 million in 2009.[2] India's passenger car and commercial vehicle manufacturing industry is the seventh largest in the world, with an annual production of more than 3.7 million units in 2010.[3] According to recent reports, India is set to overtake Brazil to become the sixth largest passenger vehicle producer in the world, growing 16-18 per cent to sell around three million units in the course of 2011-12.[4] In 2009, India emerged as Asia's fourth largest exporter of passenger cars, behind Japan, South Korea, and Thailand.[5] As of 2010, India is home to 40 million passenger vehicles and more than 3.7 million automotive vehicles were produced in India in 2010 (an increase of 33.9%), making the country the second fastest growing automobile market in the world.[6][7] According to the Society of Indian Automobile Manufacturers, annual car sales are projected to increase up to 5 million vehicles by 2015 and more than 9 million by 2020.[8] By 2050, the country is expected to top the world in car volumes with approximately 611 million vehicles on the nation's roads.[9] A chunk of India's car manufacturing industry is based in and around Chennai, with the India operations of Ford, Hyundai, Renault and Nissan headquartered in the city and BMW having an assembly plant on the outskirts. Chennai accounts for 60 per cent of the country's automotive exports.[11] Gurgaon and Manesar in Haryana are hubs where all of the Maruti Suzuki cars in India are manufactured.[12] The Chakan corridor near Pune, Maharashtra is another vehicular production hub with companies like General Motors,Volkswagen, Skoda, Mahindra and Mahindra, Tata Motors, Mercedes Benz, Land Rover, Fiat and Force Motors[13][14] having

assembly plants in the area. Ahmedabad with the Tata Nano plant, Halol again with General Motors, Aurangabad with Audi, Kolkatta with Hindustan Motors,Noida with Honda and Bangalore with Toyota are manufacturing regions around the country.[15][16][17] some of the other automotive

The Indian Automobile Industry is manufacturing over 11 million vehicles and exporting about 1.5 million every year.[18] The dominant products of the industry are two wheelers with a market share of over 75% and passenger cars with a market share of about 16%.[18] Commercial vehicles and three wheelers share about 9% of the market between them. About 91% of the vehicles sold are used by households and only about 9% for commercial purposes.[18] The industry has attained a turnover of more than USD 35 billion and provides direct and indirect employment to over 13 million people.[18] The supply chain of this industry in India is very similar to the supply chain of the automotive industry in Europe and America. This may present its own set of opportunities and threats. The orders of the industry arise from the bottom of the supply chain i. e., from the consumers and goes through the automakers and climbs up until the third tier suppliers. However the products, as channelled in every traditional automotive industry, flow from the top of the supply chain to reach the consumers. Interestingly, the level of trade exports in this sector in India has been medium and imports have been low. However, this is rapidly changing and both exports and imports are increasing. The demand determinants of the industry are factors like affordability, product innovation, infrastructure and price of fuel. Also, the basis of competition in the sector is high and increasing, and its life cycle stage is growth. With a rapidly growing middle class, all the advantages of this sector in India are yet to be leveraged. Note that, with a high cost of developing production facilities, limited accessibility to new technology and soaring competition, the barriers to enter the Indian Automotive sector are high. On the other hand, India has a well-developed tax structure. The power to levy taxes and duties is distributed among the three tiers of Government. The cost structure of the industry is fairly traditional, but the profitability of motor vehicle manufacturers has been rising over the past five years. Major players, like Tata Motors and Maruti Suzuki have material cost of about 80% but are recording profits after tax of about 6% to 11%.[18] The level of technology change in the Motor vehicle Industry has been high but, the rate of change in technology has been medium. Investment in the technology by the producers has been high. System-suppliers of integrated components and sub-systems have become the order of the 8

day. However, further investment in new technologies will help the industry be more competitive. Over the past few years, the industry has been volatile. Currently, Indias increasing per capita disposable income which is expected to rise by 106% by 2015[18] and growth in exports is playing a major role in the rise and competitiveness of the industry. Tata Motors is leading the commercial vehicle segment with a market share of about 64%.[18] Maruti Suzuki is leading the passenger vehicle segment with a market share of 46%.[18]Hyundai Motor India and Mahindra and Mahindra are focusing expanding their footprint in the overseas market. Hero Honda Motors is occupying over 41% and sharing 26%
[18]

of the

two wheeler market in India with Bajaj Auto. Bajaj Auto in itself is occupying about 58% of the three wheeler market. Consumers are very important of the survival of the Motor Vehicle manufacturing industry. In 2008-09, customer sentiment dropped, which burned on the augmentation in demand of cars. Steel is the major input used by manufacturers and the rise in price of steel is putting a cost pressure on manufacturers and cost is getting transferred to the end consumer. The price of oil and petrol affect the driving habits of consumers and the type of car they buy. The key to success in the industry is to improve labour productivity, labour flexibility, and capital efficiency. Having quality manpower, infrastructure improvements, and raw material availability also play a major role. Access to latest and most efficient technology and techniques will bring competitive advantage to the major players. Utilising manufacturing plants to optimum level and understanding implications from the government policies are the essentials in the Automotive Industry of India. Both, Industry and Indian Government are obligated to intervene the Indian Automotive industry. The Indian government should facilitate infrastructure creation, create favourable and predictable business environment, attract investment and promote research and development. The role of Industry will primarily be in designing and manufacturing products of world-class quality establishing cost competitiveness and improving productivity in labour and in capital. With a combined effort, the Indian Automotive industry will emerge as the destination of choice in the world for design and manufacturing of automobiles.

Supply Chain

Supply Chain of Automobile Industry:

Source: ImaginMor, Inderscience Enterprises Ltd and United Nations Industrial Development Organisation

The supply chain of automotive industry in India is very similar to the supply chain of the automotive industry in Europe and America. The orders of the industry arise from the bottom of 10

the supply chain i. e., from the consumers and go through the automakers and climbs up until the third tier suppliers. However the products, as channelled in every traditional automotive industry, flow from the top of the supply chain to reach the consumers. Automakers in India are the key to the supply chain and are responsible for the products and innovation in the industry.

The description and the role of each of the contributors to the supply chain are discussed below.

Third Tier Suppliers: These companies provide basic products like rubber, glass, steel, plastic and aluminium to the second tier suppliers.

Second Tier Suppliers: These companies design vehicle systems or bodies for First Tier Suppliers and OEMs. They work on designs provided by the first tier suppliers or OEMs. They also provide engineering resources for detailed designs. Some of their services may include welding, fabrication, shearing, bending etc.

First Tier Suppliers: These companies provide major systems directly to assemblers. These companies have global coverage, in order to follow their customers to various locations around the world. They design and innovate in order to provide black-box solutions for the requirements of their customers. Black-box solutions are solutions created by suppliers using their own technology to meet the performance and interface requirements set by assemblers.

First tier suppliers are responsible not only for the assembly of parts into complete units like dashboard, breaks-axel-suspension, seats, or cockpit but also for the management of second-tier suppliers.

Automakers/Vehicle Manufacturers/Original Equipment Manufacturers (OEMs): After researching consumers wants and needs, automakers begin designing models which are tailored to consumers demands. The design process normally takes five years. These companies have manufacturing units where engines are manufactured and parts supplied by first tier suppliers and second tier suppliers are assembled. Automakers are the key to the supply chain of the 11

automotive industry. Examples of these companies are Tata Motors, Maruti Suzuki, Toyota, and Honda. Innovation, design capability and branding are the main focus of these companies.

Dealers: Once the vehicles are ready they are shipped to the regional branch and from there, to the authorised dealers of the companies. The dealers then sell the vehicles to the end customers.

Parts and Accessory: These companies provide products like tires, windshields, and air bags etc. to automakers and dealers or directly to customers.

Service Providers: Some of the services to the customers include servicing of vehicles, repairing parts, or financing of vehicles. Many dealers provide these services but, customers can also choose to go to independent service providers.

12

Introduction to RMP Bearings Ltd. Established in 1978, today RMP is one of the major contributors to the automotive & Textile industry who has carved out a niche of itself as a provider of unmatched innovative solutions and products to the automotive industry. Major focus of RMP products are technological components & systems with customized solutions. As an individual partner to the automotive industry in product development & serial production, RMP have joined in the elite group as a solution provider. RMPs continuous growth is supported by its Research & Development centre which guarantees number of innovations to serve the high standard set by the automotive industry. The R & D centre is equipped with the latest computation and instrumentation technology to accurately simulate, test and develop systems for varied applications. It has over 40 years experience and with the implementation of the Quality Systems like QS 9000 / TS 16949 and over 1000 experienced employees engaged in manufacturing and sales,.

