CHAPTER-1COMPANY PROFILE

GKN Driveline India LTD traces its origin back to 1986 when Invel Transmissions Ltd, as it was then known, was established. Three years later the company became the first in India to manufacture side shafts for front wheel drive vehicles when it was selected sole CVJ supplier for Maruti Suzuki at that time the only front wheel drive car manufacturer of the country.

Later known as GKN Drive shafts (India) Ltd, the operation became a owned subsidiary of GKN Driveline in 2002 and is today the side shaft market leader in India with an installed capacity to manufacture over one million units (half a million vehicle sets) a year. Sales in 2003 stood at more than 23 million pound.

The companys growth in the 1990s was strongly linked with its supply of side shafts for the Government of Indias joint venture with Japanese car maker Suzuki Motor Corporation to make front wheel drive cars. Beginning with the Suzuki Maruti 800cc model in 1989, production rapidly expanded and GKN currently supplies all front wheel drive cars for the company (800cc, Zen, Wagon-R. Gypsy, Esteem, Baleno and Swift)

During the late 90s GKN Driveline India began supplying product for other major customers. In 1996 it was selected sole supplier to Fiat (Uno, Siena and Palio models) and Ford (Escorts/Ikon) in India. Two years later it became sole supplier to Korean manufacturer Hyundai Motors ( Santro , Accent, Sonata and Getz) and began working with Tata Motors ( Indica ), one of the largest business house in India. In 2000 Honda (City) and General Motors (Corsa) were added to the customer base.

1.1 VISION & VALUESTHIS IS GKN

Technology and engineering from GKN is at the heart of the vehicles and aircraft produced by the worlds leading automotive and aerospace manufacturers.

More than 50,000 peoples work in GKN companies and joint ventures in more than 37 countries. Everyday we harness our considerable technology and manufacturing resources to supply the highest quality systems, structures, components and services When we fulfill the trust of our customers place in us then we can enrich our Shareholders reward our people and support our communities.

And because we respect the environment and the dignity and human rights of others we are building a business, which can be sustained by future generations.

Everyone involved with a great company should expect nothing less. But those with a Stake in the performance of GKN should expect more.

21st century global leadership in our four major businesses, when ourHistory spans more than 250 years, speaks for standards of agility, innovation and excellence, which would be difficult to surpass.Customer and quality

To provide excellent and continuously improving products and services to exceed our customers expectations.

To be the best in class in terms of value through quality, technology, speed, performance and innovation.To treat our suppliers fairly as an integral part of our total capability to serve our customers.

1.2 Enterprise and Innovation

To foster the spirit of enterprise To grow profitability by managing risk, being innovative and using initiative To move with speed in our business processes. To inspire outstanding performance from teams and individuals and to recognize and appropriately reward achievement. To encourage employees to fulfill the potential for the benefit of both themselves and the organization. To foster teamwork and individual achievement within a culture of empowerment and accountability. To share knowledge and best practice across our companies to stimulate the creation of new business opportunities. To provide equal opportunity irrespective of sex, sexual orientation, disability, Religion or ethnic origin. To provide a safe environment.

1.3 Community, environment and business ethics To act with integrity at all times To meet standards of good corporate governance. To play our part in safeguarding the environment To contribute positively to the communities in which we operate.

CHAPTER-2PLANT

IN INDIA THERE ARE THREE PLANTS OF GKN WHICH ARE LOCATED AT DIFFERENT SITES IN THE COUNTRY FARIDABAD PLANT DHARUHERA PLAN ORAGADAM PLANT

2.1 FARIDABAD PLANT: GKN Driveline India traces its origin back to 1986 when Invel Transmissions Ltd, as It was known, was established. Three years later the company became the first in IndiaTo manufacture side shafts for front wheel drive vehicles when it was selected sole CVJSupplier for Maruti Suzuki at that time the only front wheel drive car manufacturer in the countryFaridabad plant is the mother plant in the country. Plant is situated in sector-24, Faridabad. This plant is 30 km away from the national capital. This plant acquired a area about 40,000Sqm. 280peoples are working here. This plant is established in 1986 and the production starts from April 1989. In all of the other three-plant Faridabad plant is the major plant. Faridabad plant is the manufacturing plant. All the sub-parts are made here.

2.3 DHARUHERA PLANT:

This plant is set-up in14th January 1997. This plant acquired a area about 68,000Sqm.The built up area is about 4,500Sqm.It is 75 km away from the national capital. There are over 150 employees at the plant which has responsibility for side shaft assembly and delivers to customers Maruti Suzuki, Tata Motors, Honda, General Motors and Fiat.In this plant GI joints are manufactured. Most of the assemblies like bell, tripod, pot, and shafts are done here.

