Summ ers Pro j ect 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: Faculty Guide:Mr. Naveen Sharma Dr. M. MallikarjunDeputy Manager Institute of Management, Marketing and Business Development Nirma University RMP Bearings Ltd.

Submitted by:Manpreet Singh (101324)

MBA (Full Time)Institute of Management, Nirma University

TITLE PAGE

Author of the Project

Organization Name

Address

Date of Report

Purpose of Report

Project Name

Prepared for

Manpreet Singh

RMP Bearings Ltd.

1007, Kirti Shikhar

Janak Puri, District CenterNew Delhi - 110058

June 30, 2010

Summer Internship Report

New Product Development and Logistics Management

Institute of Management, Nirma University

2

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.

3

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 Bearings………………………………………………………19

How Ball Bearings Manufactured…………………………………………30

About Universal joints…………………………………………………….36

7 S Framework for RMP Bearings Ltd..40

Porter’s 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

4

PART C – Learning from Internship...75

REFRENCES………………………………………………………………………………78

ANNEXURE………………………………………………………………………………80

5

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

6

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 some of the other automotive

manufacturing regions around the country.[15][16][17]

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

7

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

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, India’s 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.

8

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:

9

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

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.

10

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

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.

11

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. 

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.

12

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.

 RMP’s 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.

RMP’S 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.

RMP’S reputation and performance is built on the foundation of its vast experience in design,

engineering & technological developments.  RMP’S constant growth has been characterized by

it’s 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

RMP’s 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.

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.

13

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.

CLIENTLE

14

Sr.No. Type of Bearing Customer

1.  Angular Contact Clutch Release

Bearing

  ›  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 TRW 

  ›  Tata Motors Ltd.

  ›  Yamaha Motors India P.Ltd.

  ›  Dynamatic Gears

3. Angular  Contact Spherical

Roller Bearing

  ›  XLO India

  ›  Export

4. Taper Roller Thrust  Bearing   ›  Tata Motors Ltd. 

  ›  Eicher

  ›  Mahindra & Mahindra

  ›  Tafe

  ›  Ashok Leyland

  ›  Bajaj Tempo

5. Thrust Ball Bearing   ›  Mahindra & Mahindra 

  ›  Tata Motors Ltd. 

  ›  Gabriel India

15

6. Steering Column   ›  Sona-Koyo Steering

  ›  Rane TRW

7. Jockey Pulley

Single Row

Double Row

  ›  LMW

  ›  KTTM

8. Pellow Block Ball Bearing

( S- Type)

  ›  LMW

  ›  Trumac

9. Double Row Angular

Contact Ball Bearing

  ›  LMW

10. Steering Races   ›  Yamaha 

  ›  XLO

  ›  Rane

  ›  Gabriel

QUALITY CONTROL

16

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. Instrument Make

1. Form taly surf plus unit Taylor Hobson

2. Roundness tester unit Perthen

3. Roughness tester unit Perthen

4. Waviness measuring instrument H.T.R.C.

5. Bearing vibration tester WUXI,

6. Length measuring instrument LEITZ

7. Dial calibration tester Microtech

8. Electronic comparator Tess

9. Electo magnetic crack detector Magna Field

10. Match Gauging System Task

11. Contact angle checking machine

12. Profilee Projector Karl Zess

17

 

  (B) METALLURGICAL

Sr.No. Instrument Make

1. Microscope with Digital Printer Karl Zess

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 steel—rather 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.

By material, exploits the nature of the bearing material used. (An example would be using

plastics that have low surface friction.)

22

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.

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

24

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 FrictionStiffnes

s†Speed Life Notes

Plain

bearing

Rubbing

surfaces,

usually with

lubricant; some

bearings use

pumped

lubrication and

behave similarly

to fluid

bearings.

Depends on

materials and

construction,

PTFE has

coefficient of

friction

~0.05-0.35,

depending

upon fillers

added

Good,

provided

wear is

low, but

some

slack is

normally

present

Low to

very high

Low to

very high -

depends

upon

application

and

lubrication

Widely used, relatively

high friction, suffers

from stiction in some

applications.