R&D at RMP Bearings Ltd. RMPS R&D centre is dedicated to being a development partner for its clients. We aim to form a symbiotic relationship with our clients & become their thinking partners to find creative & innovative answer to engineering & technical requirements. RMPS reputation and performance is built on the foundation of its vast experience in design, engineering & technological developments. RMPS constant growth has been characterized by its in-house ideas and innovations.

Innovative ideas are put into realization by a process of design, prototyping, testing, validation & serial production. These projects are managed in an integrated approach by skilled project managers which forms an integral part of managing activities of each project, its requirement, progress & solutions.

Infrastrucuture RMPs core competence lies in its vast reservoir of expertise and infrastructure created over the years. Our production lines are equipped with modern and sophisticated Machines to provide uncompromising performance and technology to its clients. 13

RMP has established its credibility in manufacture of Sheet Metal, Alloy Forging, Injection Molding, Automatic Temperature Control Heat Treatment, Finishing & Super Finishing processes all under one roof. RMP follows stringent Quality checks & control measures to ensure highest quality products and to achieve international quality standards. Quality Management is applied from front design to dispatch of products to meet our aim of zero defect supplies. All our products undergoes most intensive testing on state of the art metallurgical & metrological instruments.

14

CLIENTLE

Sr.No. 1.

Type of Bearing Angular Bearing Contact Clutch

Customer Release Tata Motors Ltd. Mahindra & Mahindra Yamaha New Holland Maruti Suzuki Force Motors. (Bajaj) Tafe Ashok Leyland International Tractors Rane Luk India Ltd. Hindustan Motors

2.

Angular Contact Thrust Bearing

Sona Koyo Steering System Rane Tata Motors Ltd. Yamaha Motors India P.Ltd. Dynamatic Gears TRW

3.

Angular Contact Spherical Roller Bearing

XLO India Export Tata Eicher Mahindra & Mahindra Tafe Ashok Leyland Bajaj Tempo Motors Ltd.

4.

Taper Roller Thrust Bearing

5.

Thrust Ball Bearing

Mahindra

&

Mahindra 15

 Tata

Motors

Ltd.

Gabriel India 6. Steering Column Sona-Koyo Steering Rane TRW 7. Jockey Pulley Single Row Double Row 8. Pellow Block Ball Bearing ( S- Type) 9. Double Row Angular Contact Ball Bearing 10. Steering Races Yamaha XLO Rane Gabriel 11. Nylon cage Yamaha LMW 12. Wheel Bearing Market 13. Full compliment Bearing Single Row/ Doubel Row 14. Special Application Bearings - Cam Follower - Conveyor 15. Special Bearing 4 Point Bearing Sona Koyo Steering Systems Ltd Trelleborg Export LAL Export Export LMW Trumac LMW LMW KTTM

16

QUALITY CONTROL RMP follows stringent Quality control measures to ensure high quality products to achieve international standards. Quality management is applied from front design to dispatch of targets in order to meet the target of zero defect supplies.

INSPECTION & TEST FACILITIES (A) METTROLOGICAL Sr.No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Instrument Form taly surf plus unit Roundness tester unit Roughness tester unit Waviness measuring instrument Bearing vibration tester Length measuring instrument Dial calibration tester Electronic comparator Electo magnetic crack detector Match Gauging System Contact angle checking machine Profilee Projector Karl Zess Make Taylor Hobson Perthen Perthen H.T.R.C. WUXI, LEITZ Microtech Tess Magna Field Task

17

(B) METALLURGICAL Sr.No. 1. 2. 3. 4. 5. 6. 7. Instrument Microscope with Digital Printer Spectroscope Erichsen cupping test Micro hardness tester unit Universal testing machine Electo magnetic crack detector Rockwell Hardness tester Make Karl Zess Feed back Fie Essyway Deuteron Magna Field SMS Ind.

18

BALL BEARINGS A bearing is a device to allow constrained relative motion between two or more parts, typically rotation or linear movement. Bearings may be classified broadly according to the motions they allow and according to their principle of operation as well as by the directions of applied loads they can handle.

Plain bearings use surfaces in rubbing contact, often with a lubricant such as oil or graphite. A plain bearing may or may not be a discrete device. It may be nothing more than thebearing surface of a hole with a shaft passing through it, or of a planar surface that bears another (in these cases, not a discrete device); or it may be a layer of bearing metal either fused to the substrate (semi-discrete) or in the form of a separable sleeve (discrete). With suitable lubrication, plain bearings often give entirely acceptable accuracy, life, and friction at minimal cost. Therefore, they are very widely used. However, there are many applications where a more suitable bearing can improve efficiency, accuracy, service intervals, reliability, speed of operation, size, weight, and costs of purchasing and operating machinery. Thus, there are many types of bearings, with varying shape, material, lubrication, principle of operation, and so on. For example, rolling-element bearings use spheres or drums rolling between the parts to reduce friction; reduced friction allows tighter tolerances and thus higher precision than a plain bearing, and reduced wear extends the time over which the machine stays accurate. Plain bearings are commonly made of varying types of metal or plastic depending on 19

the load, how corrosive or dirty the environment is, and so on. In addition, bearing friction and life may be altered dramatically by the type and application of lubricants. For example, a lubricant may improve bearing friction and life, but for food processing a bearing may be lubricated by an inferior food-safe lubricant to avoid food contamination; in other situations a bearing may be run without lubricant because continuous lubrication is not feasible, and lubricants attract dirt that damages the bearings.

Common Designs There are several common designs of ball bearing, each offering various trade-offs. They can be made from many different materials, including:stainless steel, chrome steel, and ceramic (silicon nitride (Si3N4)). A hybrid ball bearing is a bearing with ceramic balls and races of metal.

20

Angular contact An angular contact ball bearing uses axially asymmetric races. An axial load passes in a straight line through the bearing, whereas a radial load takes an oblique path that tends to want to separate the races axially. So the angle of contact on the inner race is the same as that on the outer race. Angular contact bearings better support "combined loads" (loading in both the radial and axial directions) and the contact angle of the bearing should be matched to the relative proportions of each. The larger the contact angle (typically in the range 10 to 45 degrees), the higher the axial load supported, but the lower the radial load. In high speed applications, such as turbines, jet engines, and dentistry equipment, the centrifugal forces generated by the balls changes the contact angle at the inner and outer race. Ceramics such as silicon nitride are now regularly used in such applications due to their low density (40% of steel). These materials significantly reduce centrifugal force and function well in high temperature environments. They also tend to wear in a similar way to bearing steelrather than cracking or shattering like glass or porcelain. Most bicycles use angular-contact bearings in the headsets because the forces on these bearings are in both the radial and axial direction. Axial An axial ball bearing uses side-by-side races. An axial load is transmitted directly through the bearing, while a radial load is poorly supported and tends to separate the races, so that a larger radial load is likely to damage the bearing. Deep-groove In a deep-groove radial bearing, the race dimensions are close to the dimensions of the balls that run in it. Deep-groove bearings have higher load ratings for their size than shallow-groove, but are also less tolerant of misalignment of the inner and outer races. A misaligned shallow-groove bearing may support a larger load than the same sized deep-groove bearing with similar misalignment.

21

Principles of Operation There are at least six common principles of operation:

plain bearing, also known by the specific styles: bushings, journal bearings, sleeve bearings, rifle bearings

rolling-element bearings such as ball bearings and roller bearings jewel bearings, in which the load is carried by rolling the axle slightly off-center fluid bearings, in which the load is carried by a gas or liquid magnetic bearings, in which the load is carried by a magnetic field flexure bearings, in which the motion is supported by a load element which bends.

Motions Common motions permitted by bearings are:

Axial rotation e.g. shaft rotation Linear motion e.g. drawer spherical rotation e.g. ball and socket joint hinge motion e.g. door, elbow, knee

Friction

Reducing friction in bearings is often important for efficiency, to reduce wear and to facilitate extended use at high speeds and to avoid overheating and premature failure of the bearing. Essentially, a bearing can reduce friction by virtue of its shape, by its material, or by introducing and containing a fluid between surfaces or by separating the surfaces with an electromagnetic field.

By shape, gains advantage usually by using spheres or rollers, or by forming flexure bearings. 22

By material, exploits the nature of the bearing material used. (An example would be using plastics that have low surface friction.)

By fluid, exploits the low viscosity of a layer of fluid, such as a lubricant or as a pressurized medium to keep the two solid parts from touching, or by reducing the normal force between them.