2.4 ORAGADAM PLANT:

Plant is established in 1st April, 1996.It is situated 60 kilometers from Chennai, and it has 22 employees and two assembly lines for JIT supply requirements for customers Hyundai and ford. This plant acquired a area about 4000Sqm. In which built up area is 2000Sqm.

GDI LOCATIONSDharuheraFaridabad

Fig. 2.1 GDI: Faridabad Plant

Commenced operation on 13th April, 1989Land area 40,000sqm (Built-up 15,500sqm)Manpower 339

GDI: Dharuhera Plant

Commenced operation on 14th January, 1997 Land Area 68,800sqm (Built-up 4,500sqm) Manpower 150

GDI: Oragadam Plant

Commenced operation on 1st April, 1996 Land Area 4,000sqm (Built-up 2,000sqm) Manpower 205

GKN HISTORY

GKN DRIVESHAFTS (INDIA) LTD formerly known as GKN INVEL TRANSMISSION LTD was formed in the year 1986 was promoted in 1988 by GKN plc. and started commercial production in April 1989.In November 1995 Invel became a subsidiary company of GKNADD (Automotive Driveline Division) who, with facilities all over the world, fulfills a large proportion of the worlds demand for CV joints.The company manufactures drive shafts assemblies made of constant velocity (CV) joints for front wheel drive and four wheel drive vehicles, mainly passenger cars.The sophisticated high precision GKN technology required by ball and tripod joint is supported by some of the latest manufacturing and testing equipment to ensure the highest level of accuracy in every joint coming off the assembly line from completely integrated production facilities.The Faridabad plant has full range of facilities used for the manufacturing of bell assembly, Inner race and DSA. This includes heat treatment and a testing facility available for the validation of the product from all of the other facilities.The Dharuhera plant has facilities for the manufacturing of Connecting Driveshaft, Tripod, Tulip and complete assembly of CV joints with the exception of the tent house and heat treatment.The Gummidipundi plant assembly facility is effectively an additional assembly cell of Dharuhera, assembling product and shipping complete driveshaft to local customers.All the three plants are 1SO9002/ QS9000 & ISO14001 Certified. The company is trying to get TS16949 Certification.The company has got over 70% markets in the CV Joints in India & over 45% worldwide.GKN PLC

GKN plc. is an international group of companies with a turnover of around 4.3 billion pounds. The group designs, develops and manufactures automotive components as well aerospace and defense products. The group provides a range of industrial services. GKNs operations are located in more than 30 countries around the world and the group employs around 36,000 people.

The automotive and agricultural products business area is the largest within the group accounting for over 60% of total turnover. Industrial services and aerospace and special vehicles each generate approximately 20% of the groups total turnover.

The name GKN is derived from Guest, Keen and Nettlefolds. Its history dates back to 1759. Starting in iron making and coal mining, the group progressed into steel and its many derivatives, serving the railways, building and construction, automotive and other major industries. Although once world renowned steel maker and producer of screws and fasteners, the group has been through many changes over the last 25 years in response to fundamental shifts in these traditional markets.

GKN DRIVELINE

GKN is a leading global supplier to the worlds automotive, off highway and aerospace manufacturers. GKN provides technology-based, highly engineered products to virtually all of the world's major manufacturers of light vehicles, agricultural and construction equipment, aircraft and aero engines. Almost 38,000 people work in GKN companies and joint ventures in more than 30 countriesGKN is a multinational engineering company headquartered in Red ditch, United Kingdom. The company was formerly known as Guest, Keen and Nettle folds and can trace its origins back to 1759 and the birth of the industrial revolution. In 2009 the company celebrated its 250th anniversary.

GKN Driveline India LTD traces its origin back to 1986 when Invel Transmissions Ltd, as it was then known, was established. Three years later the company became the first in India to manufacture side shafts for front wheel drive vehicles when it was selected sole CVJ supplier for Maruti Suzuki at that time the only front wheel drive car manufacturer of the country.

Later known as GKN Driveshaft (India) Ltd, the operation became a owned subsidiary of GKN Driveline in 2002 and is today the sideshaft market leader in India with an installed capacity to manufacture over one million units (half a million vehicle sets) a year. Sales in 2003 stood at more than 23 million pound.

The companys growth in the 1990s was strongly linked with its supply of sideshafts for the Government of Indias joint venture with Japanese car maker Suzuki Motor Corporation to make front wheel drive cars. Beginning with the Suzuki Maruti 800cc model in 1989, production rapidly expanded and GKN currently supplies all front wheel drive cars for the company (800cc, Zen, Wagon-R. Gypsy, Esteem, Baleno and Swift)

During the late 90s GKN Driveline India began supplying product for other major customers. In 1996 it was selected sole supplier to Fiat (Uno, Siena and Palio models) and Ford (Escorts/Ikon) in India. Two years later it became sole supplier to Korean manufacturer Hyundai Motors (Santro, Accent, Sonata and Getz) and began working with Tata Motors (Indica), one of the largest business house in India. In 2000 Honda (City) and General Motors (Corsa) were added to the customer base.

