MAKE IN INDIA @ KONZERT_ATD_PTD_04_AUG_2015

ISO 9001 – 2008 Certified
Technology Maestro | Timely Delivery | Functional Brilliance | Admired Quality
www.konzertgroup.com
Tool Room Tool Makers
By
“KONZERT” - means “An Agreement in a design or plan with simultaneous Actions”.

2015 Installation of Vision Wide Double Column VMC of size 4200 x 2600 x 1200mm
Installation of 1000 Ton/ 4m Mechanical press exclusively for Trials
2014 Addition of 500T Mechanical press exclusively for trials
• Addition of 1600 x 1000mm Carl Zeiss CMM
• Addition of Ferromatic Milakron 80T & 150T Injection Moulding Machines.
• Addition of Agie Charmiles CNC EDM (Form 20)
• Addition of Vision Measuring System RAPID EYE
2013 : Additional 3600 sq.mt. Green field Tool room space (PLANT II) acquired with 15 / 5 MT
• (2 no’s) Over head cranes
• Addition of 200 & 400 Ton Mech. Press for Try-out ; 3 meters x 2 meters VMC
• Addition in Precision Tooling Division with Sodick CNC Wire-cut & Agie Charmiles CNC EDM (SP1U)
2012 : Formation of 2 new vertical Precision Tooling Division (PTD); For High precision Progressive Tools & Injection Molds &
Konzert Automation and Robotics (KAR) ;for SPM’s Welding technologies.
2011 : Addition of 1200 sq. m. shop area (PLANT 1) & Registered with OEM's like Ashok Leyland, Mahindra, DICV etc
2009 : In 2 years Konzert already a player in the large Panel dies category with accreditation in ISO 9001: 2008
with in-house trial facilities on our own 500T Spotting Press.
2007 : Established Tool room in the First Auto Hub of the country (Pune)
Team Konzert History & Growth

• PANEL DIES
• TRANSFER DIES
• PROGRESSIVE DIES
• TANDEM DIES
• JIGS & FIXTURES
ASSEMBLY LANE CNC SHOP
 Being in the first auto hub of India some basic locational advantages.
 All tier 2 vendors in the form of
 Heat treatment Support (Vacuum),
 Standard Parts suppliers,
 Conventional and CNC Machining outsourcing,
 Logistical support,
 Airport (15 km)
 Housing & Lodging
All Within a 5 km radius

Konzert – ATD & PTD Core Strengths
MANUFACTURING
 Reliable Material Source ( Local /Overseas)
 Strict Quality Control ( ISO9002 )
 High Quality Manufacturing Equipments
MARKETING
 Broad Customer Base
 Diverse Coverage of Different End Markets
 Strategically Placed Local Service Support
MANAGEMENT
•Objective Oriented Management Policy
•Harmonious Worker-Management Policy
•Environment Friendly Development Policy
•Employee Development and Upgrading Policy
ENGINEERING
•Estimation
•Detailed process plans for every tool elements
Systematic approach for controlling manufacturing
process from material, Heat treatment, Machining
& assembly
DESIGN
 In House-Design Capabilities high precision injection
moulds and high speed stamping dies
 Progressive die design and injection mould design
validation
 Standardized mould and tool design process
 Detailed mould/progressive dies log documenting
insert tolerances
A complete Tooling Solution for plastic and sheet metal products - Designing and building high-quality production tools & molds are the core of our business . We are
recognized by our existing customers for our State-of-the-art technology which ensures exceptional precision, stability, and repeatability. Our reputation as the premium
tooling specialist in India is one that we do not take lightly. We consistently provide high capacity, fast turnaround fabrication of high precision production molds & high speed
stamping dies . Furthermore, our molds & tools are built to international standards, undergo stringent qualification runs, and are constructed under the at most confidentiality.
PROJECT MANAGEMENT
 Separate CFT for major projects plans, execute & monitor each projects.
 Single Window Communication System.
 Effective Multi-Project scheduling & Resource Management, Critical Issue
Identification & Management.
 Daily Monitoring of projects and resources & project updates to customer
on weekly basis
DEVELOPMENT
•Expansion of Manufacturing Capabilities
•Extensive Experience in high precision injection moulds
& high speed stamping dies.
•In-House Tooling development Capabilities