By fields, exploits electromagnetic fields, such as magnetic fields, to keep solid parts from touching.

Combinations of these can even be employed within the same bearing. An example of this is where the cage is made of plastic, and it separates the rollers/balls, which reduce friction by their shape and finish.

Loads Bearings vary greatly over the size and directions of forces that they can support. Forces can be predominately radial, axial (thrust bearings) or bending moments perpendicular to the main axis.

Speeds Different bearing types have different operating speed limits. Speed is typically specified as maximum relative surface speeds, often specified ft/s or m/s. Rotational bearings typically describe performance in terms of the product DN where D is the diameter (often in mm) of the bearing and N is the rotation rate in revolutions per minute. Generally there is considerable speed range overlap between bearing types. Plain bearings typically handle only lower speeds, rolling element bearings are faster, followed by fluid bearings and finally magnetic bearings which are limited ultimately by centripetal force overcoming material strength. 23

Play Some applications apply bearing loads from varying directions and accept only limited play or "slop" as the applied load changes. One source of motion is gaps or "play" in the bearing. For example, a 10 mm shaft in a 12 mm hole has 2 mm play. Allowable play varies greatly depending on the use. As example, a wheelbarrow wheel supports radial and axial loads. Axial loads may be hundreds of newtons force left or right, and it is typically acceptable for the wheel to wobble by as much as 10 mm under the varying load. In contrast, a lathe may position a cutting tool to 0.02 mm using a ball lead screw held by rotating bearings. The bearings support axial loads of thousands of newtons in either direction, and must hold the ball lead screw to 0.002 mm across that range of loads.

Stiffness A second source of motion is elasticity in the bearing itself. For example, the balls in a ball bearing are like stiff rubber, and under load deform from round to a slightly flattened shape. The race is also elastic and develops a slight dent where the ball presses on it. The stiffness of a bearing is how the distance between the parts which are separated by the bearing varies with applied load. With rolling element bearings this is due to the strain of the ball and race. With fluid bearings it is due to how the pressure of the fluid varies with the gap (when correctly loaded, fluid bearings are typically stiffer than rolling element bearings).

Maintenance Many bearings require periodic maintenance to prevent premature failure, although some such as fluid or magnetic bearings may require little maintenance. Most bearings in high cycle operations need periodic lubrication and cleaning, and may require adjustment to minimise the effects of wear.

24

Bearing life is often much better when the bearing is kept clean and well-lubricated. However, many applications make good maintenance difficult. For example bearings in the conveyor of a rock crusher are exposed continually to hard abrasive particles. Cleaning is of little use because cleaning is expensive, yet the bearing is contaminated again as soon as the conveyor resumes operation. Thus, a good maintenance program might lubricate the bearings frequently but never clean them. There are many different types of bearings.

Type

Description

Friction

Stiffness

Speed

Life

Notes

Rubbing surfaces, usually

Depends on materials and Good, with construction, provided has wear is

Widely used, relatively Low to high friction, suffers very high - from stiction in some

lubricant; some PTFE Plain bearing bearings pumped

use coefficient of low, but Low friction some slack is

lubrication and ~0.05-0.35, behave similarly depending to bearings. fluid upon added

depends applications. to upon Depending upon the very high application application, lifetime and can be higher or lower

normally

fillers present

lubrication than rolling element bearings.

Rolling Ball or rollers Rolling element bearing are used coefficient of Good, Moderate

Moderat

prevent minimise rubbing

e to high Used for higher to friction with but some to high (depend moment loads than or steel can be slack is (often s on plain bearings with usually requires lubricati ~0.005 lower friction present cooling) on, (adding resistance often

25

due to seals, packed grease, preload and

requires mainten ance)

misalignment can increase friction to as much 0.125) as

Jewel bearing Off-center bearing rolls in Low seating Adequat e Low due to flexing Low (require s mainten ance) Mainly used in lowload, high precision work such as clocks. Jewel bearings may be very small.

Very high (usually Fluid is forced between Fluid bearing two Zero friction at zero limited Very high

Virtuall y infinite Can fail quickly due to grit or dust or other

faces and held in by edge seal

speed, low

in some contaminants. to a few applicati Maintenance free in hundred ons, continuous use. Can feet per may handle very large loads second wear at with low friction. at/by startup/s seal) hutdown 26

in some cases. Often negligib le mainten ance.

Zero friction at speed, constant power Faces of bearing levitation, are Magnetic bearings separate magnets kept eddy currents by are induced often Low No practical limit for Indefinit e. Active magnetic zero but

Mainten bearings (AMB) need ance free. considerable power. Electrodynamic

(electromagnets when or eddy currents) movement occurs, may but be

(with ele bearings (EDB) do not ctromag require external power. nets)

negligible if magnetic field is quasistatic

Flexure bearing

Material flexes to give and Very low Low

Very Very high. high or low dependi

Limited movement, backlash,

range

of no

constrain

extremely

27

movement

ng

on smooth motion

material s and

strain in applicati on. Usually mainten ance free.

Stiffness is the amount that the gap varies when the load on the bearing changes, it is distinct

from the friction of the bearing.

Applications

Today the ball bearing is used in numerous everyday applications. Ball bearings are used for dental and medical instruments. In dental and medical hand pieces, it is necessary for the pieces to withstand sterilization and corrosion. Because of this requirement, dental and medical hand pieces are made from 440C stainless steel, which allows smooth rotations at fast speeds.[4]

Hard drive bearings used to be highly spherical, and were said to be the best spherical manufactured shapes, but this is no longer true, and more and more are being replaced with fluid bearings.

In horology, the company Jean Lassale designed a watch movement that used ball bearings to reduce the thickness of the movement. Using 0.20 mm balls, the Calibre 1200 was only 1.2 mm thick, which still is the thinnest mechanical watch movement.

Aerospace bearings are used in many applications on commercial, private and military aircraft including pulleys, gearboxes and jet engine shafts. Materials include M50 tool steel

28

(AMS6491), Carbon chrome steel (AMS6444), the corrosion resistant AMS5930, 440C stainless steel, silicon nitride (ceramic) and titanium carbide-coated 440C.

Skateboarding. The wheels in a skateboard contain two bearings in each of the four wheels.

Yo-Yo's, there are Ball bearings in the center of high quality Yo-Yo's. Agricultural Equipment. The many moving parts in a piece of farm machinery depend on several different types of bearings to operate. Under the heavy loads and dusty conditions, these bearings need to be lubricated, repaired, or replaced often.

29

How are ball bearings Manufactured

Ever since man began to need to move things, he has used round rollers to make the job easier. Probably the first rollers were sticks or logs, which were a big improvement over dragging things across the ground, but still pretty hard work. Egyptians used logs to roll their huge blocks of stone for the pyramids. Eventually, someone came up with the idea of securing the roller to whatever was being moved, and built the first "vehicle" with "wheels." However, these still had bearings made from materials rubbing on each other instead of rolling on each other. It wasn't until the late eighteenth century that the basic design for bearings was developed. In 1794, Welsh ironmaster Philip Vaughan patented a design for ball bearings to support the axle of a carriage. Development continued in the nineteenth and early twentieth centuries, spurred by the advancement of the bicycle and the automobile. There are thousands of sizes, shapes, and kinds of rolling bearings; ball bearings, roller bearings, needle bearings, and tapered roller bearings are the major kinds. Sizes run from small enough to run miniature motors to huge bearings used to support rotating parts in hydroelectric power plants; these large bearings can be ten feet (3.04 meters) in diameter and require a crane to install. The most common sizes can easily be held in one hand and are used in things like electric motors. This article will describe only ball bearings. In these bearings, the rolling part is a ball, which rolls between inner and outer rings called races. The balls are held by a cage, which keeps them evenly spaced around the races. In addition to these parts, there are a lot of optional parts for special bearings, like seals to keep oil or grease in and dirt out, or screws to hold a bearing in place. We won't worry here about these fancy extras. 1. Raw Materials Almost all parts of all ball bearings are made of steel. Since the bearing has to stand up to a lot of stress, it needs to be made of very strong steel. The standard industry classification for the steel in these bearings is 52100, which means that it has one percent chromium and one percent carbon (called alloys when added to the basic steel). This steel

30

can be made very hard and tough by heat treating. Where rusting might be a problem, bearings are made from 440C stainless steel. The cage for the balls is traditionally made of thin steel, but some bearings now use molded plastic cages, because they cost less to make and cause less friction.

2. Manufacturing Process There are four major parts to a standard ball bearing: the outer race, the rolling balls, the inner race, and the cage.