GKN DRIVELINE PRODUCTS

Products GKN Driveline is the world leader in the design and production of driveline components.Producing systems and components for small front wheel drive to the most sophisticated four wheel drive vehicles, GKN Driveline has the products to achieve the optimum driveline solution.With these products comes technical expertise and an understanding of all aspects that affect vehicle dynamics and how these can be optimized for weight and performance improvement. CVJ Side shaft Premium Prop shafts Geared Power Transmission Products Torque Management Devices Replacement Parts Motorsport Products Solution Finder GKN Driveline has a wide range of products across the vehicle driveline to meet most vehicle configurations.With torque products for every axle, front and rear sideshafts and propshafts from one piece to three pieces - we are sure to have a solution for you.Select the vehicle configuration you need from the list below to see what solutions GKN Driveline can offer:Premium Propshafts GKN Driveline offers an entire portfolio of propshaft solutions for passenger cars and light commercial vehicles. They are tailored, tuned and harmonized to suit the characteristics and performance requirements of each application. Each propshaft is a unique, engineered product.Configuration Examples High Speed Fixed Constant Velocity Joints (CVJ) High Speed Plunging Constant Velocity Joints (CVJ) Cardan Joints Other Components

Configuration Examples High Speed Joints Other Components CVJ Sideshafts GKN Driveline CVJ sideshafts transfer the engine power transversely from the gearbox to the wheel ends on front wheel, rear wheel and four wheel drive applications. They are optimized for weight, noise, vibration, harshness (NVH), steering and suspension performance.GKN Driveline has a unique range of CVJ sideshaft configurations to meet the needs of all types of vehicle. Sideshaft CV Joints Interconnecting Shafts and Boots Configuration Examples SideshaftA sideshaft is a system that transfers torque from a differential to the driven wheels allowing wheel movement due to steering or suspension movement. This system has three major elements: Inboard Constant Velocity Joint (CVJ) Interconnecting shaft Outboard Constant Velocity Joint (CVJ)In most applications, the inboard CV Joint is a plunge joint that allows the effective length of the sideshaft to change due to suspension travel. In front (or steer) axle applications, the outboard joint must transfer torque effectively through a wide angle (up to 52 degrees). In rear axle applications, joint operating angles are much lower.Geared Power Transmission ProductsGKN Drivelines range of power transmission products ensure that driving torque is constantly transmitted to driving wheels at maximum efficiency, to provide unsurpassed levels of responsiveness and reliability.The range of geared products includes final drive units, which transfer torque from propshaft to wheels in rear- and all-wheel drive (AWD) vehicles, and power transfer units, which distribute torque between front and rear axles in AWD configurations. Power Transfer Unit Final Drive Unit Differentials Dual Differential Drive Module for Motor Assisted 4WD

Power Transfer Unit

GKN Drivelines robust and versatile Power Transfer Units provide full-time or on-demand AWD torque distribution for front wheel-drive based AWD systems. Tailored designs provided compact and cost effective AWD driveline solutions.Benefits Aluminum construction Compact designs Used in front-wheel drive based vehicles with transverse engine mount Available in part-time, full-time and on-demand AWD configurations Available installation of various differential or coupling

Final Drive Unit

GKN Drivelines proven and reliable Final Drive Units (FDU) for front and rear independent axle applications, offer robust performance and versatility for all-wheel-drive and real-wheel-drive drivelines.

Differentials

GKN Driveline offers a wide range of open bevel gear differentials for use in passenger cars, sport utility vehicles (SUVs) and light truck transmissions of final drive units.Design Features Available in eight sizes ranging from 3.000 to 20.000 Nm differential input torque Available in both 2-pinion and 4-pinion design Bevel gears are either cut or cold formed Compact and cost competitive designs

SUPPLIER NETWORK

Company has 17 local direct material suppliers, 21 overseas direct material suppliers, 15 local sub contractors & over 300 suppliers for In-direct materials. In indirect material suppliers there are 238 local suppliers, 42 technical service providers & 19 general service providers.

Figure 2.2 : Supplier network at GKN

Budget for direct material is made every year based on the customer forecast & based on the budget for direct material Purchase planning is made.

xFigure 2.3 : Budget for Direct Material

BRIEF DESCRIPTION OF MAJOR COMPONENTS Major components required for manufacturing of Driveshafts are Outer Race (Bell), Inner Race, Cage, Tulip, Shaft, Male & Female pot. Besides these other components are Tripod, Rubber boot, Clamps, Steel Balls, Damper, needle roller Bearings,

GDI- Organization Chart

GKN Customers In INDIA