22/09/2008
CERATIZIT customer report at subcontractor Metaldyne in India
Metaldyne Managing Director Sabherwal: “CERATIZIT does not sell bulk products, but engineering.” |
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“Metaldyne believes in the strength of people and ideas”, Tim Leuliette, chairman of the Metaldyne Board describes the mainspring that drives the company. Metaldyne is a leading global designer and supplier of power train and chassis products for the automotive industry. Metaldyne has been a CERATIZIT India customer since 2003.
Metaldyne supplies brands such as Ford, Honda, Renault, Nissan, Toyota and Daimler-Chrysler with high-quality products. The company has 6500 employees worldwide and achieves a turnover exceeding 2 billion dollars. The products range from dampers, exhaust parts, pumps and assemblies for clutches and differential gears to suspension components. Flywheels for trucks and dampers for cars
The Metaldyne site in Jamshedpur, India, employs 330 people. Here flywheels for trucks and dampers for cars are produced. The products arrive as cast iron components and are then machined with CERATIZIT tools. Per month around 4,500 flywheels are manufactured by Metaldyne. It takes 13 minutes to machine a flywheel. With a cutting edge of the CERATIZIT turning insert CNMG120408/12EN TFQ in the grade CTC1110, Metaldyne machines up to 30 flywheels.
Metaldyne Jamshedpur produces about 25,000 ’dampolators’. A ‘dampolator’ is a ring which reduces vibration of the crankshaft when machining at high or also low RPM. Six machining operations are necessary until a blank is finished. For this purpose the CERATIZIT inserts CTC11353 and CTC1125 are applied. A damper is completely machined within only four minutes. This short machining time can only be achieved because tool life is relatively long. One cutting edge (CTC1125) can be used to face turn up to 270 parts and a cutting edge of CTC1135 does the finish turning for 90 components until it has to be reversed. Interview with Sanjay Sabherwal, Managing Director Metaldyne India
Mr. Sabherwal, what is most typical of the Indian industry?
Sabherwal: “I would say the speed, definitely. In 1991 it took about three weeks to get a telephone installed, now there are approximately six million new telephone contracts per month. This is why India has a telecommunications system which is far more modern than, for example, the American system. Mobility is also increasing rapidly: We have so many airline flights now that we cannot train enough pilots – we employ them from other countries.“ The automotive industry is booming in India. An example is Tata presenting its new small-sized and low-budget car called the 'Nano'. What does this mean for the suppliers to the automotive industry such as Metaldyne?
Sabherwal: “For us this means an incredible price pressure. Cost reduction is an ongoing process in this industry, translated into as many parts per minute as possible. Today the production volumes are about 1.4 million cars and 500,000 trucks per year. These numbers require a different approach in production.” What about quality?
Sabherwal: “Quality is taken for granted. Customers are more interested in process stability and reliability.” CERATIZIT is your preferred partner for cutting tool solutions. Why is CERATIZIT different?
Sabherwal: “CERATIZIT does not sell a commodity, it sells engineering, and this is what we need. Our customers pay for designed products with added value, so we design for our customers. CERATIZIT offers great solutions which enable the highest speeds with the best feeds at the lowest prices! Another plus for CERATIZIT is the enormous commitment to our company, which is the basis of a healthy relationship“
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