Races

Both races are made in almost the same way. Since they are both rings of steel, the process starts with steel tubing of an appropriate size. Automatic machines similar to lathes use cutting tools to cut the basic shape of the race, leaving all of the dimensions slightly too large. The reason for leaving them too large is that the races must be heat treated before being finished, and the steel usually warps during this process. They can be machined back to their finished size after heat treating.

The rough cut races are put into a heat treating furnace at about 1,550 degrees Fahrenheit (843 degrees Celsius) for up to several hours (depending on the size of the parts), then dipped into an oil bath to cool them and make them very hard. This hardening also makes them brittle, so the next step is to temper them. This is done by heating them in a second oven to about 300 degrees Fahrenheit (148.8 degrees Celsius), and then letting them cool in air. This whole heat treatment process makes parts which are both hard and tough.

After the heat treatment process, the races are ready for finishing. However, the races are now too hard to cut with cutting tools, so the rest of the work must be done with grinding wheels. These are a lot like what you would find in any shop for sharpening drill bits and tools, except that several different kinds and shapes are needed to finish the races. Almost every place on the race is finished by grinding, which leaves a very smooth, accurate 31

surface. The surfaces where the bearing fits into the machine must be very round, and the sides must be flat. The surface that the balls roll on is ground first, and then lapped. This means that a very fine abrasive slurry is used to polish the races for several hours to get almost a mirror finish. At this point, the races are finished, and ready to be put together with the balls.

The Balls

The balls are a little more difficult to make, even though their shape is very simple. Surprisingly, the balls start out as thick wire. This wire is fed from a roll into a machine that cuts off a short piece, and then smashes both ends in toward the middle. This process is called cold heading. Its name comes from the fact that the wire is not heated before being smashed, and that the original use for the process was to put the heads on nails (which is still how that is done). At any rate, the balls now look like the planet Saturn, with a ring around the middle called "flash."

3. The first machining process removes this flash. The ball bearings are put between the faces of two cast iron disks, where they ride in grooves. The inside of the grooves are rough, which tears the flash off of the balls. One wheel rotates, while the other one stays still. The stationary wheel has holes through it so that the balls can be fed into and taken out of the grooves. A special conveyor feeds balls into one hole, the balls rattle around the groove, and then come out the other hole. They are then fed back into the conveyor for many trips through the wheel grooves, until they have been cut down to being fairly 32

round, almost to the proper size, and the flash is completely gone. Once again, the balls are left oversize so that they can be ground to their finished size after heat treatment. The amount of steel left for finishing is not much; only about 8/1000 of an inch (.02 centimeter), which is about as thick as two sheets of paper.

4. The first machining process removes this flash. The ball bearings are put between the faces of two cast iron disks, where they ride in grooves. The inside of the grooves are rough, which tears the flash off of the balls. One wheel rotates, while the other one stays still. The stationary wheel has holes through it so that the balls can be fed into and taken out of the grooves. A special conveyor feeds balls into one hole, the balls rattle around the groove, and then come out the other hole. They are then fed back into the conveyor for many trips through the wheel grooves, until they have been cut down to being fairly round, almost to the proper size, and the flash is completely gone. Once again, the balls are left oversize so that they can be ground to their finished size after heat treatment. The amount of steel left for finishing is not much; only about 8/1000 of an inch (.02 centimeter), which is about as thick as two sheets of paper.

The heat treatment process for the balls is similar to that used for the races, since the kind of steel is the same, and it is best to have all the parts wear at about the same rate. Like the races, the balls become hard and tough after heat treating and tempering. After heat treatment, the balls are put back into a machine that works the same way as the flash remover, except that the wheels are grinding wheels instead of cutting wheels. These wheels grind the balls down so that they are round and within a few ten thousandths of an 33

inch of their finished size.

After this, the balls are moved to a lapping machine, which has cast iron wheels and uses the same abrasive lapping compound as is used on the races. Here, they will be lapped for 8-10 hours, depending on how precise a bearing they are being made for. Once again, the result is steel that is extremely smooth.

5. Steel cages are stamped out of fairly thin sheet metal, much like a cookie cutter, and then bent to their final shape in a die. A die is made up of two pieces of steel that fit together, with a hole the shape of the finished part carved inside. When the cage is put in between and the die is closed, the cage is bent to the shape of the hole inside. The die is then opened, and the finished part is taken out, ready to be assembled.

Plastic cages are usually made by a process called injection molding. In this process, a hollow metal mold is filled by squirting melted plastic into it, and letting it harden. The mold is opened up, and the finished cage is taken out, ready for assembly.

Assembly

Now that all of the parts are made, the bearing needs to be put together. First, the inner race is put inside the outer race, only off to one side as far as possible. This makes a space between them on the opposite side large enough to insert balls between them. The 34

required number of balls is put in, then the races are moved so that they are both centered, and the balls distributed evenly around the bearing. At this point, the cage is installed to hold the balls apart from each other. Plastic cages are usually just snapped in, while steel cages usually have to be put in and riveted together. Now that the bearing is assembled, it is coated with a rust preventative and packaged for shipping.

Quality Control

Bearing making is a very precise business. Tests are run on samples of the steel coming to the factory to make sure that it has the right amounts of the alloy metals in it. Hardness and toughness tests are also done at several stages of the heat treating process. There are also many inspections along the way to make sure that sizes and shapes are correct. The surface of the balls and where they roll on the races must be exceptionally smooth. The balls can't be out of round more than 25 millionths of an inch, even for an inexpensive bearing. High-speed or precision bearings are allowed only five-millionths of an inch.

The Future

Ball bearings will be used for many years to come, because they are very simple and have become very inexpensive to manufacture. Some companies experimented with making balls in space on the space shuttle. In space, molten blobs of steel can be spit out into the air, and the zero gravity lets them float in the air. The blobs automatically make perfect spheres while they cool and harden. However, space travel is still expensive, so a lot of polishing can be done on the ground for the cost of one "space ball".

35

UNIVERSAL JOINTS A universal joint, universal coupling, U joint, Cardan joint, Hardy-Spicer joint, or Hooke's joint is a joint or coupling in a rigid rod that allows the rod to 'bend' in any direction, and is commonly used in shafts that transmit rotary motion. It consists of a pair ofhinges located close together, oriented at 90 to each other, connected by a cross shaft.

The main concept of the universal joint is based on the design of gimbals, which have been in use since antiquity. One anticipation of the universal joint was its use by the Ancient Greeks on ballistae. The first person known to have suggested its use for transmitting motive power was Gerolamo Cardano, an Italian mathematician, in 1545, although it is unclear whether he produced a working model. In Europe, the device is often called the Cardan joint or Cardan shaft. Christopher Polhem of Sweden later reinvented it, giving rise to the namePolhemsknut in Swedish. The mechanism was later described in Technica curiosa sive mirabilia artis (1664) by Gaspar Schott, who called it the paradoxum, but mistakenly claimed that it was a constant-velocity joint.[1] Shortly afterwards, between 1667 and 1675, Robert Hooke analysed the joint and found that its speed of rotation was nonuniform, but that this property could be used to track the motion of the shadow on the face of a sundial. In fact, the component of the equation of time which 36

accounts for the tilt of the equatorial plane relative to the ecliptic is entirely analogous to the mathematical description of the universal joint. The first recorded use of the term universal joint for this device was by Hooke in 1676, in his book Helioscopes. He published a description in 1678,[3] resulting in the use of the term Hooke's joint in the English-speaking world. In 1683, Hooke proposed a solution to the nonuniform rotary speed of the universal joint: a pair of Hooke's joints 90 out of phase at either end of an intermediate shaft, an arrangement that is now known as a constant-velocity joint. The term universal joint was used in the 18th century and was in common use in the 19th century. Edmund Morewood's 1844 patent for a metal coating machine called for a universal joint, by that name, to accommodate small alignment errors between the engine and rolling mill shafts. Lardner's 1877 Handbook described both simple and double universal joints, and noted that they were much used in the line shaft systems of cotton mills. Jules Weisbach described the mathematics of the universal joint and double universal joint in his treatise on mechanics published in English in 1883. 19th century uses of universal joints spanned a wide range of applications. Numerous universal joints were used to link the control shafts of the Northumberland telescope at Cambridge University in 1843. Ephriam Shay's locomotive patent of 1881, for example, used double universal joints in the locomotive's drive shaft. Charles Amidon used a much smaller universal joint in his bit-brace patented 1884. The term Cardan joint appears to be a latecomer to the English language. Many early uses in the 19th century appear in translations from French or are strongly influenced by French usage. Examples include an 1868 report on the Exposition Universelle of 1867 and an article on the dynamometer translated from French in 1881.[11]

To couple two shafts in different planes, you need to use a universal joint. Universal joints have various

37

Figure 11-21.-Universal joint (Hooke type).

