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UNO MINDA
Group ProfileMINDA KOSEI ALUMINUM WHEEL PVT. LTD.
2019
1/27
UNO MINDA: Group overview
Confidential
To be a Sustainable
Global organization that
enhances value for all its
Stakeholders, attains
Technology Leadership
and cares for its people
like a Family.
VISION VALUES
Customer is Supreme
Live Quality
Encourage Creativity and Innovation to drive people process & products
Respect for Individual
Respect for work-place Ethics
Group Overview
Nurtured Partnerships & Affiliations
2/27
UNO MINDA - Product Portfolio3/27
UNO MINDA - Domestic & Global CustomersDomestic Customers
Global Customers
4/27
Kosei Group (JV Partner): Overview
Kosei Group Brief (JV Partner)
Product Portfolio
Kosei Locations:
Alloy Wheel Plant: Hokkaido, Fukui, Thailand, USA
General Castings: Japan, China
R&D Centre: Hong Kong
Trade & Investment: Hong Kong
Sales & Distribution: Japan, Philippines, USA
Minda Entered into JV with Kosei2010
First Production facility established in Chennai (KMA)2012
Production Facility Established at Bawal in Mar 2016
with Capacity 30K Nos/ month (MKA)2016
Capacity increased to 60K Nos/ months in Sep 20162016
Capacity increased to 90K Nos/ month in Mar 20172017
Capacity increased to 120K Nos/ month in July 20172017
Facility established at Gujarat in April 2018 with
Capacity 30K Nos/ month (MKA)2018
Capacity of Gujarat Plant increased to 60K Nos/ month
in July 20182018
Capacity expansion and announcement of LPDC
Wheels manufacturing at Gujarat Plant2019
Minda Kosei JV: Journey Brief
5/27
Customers & Market Share
Customer Supplying from Plant at
Share of our Sales
Maruti Suzuki India Ltd. Bawal 41%
Suzuki Motors Gujarat Bawal / Gujarat 20%
Mahindra & Mahindra Bawal 11%
Honda Cars India Ltd Chennai 9%
Toyota Kirloskar Motor Ltd Chennai 11%
Renault Nissan Chennai 5%
ISUZU Motors Chennai 1%
Largest Manufacturer of Alloy Wheels for Passenger
Vehicles in India with Annual Capacity of 3 Million Wheels
Minda Group
Market share
(India)
46%
Other
Competitor
KMA
MKA
6/27
Presence In India
NORTH Zone
Minda Kosei Aluminum Wheel Pvt. Ltd., Bawal, Haryana
3 Plants
WEST ZoneMinda Kosei Aluminum Wheel Pvt.
Ltd., Dekavada, Gujarat
SOUTH Zone
Kosei Minda Aluminum Wheel Pvt. Ltd., Oragadam, Tamil Nadu
Plant Present capacity per month
Bawal 120K pm
Gujarat 60K pm
Chennai 75K pm
#1Alloy Wheels46% Market Share in FY 18
Market Position
7/27
LPDC Wheel Manufacturing
Plan with Dayou, KoreaProduct Portfolio
8/27
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Product Portfolio
After Market WheelsApplicable for Maruti Suzuki & Hyundai
9/27
15” Diamond 15” Diamond 16” Painted
16” Diamond
16” Painted 16” Painted
17” Diamond 17” Diamond17” Painted 18” Diamond
Product Portfolio (OEMs)10/27
Product Portfolio (Accessories & After Market)
14” Painted
15” Diamond &
Painted
14” Diamond &
Painted
16” Diamond
11/27
12/612/27
LPDC Wheel Manufacturing
Plan with Dayou, KoreaEngineering and Development
13/27Capabilities Overview: Alloy Wheel
Styling
Product design & engineering
Prototyping
Product validation & test
Process design & engineering
Tooling design & engineering
TechnologyPart
14/27
Confidential
Full Service Solution
Manufacturing
Styling &
definition
Process Design &
Engineering
Product Design
& Engineering
VA / VE / DFMTesting &
Validation
GDC, LPDC
Manufacturing
Product validation & test
Wheel perf test:
CFT, RFT, Impact, Rigidity
Tooling Design
& Engineering
Prototyping
Co design & Simultaneous
engineering
Tooling Design
& Engineering
Prototyping
Paint test:
SST, CCT, CASS, Resistance
Flow forming
Machining
Painting & Powder coating
Process design & engineering
Manufacturing process from
Ingot to Invoice
Programming, Interfacing &
Integration of PLC / CNC
Teaching of Robots, Camera
Product design & engineering
Value engineering & analysis
CAD & CAM
Color rendering
FEA• Linear and nonlinear
structural analysis
• Durability/fatigue
analysis
• Optimization
analysis
Mockup models
Prototyping
Production models
Tooling design
Tooling design & Engineering
Tooling manufacturing
Simulation
Trials, Process setting &
Prove-outs
Styling
Research
Concept & Theme
Sketching, Modelling &
Optimization
Styling proposals
15/27Typical Development Process
2D PRODUCT DRAWING BY CAD
MOLD MAKINGTRIAL PROCESS
• CASTING TRIAL
• SUPER FORMING ( OPTIONAL )
• MACHINING
• PAINTING TRIAL
• DATA PREPARATION
• FABRICATION
• ASSEMBLY
• CORNERING FATIGUE
TEST
• RADIAL LOAD ENDURANCE
TEST
• IMPACT TESTING
• HOMOLOGATION TESTING
DESIGN STRENGTH SIMULATION - CAE
• ROTARY FATIGUE TEST SIMULATION
• RADIAL LOAD ENDURANCE TEST SIMULATION
• RESONANT FREQUENCY TEST
• STIFFNESS TEST
SAMPLE COMPLETION
STRENGTH TESTING
• STYLING INPUT FROM OEM
• PREPARATION OF DESIGN USING 3D
SOFTWARE (CATIA).