Depending upon the

application, lifetime

can be higher or lower

than rolling element

bearings.

Rolling

element

bearing

Ball or rollers

are used to

prevent or

minimise

rubbing

Rolling

coefficient of

friction with

steel can be

~0.005

(adding

resistance

due to seals,

packed

grease,

preload and

Good,

but some

slack is

usually

present

Moderat

e to high

(often

requires

cooling)

Moderat

e to high

(depend

s on

lubricati

on,

often

requires

mainten

ance)

Used for higher

moment loads than

plain bearings with

lower friction

25

misalignment

can increase

friction to as

much as

0.125)

Jewel

bearing

Off-center

bearing rolls in

seating

LowLow due

to flexingLow

Adequat

e

(require

s

mainten

ance)

Mainly used in low-

load, high precision

work such as clocks.

Jewel bearings may be

very small.

Fluid

bearing

Fluid is forced

between two

faces and held

in by edge seal

Zero friction

at zero

speed, low

Very

high

Very

high

(usually

limited

to a few

hundred

feet per

second

at/by

seal)

Virtuall

y

infinite

in some

applicati

ons,

may

wear at

startup/s

hutdown

in some

cases.

Often

negligib

Can fail quickly due to

grit or dust or other

contaminants.

Maintenance free in

continuous use. Can

handle very large loads

with low friction.

26

le

mainten

ance.

Magnetic

bearings

Faces of bearing

are kept

separate by

magnets

(electromagnets 

or eddy

currents)

Zero friction

at zero

speed, but

constant

power for

levitation,

eddy currents

are often

induced

when

movement

occurs, but

may be

negligible if

magnetic

field is quasi-

static

Low

No

practical

limit

Indefinit

e.

Mainten

ance

free.

(with ele

ctromag

nets)

Active magnetic

bearings (AMB) need

considerable

power. Electrodynamic

bearings (EDB) do not

require external power.

Flexure

bearing

Material flexes

to give and

constrain

movement

Very low Low Very

high.

Very

high or

low

dependi

ng on

material

s and

Limited range of

movement, no

backlash, extremely

smooth motion

27

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

(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.

28

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.

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

29

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

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.

30

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

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.

31

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

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.

32

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

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

33

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

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

34

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

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,

36

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 FRAMEWORK39

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 organization’s 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 well-

established 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 company’s 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 company’s 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: Porter’s 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. It’s 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 RMP’s 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 RMP’s 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

FRONT

SHAFT

INSKU-

100247

ITEM PART NO. DESCRIPTION MODIFICATION NEEDED BY US REMARKS

8INSKU-

100116-2Bracket

In this, We need to change Dimension

of mounting Holes from 80 to 87.5mm

& 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  

9 580926 BearingIt is TATA 6207 ball Bearing, BUT We

need 6211 ball Bearing  

10INSKU-

100098CB Rubber

This has to be modified according to

Our above Bearing 6211  

11 232769 Dust Seal As above (for shaft Outer dia in our  

54

case is 55 & not 40)

12 232770 Dust Seal retainerApplicable for above referred Dust

Seals.  

13INSKU-

100010L'Type Spacer

For Shaft OD 55mm & above specified

bearings & Dust Seals  

         

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 Sept’10 . 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

Ref.No:

32/10-

11          

Date

:

12/10/201

0

                       

Pa

ge

:

01

of

01

PART NAME Race Ball 03 CUSTOMER Yamaha

PRODU

CT  Race DRAWING No. 1PM F 3413 00 C

[A] RAW MATERIAL

DETAIL                    

Sr. No.

COMP

ON-

ENT

DR

G.N

O.

MAT

ERIA

L

TYPE

&

SIZE

SUPPLIER

NAMEBASIC RATE Tax 4%

FREIG

HT %

Wt /

Pc in

Kg.

TOTAL

Rs.