Figure 11-22.-Ring-and-trunnion universal joint. forms. They are used in nearly all types and classes of machinery. An elementary universal joint, sometimes called a Hooke joint (fig. 11-21), consists of two U-shaped yokes fastened to the ends of the shafts to be connected. Within these yokes is a cross-shaped part that holds the yokes together and allows each yoke to bend, or pivot, in relation to the other. With this arrangement, one shaft can drive the other even though the angle between the two is as great as 25 from alignment.

38

Figure 11-22 shows a ring-and-trunnion universal joint. It is merely a slight modification of the old Hooke joint. Automobile drive shaft systems use two, and sometimes three, of these joints.

THE 7 - S FRAMEWORK
39

The basic premise of the 7 - S framework (developed in early 1980s) is that there are seven internal aspects of an organization that need to be aligned if it is to be successful. The 7S model is used in many situations where an alignment point of view is useful. For example it can help you improve the performance of a company, examine the likely effects of future changes within a company, align departments and processes during a merger or acquisition, determine how best to implement a proposed strategy. The McKinsey 7S model involves seven interdependent factors which are categorized as either "hard" or "soft" elements:

Hard Elements:
Strategy Structure Systems

Soft Elements:
Shared Values Skills Style Staff

40

Applying the 7 S model to RMP Bearings Ltd. gives us insight into the below mentioned aspects of the organization:

Shared Values
The shared values reflect the central beliefs and attitudes of an organization. Bank of India has a strong culture and deep-rooted shared values. Honesty, integrity and trust are the values that the company follows. There is also a sense of helping each other in the company. The working style is quite informal.

Strategy
Strategy is the plan and direction that an organization follows over time, to reach identified goals. Bank of India has a well developed strategic planning department aiming to achieve following objectives:

To become a world class customer centric organization. To achieve total performance Adopt best practice code in every area of operation for better business processes.

Structure
Structure is the way in which the organizations units relate to each other. RMP Bearings Ltd. has a two tier structure.

41

Head Office

4 Zonal Offices

Figure 2: The two tier structure of RMP Bearings Ltd.

An organizational chart is a diagram that shows the structure of an organization as well as the relationships and relative ranks of its positions. The organization chart of RMP Bearing Ltd. has been shown below. The centralized processes create many levels in the structure and it is strictly followed. There are various scales of officers and it is defined as to what scale is needed at what level of the structure.

Organizational chart of the organization is as follows 42

43

System
Systems represent the procedures, processes and routines that characterize how the work should be done. RMP Bearings Ltd. has the following systems:

Operational System

RMP Bearings Ltd. has operational systems which take care of all the manufacturing activities are taken care of such as manufacturing, delivery, raw material procurement etc.

Human Resource System

HR department is the backbone of the organization long run. RMP Bearings Ltd has wellestablished HR department takes care of its employees. Schemes like provident funds, gratuity, medical aid and expenses, etc. for the welfare of the employees. The HR systems in place make working an enriched experience for the employees in the organization.

Style
Organization style is a way of expressing something that is characteristic of employees or common way of thinking and behaving unwritten norms of behavior and thought. RMP Bearing Ltd. is adapting the transformational style. In order to achieve this it is also going for the lateral recruitment of managers and technicians to bring fresh ideas, dynamism, enthusiasm and new attitude in the organization. Regular meetings are conducted where it is seen that everything is on track in terms of the business it is expected to be done. Responsibilities are clearly defined and everyone has his/her defined area of work which makes it easy for both the employee and the manager.

Staff
Bank of India has approximately 2000 staff. It also has various training program for employees to enhance and improve their skills. Selection, training, reward and recognition, retention, motivation and assignment to appropriate work are all key issues. All these issues are taken care of by the HR department in RMP Bearings Ltd. The companys staff is very agile and feels 44

accountable for their work. Training of staff at all levels are conducted from time to time and the same is expected to be incorporated in day to day operations. Training process is well defined where need is identified and then training plan developed. The basic trainings are delivered to every employee and then role specific training is also provided.

Skills
Skills play an important role for the execution of companys Strategy. Training and Development ensures that proper skills get developed among the people so that they know to do their jobs and stay up to date with the latest techniques.

45

PORTER FIVE FORCES MODEL

Figure 4: Porters five force model

Threat of New Entrants

Not only is the establishment cost for automobile component development industry is high but also establishing a distribution channel, getting customers credit, managing losses and the need of huge pool of expert personnel are the reasons that make the setting up of a new manufacturing facility a costly affair. Hence the threat of new entrants is considerably low. RMP Bearings Ltd. specifically does not face much threat from new entrants as they are the only manufacturer of 46

universal joints via sheet metal technology in India. Its widespread network and years of technical expertise puts it in a very strong position.

Bargaining Power of Suppliers

For a this industry, services offered by the employees and raw material suppliers can be seen as supplies. Thus the suppliers to this industry are: Labor that gives man-power to the company Raw Material suppliers(Iron and steel)

In this sector the suppliers of raw-material might pose a big threat as there not many raw material suppliers in India, and the threat of supplier luring away human capital also poses large threat to the industry as this is labor intensive industry. If a talented individual is working with other companies then it may not be able to achieve operational efficiency as the success of firms in this sector largely depends upon the skill of human resources, chances of buying efficient employee is very high.

Bargaining Power of Customers

Customer does not exercise much of bargaining power as if we come up with some innovative technology such as Sheet metal yokes (in case of RMP) then customers may not have much options to go for other suppliers. In case customer want to switch suppliers he may even have to change the designing of the product which is not a desirable option for customer

Threat of Substitute Products

47

Threat of substitute product is there as most of the companies can make auto-component with similar dimensions without much change in their manufacturing process. But this can be avoided by coming up with innovative products such as sheet metal yokes(in case of RMP) which is not easy to replicate

Competitive Rivalry within Industry

Competitive rivalry is the most effective force among the five forces for the auto component industry. The various firms in India usually compete on the basis of new product introduction and increased customer services or warranties. This occurs because the competitors see the opportunity to improve their position. Because of this, firm must attempt to lure clients away from competitor firms. They do this by offering lower cost, better quality, and customer-friendly credit terms. Also the automobile sector is in a race to see who can offer the better and faster services at a lower cost, but this also causes firms to experience a lower return on asset. So to beat the competition innovation would be given more importance and that to with technology in place.

48

PART B PROJECTS DONE AT RMP BEARINGS LTD.

49

PROJECTS AT RMP BEARINGS LTD.

1. NEW PRODUCT DEVELOPMENT FOR INTERNATIONAL TRACTORS LIMITED (HOSHIARPUR) 2. NEW PRODUCT DEVELOPMENT FOR NEW HOLLAND FIAT (INDIA) PVT. LTD. 3. NEW PRODUCT DEVELOPMENT FOR INDIA YAMAHA MOTORS PVT. LTD. 4. VENDOR DEVELOPMENT FOR OUTSOURCING OF A PROCESS FOR RMP BEARINGS LTD. 5. LOGISTICS MANAGEMENT FOR VARIOUS CUSTOMERS (DOMESTIC AND INTERNATIONAL)

50

1. NEW PRODUCT DEVELOPMENT WITH INTERNATIONAL TRACTORS LTD. (HOSHIARPUR) Following are some of the steps that were taken during New Product Development for International Tractors Ltd.
1. Idea Generation: - International tractors were about to come up with 4x4 tractors, but during the testing phase they faced a problem of cracks on popular shaft of the tractor when in field. This was due to the fact that Popular shaft was not able to resist the shocks when tractor was on field. For this we went to Hoshiarpur at International tractors Limited manufacturing plant. There we were given technical specifications and other details about bearing needed through drawings and similar ball bearings of smaller sizes. The company needed RMPs current ball bearing 88511 to be supplied with some modifications such as a) Increase in air gaps in rubber casing of the bearing b) Modification in Inner Diameter of the oil seal of the bearings c) Bearing to be supplied with wrought Iron cage for fitment in the tractor

51

52

53

2. Idea Screening: - Idea screening part was done when we discussed the idea with higher authorities at RMP Bearings Ltd. and depending on demand and feasibility of the product. Idea was taken forward to next step. 3. Concept Development and testing: - Depending on the requirements of International Tractors Ltd. we checked out with other 4x4 tractor manufacturers and other manufactures of similar structure and checked how they were preventing there popular shaft from breaking. Conjoint Analysis was used to check various options that can be offered from RMP Bearings Ltd. For the concept development we checked out with various manufacturers and Ball Bearings markets in Delhi such as GB Road and Kashmiri gate where we found out about TATA producing Iron Casing for RMPs 6211. Current oil seal supplier was contacted to provide us with oil seal samples with modified ID Current supplier of rubber casing for 6211 was contacted to provide some samples of rubber casing with more air gaps. Both samples were sent to factory at Ranpur, Gujrat along with iron cage fitment of the bearing and after few days sample of required Ball Bearing was received at Delhi office. These samples along with Metallurgical Test reports was taken to Hoshiarpur Plant for Testing by International Tractors Ltd.