EXPERIENCED DESIGNERS FOR
• PANEL DIES
• TRANSFER DIES
• PROGRESSIVE DIES
• TANDEM DIES
• PRECISION INJECTION MOULDS
• JIGS & FIXTURES
• PART 3D DESIGN
• 2D DRAFTING
DESIGN

BFW – BMV 80 BFW – BMV 60BFW – BMV 65 (2 nos.)Four star- MN 2132
Four Star
MN2132
BFW
BMV -80
BFW
BMV 65(2 Nos)
BFW
BMV 60
TRAVEL 3400x2200x1100 mm 2200x850x810mm 1500x710x710mm 1200x610x610mm
MAX LOAD 15000 kg 3000 kg 1500 kg 1200 kg
CONTROLLER Mitsubishi M720 Mitsubishi M720 Mitsubishi M720 Mitsubishi M720
FOR DELICATE PRECISION WORKS, WE ARE EQUIPPED WITH BFW FOR CNC PRECISION MILLING.
5 Nos..CNC Machines (VMC)

6th CNC Machines (VMC)
NEW MACHINE UNDER INSTALLATION !!!!
Vision wide NF 4226
Bed Size: 4200 x 2600 x 1200 mm
16000kg Table load with
Mitsubishi M720 Controller

Hydraulic
2400 x 1450 x 1200
200 Ton
Mechanical
Mechanical
1550 x 1150 x 750
100 Ton
Mechanical
Mechanical
2500 x 1450 x 950
TRIAL PRESSES 5 No’s
ERFURT 500 Ton
KONZERT 400 Ton
MILAP 250 Ton

Conventional Tool room Machines
Machine Qty.
Horizontal Boring 1
Surface Grinder 5
Radial Drilling m/c. 7
Milling M/c. 5
Lathe 3
CO2 Welding 3
Knee Type Milling 2
OET Crane ( 15/5 Ton) 2
OET Crane ( 10/3 Ton) 1
OET Crane (5 Ton) 4
26 no’s

Konzert is able to manage the whole procedure from concept of the very beginning to perfect completion
of new project developments. This means higher efficiency, lower cost, shorter lead-time and much better
overall control of the operation. We will make detailed production planning and timing which are followed
up strictly by project managers who are rich experienced in mould /progressive die design, tooling
manufacture, process management. Each project is separately handled by one Project leader. We will
keep customer updated about detail information of the project by weekly report and digital picture. It is
easy for customer to monitor the project time to time. We setup an efficient team to ensure that projects
development transit smoothly from design-engineering-manufacturing to production or client.
Project Management

PROCESS ENGINEERING
• Product design.
• Tooling Feasibility study
• Engineering, Process planning & Method plan
• Manufacturing process plan
• Conceptualization of jigs and fixtures
• Thorough reviews before production
• Process plan along with planning for Tools & Gauges
• Preparation of manufacturing drawings as per
Konzert Precision Engineering standards
• Our own drawings used for manufacturing to
maintain uniformity on shop floor
• In – House CAD/CAM Facilities
• 15 HI-Definition Work Station
• Work NC for CAD/CAM

100% Vacuum Heat Treatment of Die Steels.
Heat Treatment Source s:
 Indo German
 Bhatt Metals
Standard Elements from:
 Misumi India
 Punch Industries
 Sankyo Oilless
 Dayton
 Dadco /Hyson
 Tohatsu
Raw Materials Used :
 K340 (HSS grade)/D2 / SKD11/Stavax From
Bohler,ASSAB,Hitachi , Tyssen, Poldi
 Castings from WIL / BSL / Premier / Smart
 Test Certificate verified/procured for every lot.
Supplier Partnership
Preffered Hot Runner :
 Mould Master
 Synventive
 Yudo
 Hasco
 DME