01Race  

SAE-

52100 Roundbar  65.00 Per Kg.

    0.100 6.50  

  TOTAL [A]             6.50

[B] PROCESS                    

Sr. No. OPERATION TO  

65

TA

L

Rs.

A OUTER RACE  

1 Forging & Annealing  

2 Rough Turning  

3 Final Turning  

4 Heat Treatment  

5 Centreless Grinding  

6 Track Grinding  

7 Vibrating  

8 Assembly Inspection  

  TOTAL [B] 0.00         12.50

[C]BOUGHT-OUT

PARTS                 

Sr. No.

COMP

ONEN

T

 DRN.

NO.

MATERI

AL

US

E /

BR

G

UnitBASIC

RATE

TAX

AND

FREIG

HT %

RATE

/ UNIT

TOTAL

Rs.

1 Oil               1.00 1.00

  TOTAL [C]             1.00

[D] REJECTION                   0.52

[E] PACKAGING                  

1.00[F] FORWARDING &

FREIGHT                

[G] INVENTORY                   0.64

[H] OVER HEAD                   1.88

[I]

PROFIT                    1.88

TOTAL [D] TO [I] Rs. 5.94

TOTAL [A] TO [I] Rs. 25.94

  QUOTED PRICE Rs. 25.94

PREPARED BY CHECKED BY APPROVED BY

66

                         

12/10/2010 12/10/2010 12/10/2010

Since my team didn’t 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 didn’t had enough spare capacity and labour to cater to RMP’s

requirements.

After pitching in to multiple factories in Faridabad Industrial area and Mayapuri , most of

which either didn’t 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

company’s 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. "Automobile Industry India" http://imaginmor.com/automobileindustryindia.html . Imagin Mor Pty Ltd.

2. "Honda to Build Second Motorcycle Production Plant in India" . World.honda.com. 2010-03-09. Retrieved 2010-11-28.

3.  http://oica.net/wp-content/uploads/all-vehicles-2010-provisional.pdf

77

4.  Nair, Vipin V. (2009-09-07). "Suzuki, Hyundai’s Indian Car Exports Beat China’s". Bloomberg.com. Retrieved 2010-

09-01.

5.  Gulati, Nikhil (2010-09-09). "India Car Sales Touch Record High". Online.wsj.com. Retrieved 2010-11-28.

6.  "India second fastest growing auto market after China". Thehindubusinessline.com. 2010-04-10. Retrieved 2010-11-

28.

7.  "Restarting trouble in Indian Auto Industry - Forbes India". Moneycontrol.com. Retrieved 2011-01-01.

8.  S Kalyana Ramanathan. "India to top in car volumes by 2050". Rediff.

9.  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. http://en.wikipedia.org/wiki/Ball_bearing

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

21. http://en.wikipedia.org/wiki/Universal_joint

78

Annexure :

Product line of RMP Bearings Ltd.

CLUTCH BEARINGS

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

79

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

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

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

RACES

BALL RACE 324015 ---------------------------------------------------------------------------------------------------------------------

BALL RACE 324019

80

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

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

SPACER 4.60

REPLACEMENT MARKET

BEARING NO. RT 6003 Z ---------------------------------------------------------------------------------------------------------------------

CAGE F-7

81

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

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

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

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

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

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

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

82

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

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

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

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

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

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

83

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

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

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

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

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

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

84

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

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

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

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

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

85

STEERING (RACES) APPLICATION

ADJ. RACE 530 ---------------------------------------------------------------------------------------------------------------------

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

86

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

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

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

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

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

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

87

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

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

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

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

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

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

88

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

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

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

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

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

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

89

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

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

91

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

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

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

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

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

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

92

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

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

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

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

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

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

93

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

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

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

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

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

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

94

YOKES

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

DSC_5330

95

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

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

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

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

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

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

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

96

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

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

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

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

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

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

97

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

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

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

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

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

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

98

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

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

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

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

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

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

99

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

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

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

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

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

100