BELOW IS THE REQUIREMENTS SENT BY ITL

Ref. Drawing no. INSKU-101088 DATED 29-APR-2006 for MONOTRON ASSY (1310) Supplied to ICML MUV ITEM PART NO. DESCRIPTION MODIFICATION NEEDED BY US In this, We need to change Dimension of mounting Holes from 80 to 87.5mm FRONT SHAFT INSKU100247 9 580926 INSKU100098 Bearing 8 INSKU100116-2 Bracket & Also Change Dim 60 REF to 116 REF. Further, Slots size 14.5x13 should be changed accordingly so as to accommodate Mtg. Screw Size M16 It is TATA 6207 ball Bearing, BUT We need 6211 ball Bearing This has to be modified according to Our above Bearing 6211 REMARKS

10

CB Rubber

54

11

232769

Dust Seal

As above (for shaft Outer dia in our case is 55 & not 40) Applicable for above referred Dust Seals. For Shaft OD 55mm & above specified bearings & Dust Seals

12

232770 INSKU100010

Dust Seal retainer

13

L'Type Spacer

55

4. After this we received the approval for the required product and the steps that followed were sending of price quotations for required product by RMP Bearings Ltd. and product pricing settlements for the same.

2. NEW PRODUCT DEVELOPMENT FOR WITH NEW HOLLAND FIAT(INDIA) PVT. LTD.

56

Following are some of the steps that were taken during New Product Development for New Holland FIAT (India) Pvt. Ltd.
1. Idea generation: - Since RMP Bearing is the only manufacturer in India to make yokes with sheet metal process rather than conventional forged yokes which led to reduced product cost and better functionalities. New Holland Fiat (India) Pvt. Ltd. are to come up with New Range of tractors and they needed Universal joint assembly for the same. Some of the requirements were that the universal joint should be able to move 45 degrees in either direction. Meeting was arranged with Product Manager at New Holland Fiat (India) Pvt. Ltd. Product Manager gave us the overview of the requirement with the help of CAD drawings. Another concern of the customer was cost factor of the product required. Since currently universal joints were being supplied to SONA KOYO STEERING SYSTEMS and they were using spider and needle bearings to connect to yokes, but the this assembly had an estimate cost of about Rs 160 providing much more functionalities than needed by the customer.

2. Depending upon the requirements of the customer and drawings given by him, we followed up with our factory at Ranpur to check whether we have any existing product to match the requirements of the customer. 3. CAD drawings were sent to Product Manager at New Holland Fiat (India) Pvt. Ltd. and one of the yokes assembly manufactured by RMP Bearings Ltd. matched the requirement of the dimensions needed by the company. We contacted other customers to whom we supplied yokes for universal joints about the alternatives of spider and needle bearing to provide limited functionalities and reduced cost. After checking out the production line of ESCORTS (FTD) we saw that they catered to similar requirements using yokes and two-way joint that was cheaper alternative of spider. Then we met the product manager for that product and requested for 5-6 samples of 2-way joints used by them. These samples were sent to factory for samples to be created for required product. 4. As a next step meeting was arranged with Product manager at customer end and taking the samples to New Holland Fiat (India) Pvt. Ltd. along with metallurgical test reports. 5. New Holland Fiat (India) Pvt. Ltd. carried out the required performance test on the samples and samples were passed by the company 6. Next step that followed was to settle product pricing and payment terms for the required product.

57

3. NEW PRODUCT DEVELOPMENT FOR INDIA YAMAHA PVT. LTD. India Yamaha Pvt. Ltd. is to come up with new model of two-wheelers. They were currently buying Ball Races for manufacturing of RX100 which is exported to other countries for final assembly and selling. For new model they were looking for suppliers of the same. Following are drawings of Ball Races needed by the company

58

Ball Race 01

59

Ball Race 02

60

Ball Race 03 61

Ball Race 04

62

63

Since this process of new product development was inline since Sept10 . I was introduced in much later stage. Before I joined as Summer Intern, Following steps of Product development were already executed. 1. Taking of drawings for required ball races. 2. Sending these drawing to factory for sample manufacturing 3. Testing of samples at customer end

I was introduced in the process when India Yamaha Pvt. Ltd. had already accepted the samples and next step was to do follow up with Product Manager at India Yamaha Pvt. Ltd. During our first meeting, Product manager was not sure about costing design of RMP and had some issues about how weight of ball races was calculated and how process cost was calculated. Costing of one of the races is as given below.

64

COST BREAK UP
32/10Ref.No: 11 : Date 12/10/201 0 Pa ge : 01 of 01 PART NAME PRODU CT Race Ball 03 Race CUSTOMER DRAWING No.

Yamaha
1PM F 3413 00 C

[A] RAW MATERIAL DETAIL MAT COMP Sr. No. ONENT DR G.N O. ERIA L TYPE & SIZE 01 SAERace 52100 TOTAL [A] [B] Sr. No. PROCESS OPERATION TO Roundbar 65.00 Per Kg. SUPPLIER NAME BASIC RATE Tax 4% FREIG HT % Wt / Pc in Kg.

TOTAL Rs.

0.100

6.50

6.50

65

TA L Rs. A 1 2 3 4 5 6 7 8 OUTER RACE Forging & Annealing Rough Turning Final Turning Heat Treatment Centreless Grinding Track Grinding Vibrating Assembly Inspection TOTAL [B] [C] BOUGHT-OUT PARTS COMP Sr. No. ONEN T 1 Oil TOTAL [C] [D] REJECTION [E] PACKAGING [F] FORWARDING & FREIGHT [G] INVENTORY [H] OVER HEAD [I] PROFIT 0.64 1.88 1.88 1.00 US DRN. NO. MATERI AL E/ BR G Unit BASIC RATE TAX AND FREIG HT % 1.00 RATE / UNIT TOTAL Rs.

0.00

12.50

1.00

1.00
0.52

TOTAL [D] TO [I] TOTAL [A] TO [I] QUOTED PRICE

PREPARED BY CHECKED BY

Rs. Rs. Rs.

APPROVED BY

5.94

25.94
25.94

12/10/2010

12/10/2010

12/10/2010

66

Since my team didnt had details about how weights were calculated we postponed the pricing settlements to next meeting. After that we had to contact our Marketing Head at Ahmedabad for the details about how product weights was calculated and had to follow up with Product Manager at India Yamaha Pvt. Ltd. for next meeting. Next meeting was scheduled after 2 weeks and we gave him details about weighing calculations about the Ball Races and payment receipts of Raw Material bought at RMP, he was satisfied with costing provided by RMP and after negotiations final prices for Ball Races were settled around overall 8% less than quoted price. Since both the companies were already doing business for Ball Races for Yamaha RX100 Ball races, payment terms were decided on same grounds.

67

4. VENDOR DEVELOPMENT FOR OUTSOURCING OF A PROCESS FOR RMP BEARINGS LTD.

RMP is currently supplying Thrust ball bearings to TATA MOTORS for their four-wheelers passenger cars INDICA and INDIGO. RMP had outsourced turning job required to some vendors in neighboring area but they were not able to meet the monthly requirements. So we were asked to develop vendors at Industrial Areas located in Delhi. Some of the areas identified by us for the same were Faridabad Industrial Area, Manesar Industrial Area, Anand Parbat and Mayapuri Industrial Area. Since the requirement was for high accuracy and large quantity CNC machines were required to do the turning job instead of conventional Lathe Machines Following are some of the vendors in each area and standards on the basis of which each of them were selected/rejected for vendorship. Following were the target costs given by the management for turning job of Indica and Indigo Thrust Bearings. Indica thrust Bearings :- Rs 7 per set of two Indigo thrust Bearings :- Rs 6.50 per set of two Following are the drawings for both thrust bearings

68

Indica Thrust Bearings

69

Indigo Thrust Bearings

70

71

Although most of the interactions with prospective vendors were in interview format where we interviewed each of the vendor and noticed their infrastructure.