Long Member Die
7 M Blank & Pierce Long Member Die (30T ) for
4 – Variant's
DAP to Proving in 93 Working Days
TOOLING PRODUCTS

EXPORT DIES FOR COMPLETE ASSEMBLY
Material SPHN400W-DS / SG41BL
Sheet Thickness 3.2
MaterialSPHN400W-DS / SG41BL
Sheet Thickness 2.9
Material SPHN400W-DS
Sheet Thickness 2.0
Sheet Thickness 2.6
Sheet Thickness 3.2
Sheet Thickness 2.9
SF HR 290 Sheet Thk.3.2MM
Sheet Thk.2MM
Sheet Thk.2MM

TOOLING PROJECTS – JUST COMPLETED
Material JSH270C
Sheet Thickness 2.8 mm

Material EDDIS1079
Sheet Thickness 5.50
TOOLING PROJECTS – JUST COMPLETED

Chassis Products For Commercial Vehicles Chassis Products For SUV
Automotive Tooling Products

TOOLING PARTS

Panel Checkers
CHECKING FIXTURES

Konzert Precision Tooling Division
PTD delivers advanced automation, process simulation and latest technology to improve productivity and ensure first-time quality in tooling development in sectors such
as Electrical, Electronic & automotive..

Konzert PTD team combines manufacturing, technical and creative disciplines to support customers in their product development, and total solution provider for manufacturing
challenges. Konzert has the unique understanding of complex plastic & sheet metal product design and the mold & progressive dies requirements suited to achieve customers' design
criteria & quality requirements. Our in-house tool-room supports fast turnaround for tool modifications, iterations, and reduces overall design cycle and lead time. Whether a product is
only a conceptual idea or fully developed, Konzert PTD offers a trusted, confidential partnership, even at the beginning with evaluation of product design suitability for plastic & sheet
metal applications. The earlier you leverage on Konzert-PTD’s expertise, the faster you can reach your goals in today's aggressive time-to-market environment.
Cad Solutions
 Siemens-Uni-graphics NX10
 Siemens-Uni-graphics- Progressive die wizard
 Auto form for forming simulations
Key Capabilities
 Progressive Die Design & Validation
 Mould Design & validation
 Process Design
 Design Change and Propagation Control
 Documentation and Quality System
 Standardized Tool /Mould design process
 Detailed Mold /Progressive dies log documenting insert tolerances
Tool design to ensure maximum production efficiency and repeatability
TOOL DESIGN

Automotive Progressive Dies
World class progressive dies that meet global die standards
Automotive Progressive dies up to 4 M in length
High Precision dies for close tolerance parts
Cast or plate die construction
SPM: 80-800
Standard parts from Dayton, Misumi, Fibro,Meusburger etc.
100 % 3D design

Automotive Progressive Dies
World class progressive dies that meet global die standards

Automotive Progressive Dies-Strip Layouts
10 Stage Progressive Tool
Material :SCGA270C-45
Sheet Thickness 2mm
Pitch 67.5 mm
Strip Width:264.0mm
Material SPC440
Sheet Thickness 1.6mm
Pitch 95.0 mm
Strip Width: 138.0mm
Material SPC270C
Sheet Thickness 0.9 mm
Pitch 65 mm
Strip Width:135.0mm

Automotive Progressive Dies-Strip Layouts
Material SPH440-OD
Pitch 136 mm
Strip Width:180.0mm
Material SPH440
Pitch 57 mm
Strip Width:238.5mm
Material:WSS-M1A365-A21
Pitch 26.5 mm
Strip Width:71.0mm

AUTOMOTIVE PROGRESSIVE DIES
2 out Progressive tool with quick interchangeable inserts– End Product: Automotive Liquid-to-liquid layered-core oil coolers
Material : Aluminum 2mm thickness
Tool Size: 1350x820x520mm
SPM:100
World class Progressive Dies that meet global die standards