• SAMPLE SUBMISSION
• PAINT TESTING (PARALLEL)
• PPAP DOCUMENTATION
• PILOT LOT
MASS PRODUCTIONSAMPLE SUBMISSION
Timeline : TGA to sample (with Validation) – 4 months
• PRODUCT DRAWING IS MADE AFTER STRENGTH
ANALYSIS,
• TOOL GO AHEAD BY CUSTOMER
16/616/27
LPDC Wheel Manufacturing
Plan with Dayou, KoreaManufacturing facilities
PAINTING FINAL INSPECTION/PACKING
SHOT-BLASTING
Shot blasting is applied to clean and
strengthen(peen) the surface of the
wheel using 0.4/0.6mm (50/50 ratio)
stainless steel balls at 40 sec.
MACHINING
The rim, hub,
bolt holes,
valve hole
and other
features are
done in this
processKosei uses both fully automated and
robotic Horizontal and Vertical
machining process
CASTING
Fully Automatic (un-manned) Gravity Die Casting: As the
machine tilts, the molten aluminum flows unto the gate and
goes to the inner rim until it reaches 90゜or normal vertical
position, the cavity will be fully filled with the molten
aluminum and the solidification starts.
MELTING
Melting Temp. = 690 ℃ +/-10 ℃.
Kosei’s melting furnace uses advanced
technology in controlling and reducing the
oxides/porosity to maintain best quality of
aluminum for better casting results
Melting Furnace
AIR LEAK TEST AND INSPECTION
Check for any air leakage using
Automatic Helium Leak Test machine;
wheels are then visually checked for
any defects
WHEEL BALANCING
Check for any imbalance. 100%
in-line process using Computerized
Wheel Balancing machine. This
process also checks the Radial and
Lateral Run-out of the wheel
Alloy Wheel- Process Flow
SOLUTION HEAT TREATMENT AGING HEAT TREATMENT
Starts at low temperature with heat-up
time of 30mins, Soaking for 15mins at
160℃(Time in aging furnace = 45mins
including heat-up time). This process
stabilizes the micro components of the
aluminum
Starts at low temperature with heat-up time
of 40mins, Soaking for 30mins at 545℃(Time
in T6 furnace = 70mins including heat-up
time), then 30sec water quenching reducing
temp. to 80℃ (rapid cooling increases
strength)
WATER
QUENCHING
Utilizes rotary type heat treatment furnace with high speed treatment process
17/27
Facilities- Casting
Robotic Casting Extractor
Conveyor to Heat Treatment
All Key machinery is
imported from Japan
Gravity die Casting
Auto PouringMelting
Gravity die Casting
18/27
Shot Blasting
Facilities- Heat Treatment
Riser Cutting
Aging
All Key machinery is
imported from Japan
Water Quenching
Solutionizing
Heat Treatment (Overall view)
19/27
OP2
Facilities- Machining
Machine Shop(Overall view)
OP1 Air Leak Testing
Auto Balancing & Runout Check
All Key machinery is
imported from Japan
PCD
20/27
Powder CoatingRobotic
Paint Shop
Facilities- Painting
Pre-Treatment
Robotic Paint Shop
BASE COAT BOOTH
TOP COAT BOOTH
All Key machinery is
imported from Japan
AutomatedPowder Coating
Conveyor for Pre-Treatment
21/27
Dynamic Radial Fatigue test Universal Testing
Machine
Corner Fatigue Test
13º Impact Test
Facilities- Engineering Lab22/27
Humidity Chamber
Paint behavior in humid
environment
Facilities- Quality Assurance
Chroma Meter
Density Machine
CASS Machine
Water Bath Machine
Paint behavior in acid rain
To check delta ePaint behavior
in hot water
To Measure density of alloy
Ford Cup
To measure fluidity
23/27
CMM Machine
RoughnessTester
DFT Meter
Spectrometer
X-ray Machine
Salt Spray Chamber
Facilities- Quality Assurance
To measure dimension
To check Chemical
composition
To measure roughness
To check internal porosity
To measure DRY film thickness
Paint behavior in rain water
24/27
Facilities (Bawal & Gujrat)
SN Process Machine description MKA Bawal, Nos MKA Gujarat, Nos
1
Casting
Melting Furnace 8 4
2 Holding Furnace 8 4
3 GDC Machines 16 8
4 Heat Treatment (Solutionising) 8 4
5 Riser Cutting Machine 4 2
6 Heat Treatment (Aging) 4 2
7 Shot Blasting Shot Blasting 4 2
8
Machining
CNC Machines- (OP1) 16 8
9 CNC Machines- (OP2) 16 8
10 VMC Machines- (PCD) 16 8
11 CNC Machines- (Diamond finish) 4 4
12 Leak Testing Air Leak Testing 4 2
13 Balancing & Run-out Balancing & Run-out 1+1(SPARE) 1+1(SPARE)
14 PaintingPaint Shop (1 Pre-Treatment, 1 Powder Coat, & 2- Paint Lines)
1 1
25/27
Quality System & Environmental Certificates
IATF 16949:2016 ISO 14001:2015OHSAS 18001:200726/27
Minda Kosei Aluminum Wheel Pvt. Ltd.Plot No- 384, Ph.-II Industrial Growth Centre, Sector-3,
Bawal -123501 Distt.- Rewari, Haryana , India
www.unominda.com
Thank You
27/27
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