Following are details about some of the vendor interactions that happened during field visits. Perfect Gear Ind Regd is located in Anand Parbat and we came to know about some refrences that they were having some of the largest CNC machine Infrastructre in the area. We talked to Mr. Kamal (owner) and fixed meeting with him regarding the same. We presented him with some of the samples of raw material (to be supplied by RMP) and expected finished goods. Mr Kamal had enough spare capacity and infrastructure to cater to requirement of RMP. On the basis of Infrastructure and spare capacity Request for Quotation(RFQ) was given to Mr Kamal. Mr Kamal requested for 2-3 days time to calculate his costing on the basis of drawings given by RMP. Quotation offered by Mr Kamal was Indica Thrust Bearings :- Rs 12 per set of two Indigo Thrust Bearings :- Rs 10 per set of two

On the basis if this quotation Perfect Gear Ind Regd, was rejected for Vendorship Through referral we also visited Mr Harvinder Singh having CNC setup in Anand Parbat. They were having 7 CNC machines installed in their premises which were enough to cater to demands of our company. After we presented them with samples and drawings of the job they were not interested in turning job of small parts such as Thrust Ball Bearings. Some of the other factories were also visited in the same area but most of them were not having required infrastructure or enough spare capacities to cater to demands of RMP Bearings Ltd.

Next we pitched in for prospective vendors in Gurgaon Manesar area. Some of the factories with installed CNC machines were Solo Mfg Pvt. Ltd. Sterling Auto Mega Pert Technologies Micron Tools and Industries

72

Out of these, Mega Pert Technologies had required Infrastructure (5 CNC machines) to meet the requirements of RMP Bearings Ltd. Mr. Kapil Malhotra was our POC for the same. We fixed meeting with him regarding the same. We presented him with some of the samples of raw material (to be supplied by RMP) and expected finished goods. Mega Pert had required infrastructure but they didnt had enough spare capacity and labour to cater to RMPs requirements.

After pitching in to multiple factories in Faridabad Industrial area and Mayapuri , most of which either didnt had enough Infrastructure or spare capacity to meet requirements. We pitched in to Madhok Engineering works in Mayapuri and fixed meeting with Mr. Charanjeet Singh(owner) and his son Mr Amandeep Singh(PR). They had 23 automatic Lathe machines and 2 CNC machines installed in Rajouri Garden and 3 CNC machines in Mayapuri branch. They had enough Infrastructure as well as spare capacities to meet requirements of RMP Bearings Ltd. We presented him with some of the samples of raw material (to be supplied by RMP) and expected finished goods. They agreed to do turning job for RMP and requested for 2 days time to work out with costing of the process on the basis of drawings presented to them. Price quoted by them was as follows Indica Thrust Bearings :- Rs 9 per set Indigo Thrust Bearings :- Rs 8 per set This price was pretty close to the target cost assigned by top management. Thus after a week we again went for pricing settlements with them. After negotiations the price was settled at Indica thrust Bearings :- Rs 6.80 per set of two Indigo thrust Bearings :- Rs 6.25 per set of two Payment and delivery terms were also fixed in the same meeting.

73

5. LOGISTICS MANAGEMENT FOR VARIOUS CUSTOMERS (DOMESTIC AND INTERNATIONAL)

While we were not on field, I also assisted Deputy Manager Mr. Naveen Sharma in handling logistics for various domestic and International Customers Process that followed was that at the end of each month we received schedule for next month and tentative schedule for next 3 months. On the basis of schedule received, dispatch scheduled at Ahmedabad and copy of same was given to us. Our job was to keep track of consignment and to decide on mode of transfer on the basis of urgency of the product required. Since all of the customers had assembly line manufacturing at their ends, so it was very important to make each part deliver on time so as to prevent their assembly lines from stopping. Since most of the material was delivered either by RMP owned trucks or OM Logistics we had the responsibility of tracking each consignment to customers. In case if any of the product was critical for any customers we decided on the lot size and mode of transport (Air, Train or Road) so as to prevent customers production line.

74

PART C LEARNING FROM THE PROJECT

Learning from the summer project

75

1. Working with an organization like RMP Bearings Ltd gave me very useful insight into the working of a B2B Environment. Interacting with the employees and customers every time brought up new information for me not just related to the project but to the companys operations in general. 2. As a part of the Marketing and Business Development department, I got to see entire procedure of new product development, pricing settlements with existing customers. 3. Doing Vendor development for RMP required me to meet new people and look for factors not explicitly mentioned which was a boost to my soft skills. 4. I even got to apply various marketing concepts learnt in the first year. 5. Working on various sub-projects gave me an opportunity to apply the tools and techniquesI learnt in the first year in subjects like Marketing Management, Organizational Behaviour etc. 6. I got opportunity to get first-hand experience of various Marketing concepts such as Stages in B2B buying process, How new product development decisions are taken in the organization, Various factors to be taken care when making Channel Management and Market-Logistics Decisions for the organization. 7. The literature review helped me a lot to develop my knowledge base on the various aspects of B2B markets, automobile component development Industry and even the economic aspects of the businesses. On a personal note: I was a fresher and had no industry experience. Coming from a computer science background, banking was a totally new field for me. I remember my first day at the branch. I was given a file about a client and I could not understand anything. Though I had studied balance sheets and other financial statements in my course earlier but I could not understand anything. My mentor Mr. Thaker told me it was fine because I am from an engineering background. Then at the end of the day he said to me never say die. Those words somehow struck a chord in me and motivated me very high. I will never forget these words because they really helped me in my total experience at RMP Bearings Ltd.

76

References

1. 2. 3.

"Automobile Industry India" http://imaginmor.com/automobileindustryindia.html . Imagin Mor Pty Ltd. "Honda to Build Second Motorcycle Production Plant in India". World.honda.com. 2010-03-09. Retrieved 2010-11-28. http://oica.net/wp-content/uploads/all-vehicles-2010-provisional.pdf

77

4.

Nair, Vipin V. (2009-09-07). "Suzuki, Hyundais Indian Car Exports Beat Chinas". Bloomberg.com. Retrieved 201009-01.

5. 6.

Gulati, Nikhil (2010-09-09). "India Car Sales Touch Record High". Online.wsj.com. Retrieved 2010-11-28. "India second fastest growing auto market after China". Thehindubusinessline.com. 2010-04-10. Retrieved 2010-1128.

7. 8. 9.

"Restarting trouble in Indian Auto Industry - Forbes India". Moneycontrol.com. Retrieved 2011-01-01. S Kalyana Ramanathan. "India to top in car volumes by 2050". Rediff. N. Madhavan (2008-07-07). "India's detroit". Businesstoday.intoday.in. Retrieved 2011-12-02.

10. "CII launches Chennai zone". The Hindu Business Line. 2007-10-19. Retrieved 2010-11-28. 11. Japan. "Maruti Suzuki - Wikipedia, the free encyclopedia". En.wikipedia.org. Retrieved 2011-01-01. 12. "Mahindra Chakan - News". Zigwheels. Retrieved 2010-11-28. 13. "Volkswagen Inaugrates Chakan Plant!". cubi[CC]apacity. Retrieved 2010-11-28. 14. "Skoda plant commissioned near Aurangabad". Autonews.indiacar.com. Retrieved 2010-11-28. 15. "Car Manufacturers". Automobileindia.com. Retrieved 2010-11-28. 16. "General Motors; Electric Vehicles; Eco Friendly Car". Living.oneindia.in. 2010-10-25. Retrieved 2010-11-28. 17. http://www.imaginmor.com/automobileindustryindia.html 18. Rmpbearings.com 19. 20. 21.

http://en.wikipedia.org/wiki/Ball_bearing http://en.wikipedia.org/wiki/Bearing_(mechanical) http://en.wikipedia.org/wiki/Universal_joint

78

Annexure : Product line of RMP Bearings Ltd.

CLUTCH BEARINGS

79

BEARING NO. 60-22 2RS ---------------------------------------------------------------------------------------------------------------------

BEARING NO. 306445C(6010) ---------------------------------------------------------------------------------------------------------------------

BEARING NO. 5122028 ---------------------------------------------------------------------------------------------------------------------

BEARING NO. RT-6014 2RS ---------------------------------------------------------------------------------------------------------------------

RACES

BALL RACE 324015 80

---------------------------------------------------------------------------------------------------------------------

BALL RACE 324019 ---------------------------------------------------------------------------------------------------------------------

INNER RING G-76 ---------------------------------------------------------------------------------------------------------------------

SPACER 4.60

REPLACEMENT MARKET

BEARING NO. RT 6003 Z 81

---------------------------------------------------------------------------------------------------------------------

CAGE F-7 ---------------------------------------------------------------------------------------------------------------------

RACE MK2 LARGE ---------------------------------------------------------------------------------------------------------------------

RACE MK3 LARGE ---------------------------------------------------------------------------------------------------------------------

RACE MK3 SMALL ---------------------------------------------------------------------------------------------------------------------

RACE MKII SMALL ---------------------------------------------------------------------------------------------------------------------

RT-6001 Z ---------------------------------------------------------------------------------------------------------------------

82

RT-6004 ---------------------------------------------------------------------------------------------------------------------

RT-6005 ZZ ---------------------------------------------------------------------------------------------------------------------

RT-6011 ZZ ---------------------------------------------------------------------------------------------------------------------

RT-6204 ZZ ---------------------------------------------------------------------------------------------------------------------

RT-6205 2RS ---------------------------------------------------------------------------------------------------------------------

RT-6207 WOS ---------------------------------------------------------------------------------------------------------------------

83

RT 6208 WOS ---------------------------------------------------------------------------------------------------------------------

RT-6211 ---------------------------------------------------------------------------------------------------------------------

RT-6211 WOS ---------------------------------------------------------------------------------------------------------------------

RT-6212 R2S ---------------------------------------------------------------------------------------------------------------------

RT 6304 ZZ ---------------------------------------------------------------------------------------------------------------------

RT-51107 ---------------------------------------------------------------------------------------------------------------------

84

RT-306497 (6011) ---------------------------------------------------------------------------------------------------------------------

RT-356837 INDICA WHEEL BEARING ---------------------------------------------------------------------------------------------------------------------

RT-366833 ( MARUTI WHEEL BRG) ---------------------------------------------------------------------------------------------------------------------

RT-1888180 ---------------------------------------------------------------------------------------------------------------------

RT-1888180 WH ---------------------------------------------------------------------------------------------------------------------

RT-QJ309 ---------------------------------------------------------------------------------------------------------------------

85

STEERING (RACES) APPLICATION

ADJ. RACE 530 86

---------------------------------------------------------------------------------------------------------------------

BALL RACE 01 ---------------------------------------------------------------------------------------------------------------------

BALL RACE 02 ---------------------------------------------------------------------------------------------------------------------

BALL RACE 03 ---------------------------------------------------------------------------------------------------------------------

BALL RACE 04 ---------------------------------------------------------------------------------------------------------------------

BALL RACE 601 ---------------------------------------------------------------------------------------------------------------------

BALL RACE 650 ---------------------------------------------------------------------------------------------------------------------

87

BALL RACE 651 ---------------------------------------------------------------------------------------------------------------------

BALL RACE KAWASAKI ---------------------------------------------------------------------------------------------------------------------

CAGE 1-4 ---------------------------------------------------------------------------------------------------------------------

CAGE 530 ---------------------------------------------------------------------------------------------------------------------

CAGE 3-16 ---------------------------------------------------------------------------------------------------------------------

INNER RACE 571 ---------------------------------------------------------------------------------------------------------------------

88

RACE 518 -2 ---------------------------------------------------------------------------------------------------------------------

RACE 518 -1 ---------------------------------------------------------------------------------------------------------------------

RACE 701 ---------------------------------------------------------------------------------------------------------------------

RACE REAR AXLE BUSH ---------------------------------------------------------------------------------------------------------------------

YAMAHA KIT WITH CAGE STEERING COLUMN BEARING ---------------------------------------------------------------------------------------------------------------------

BALL BEARING 6001 ---------------------------------------------------------------------------------------------------------------------

89

BALL BEARING 6004 4PC ---------------------------------------------------------------------------------------------------------------------

BALL BEARING 6004 22B ---------------------------------------------------------------------------------------------------------------------

BALL BEARING 6904 ---------------------------------------------------------------------------------------------------------------------

BALL BEARING 6904 1RS ---------------------------------------------------------------------------------------------------------------------

BALL BEARING 16005 4PC ---------------------------------------------------------------------------------------------------------------------

BALL BEARING DG-1935 ---------------------------------------------------------------------------------------------------------------------

90

TEXTILE BEARINGS

BEARING NO. 3203 ZZ --------------------------------------------------------------------------------------------------------------------91

BEARING NO. GE 40 ---------------------------------------------------------------------------------------------------------------------

BOBBIN WHEEL CAGE ---------------------------------------------------------------------------------------------------------------------

JOCKEY PULLEY BSR-70 ---------------------------------------------------------------------------------------------------------------------

JOCKEY PULLEY SR-6 ---------------------------------------------------------------------------------------------------------------------

TEXTILE BEARING 45 NPPB ---------------------------------------------------------------------------------------------------------------------

TEXTILE BEARING 50-90 ---------------------------------------------------------------------------------------------------------------------

92

TEXTILE BEARING 3204 WITH STRUD ---------------------------------------------------------------------------------------------------------------------

TEXTILE BEARING 215514 ---------------------------------------------------------------------------------------------------------------------

TEXTILE BEARING 519484 ---------------------------------------------------------------------------------------------------------------------

TEXTILE BEARING BT 2015 ---------------------------------------------------------------------------------------------------------------------

TEXTILE BEARING BT 2015(19.5) ---------------------------------------------------------------------------------------------------------------------

TEXTILE BEARING BT 2019 ---------------------------------------------------------------------------------------------------------------------

93

TEXTILE BEARING NO. 6206 2RS ---------------------------------------------------------------------------------------------------------------------

TEXTILE BEARING NO. GE 25 ---------------------------------------------------------------------------------------------------------------------

TEXTILE BEARING NO. GE-35 KRRB ---------------------------------------------------------------------------------------------------------------------

TEXTILE BEARING NO. GE 50 ---------------------------------------------------------------------------------------------------------------------

TEXTILE BEARING RAE 25 ---------------------------------------------------------------------------------------------------------------------

TEXTILE BEARING SRO 10 ---------------------------------------------------------------------------------------------------------------------

94

TEXTILE BEARING SRO 47 ---------------------------------------------------------------------------------------------------------------------

YOKES

95

DSC_5329 ---------------------------------------------------------------------------------------------------------------------

DSC_5330 ---------------------------------------------------------------------------------------------------------------------

DSC_5331 ---------------------------------------------------------------------------------------------------------------------

DSC_5332 ---------------------------------------------------------------------------------------------------------------------

DSC_5333 ---------------------------------------------------------------------------------------------------------------------

DSC_5334 ---------------------------------------------------------------------------------------------------------------------

96

DSC_5335 ---------------------------------------------------------------------------------------------------------------------

DSC_5338 ---------------------------------------------------------------------------------------------------------------------

DSC_5340 ---------------------------------------------------------------------------------------------------------------------

DSC_5341 ---------------------------------------------------------------------------------------------------------------------

DSC_5342 ---------------------------------------------------------------------------------------------------------------------

DSC_5343 ---------------------------------------------------------------------------------------------------------------------

97

DSC_5344 ---------------------------------------------------------------------------------------------------------------------

DSC_5345 ---------------------------------------------------------------------------------------------------------------------

DSC_5346 ---------------------------------------------------------------------------------------------------------------------

DSC_5347 ---------------------------------------------------------------------------------------------------------------------

DSC_5348 ---------------------------------------------------------------------------------------------------------------------

DSC_5349 ---------------------------------------------------------------------------------------------------------------------

98

DSC_5350 ---------------------------------------------------------------------------------------------------------------------

DSC_5351 ---------------------------------------------------------------------------------------------------------------------

DSC_5352 ---------------------------------------------------------------------------------------------------------------------

DSC_5353 ---------------------------------------------------------------------------------------------------------------------

DSC_5355 ---------------------------------------------------------------------------------------------------------------------

DSC_5356 ---------------------------------------------------------------------------------------------------------------------

99

DSC_5357 ---------------------------------------------------------------------------------------------------------------------

DSC_5358 ---------------------------------------------------------------------------------------------------------------------

DSC_5381 ---------------------------------------------------------------------------------------------------------------------

DSC_5383 ---------------------------------------------------------------------------------------------------------------------

DSC_5386 ---------------------------------------------------------------------------------------------------------------------

DSC_5388 ---------------------------------------------------------------------------------------------------------------------

100

DSC_5415 ---------------------------------------------------------------------------------------------------------------------

101