HIGH SPEED PROGRESSIVE DIES
High Speed Stamping Dies SPM 60 – 800
Strip Lay Out for 27 stage Progressive Die (Component Size :0.65x2.0x26.0mm) Matl: Phosphor bronze
Our tools are always maintained to very close tolerances (0.002 -0.005mm onwards) to attain the highest tool quality

High Precision Plastic Injection Molds
Customer : BEHR
Mould Type: 2 Plate single cavity
Component Name & Material:
Temperature Bracket-ABS
Customer : BEHR
Mould Type: 3 Plate 2 cavity mould
Bracket Seal -PP
Customer : L&T
Mould Type: 2 Plate 4 cavity
Card Holder-PBT-PC
Customer : L&T
Mould Type: 2 Plate single cavity
Linear Front Cover-PBT-PC
Konzert’s continual investment in new manufacturing capabilities and constant drive to increase automation have resulted in improved mold quality.
We offer a wide range of mold technologies and options based on your part and development needs.
Once the design team completes the appropriate development steps, our manufacturing team uses an established step-by-step process and industry-leading
CNC machining technology to build in quality. This results in full interchangeability in mold components.

CNC SINK EDM Agie Charmilles
Max Job 790 x 480 x 235
Travel 320 x 250 x 250
Surface Finish Ra0.3µm
CNC WIRE EDM Sodick
Travel 780 x 570 x 215 mm
Taper Angle : +/-15°
Max. Thickness:120mm
Precision Tool room Machines
CNC SINK EDM-FORM 20 Agie Charmilles
Max Job 800 x 550 x 265
Travel 350 x 250 x 250
Surface Finish Ra0.1µm
Tight and Rigorous repeatable Machining using high speed, high precision machines from Germany, Switzerland and Japan , Reaching steel tolerances of +/-0.002, to +/- 0.005

 OUR QC/QA PROCEDURES INCLUDES
 Inward Inspection
 Tool Steel Hardness Inspection
 Tool Steel / inserts Dimension Inspection
 Pattern Inspection
 Casting inspection
 Moulds Electrodes Inspection
 Tool Pre-Assembly / Stage wise Inspection
 Trial Report and Samples Inspection
 Part and checking fixture CMM inspection
 Tool / Parts buy off & Pre Dispatch Inspection
CERTIFICATION & QC PRO

CARL ZEISS 3D CMM 10-16-6
Measuring Range : 1000 X 1600 X 600 MM
2 micron resolution
Our molds & Dies will be fully qualified in our dedicated mold/dies testing centers, and plastic parts will be validated in our metrology laboratory. Our process and QC engineers
have in depth knowledge of mold /tool validation and various industry validations protocols (PPAP) documentations.100% steel check of critical dim's and shut-off areas. Konzert
has a dedicated in-house metrology laboratory. The lab's multi-shift operation supports Konzert's mold /Tool qualifications, production facility and customers' metrology inspection
needs. The lab has a full suite of measurement equipment including: CMM (ZEISS), VMM,2D height gauge (Tessa)& digital calipers and gauges (Mitutoyo).
Quality Control
Rapid I CNC Vision Measuring System
Measuring Range : 200 X 150 X 150 MM
2 micron resolution

BUY-OFF DOCUMENTATION
We supply all the Tools and fixtures with required Buy off Documents.
 Design records
 Method Plan
 3D Design
 2D Detailing
 Design sign off Documents
 Test Certificates
 Raw Material, Heat treatment , etc.
 Dimensional Inspection report
 Part Lay out Inspection
 Part CMM Inspection
 Checking Fixture Designs
 Checking fixture CMM Report
 Part CF report
 Dispatch documents

Injection Moulding Machines- 80T&150T (2 - No's)
Nova servo From Ferromatik Milacron with bimetallic screw barrel
Under Installation
MACHINE SPECIFICATIONS
NOVA SERVO 150 (B610) NOVA SERVO 80 B 32
FRAME
INJECTION UNIT SPECIFICATIONS UNITS
INJECTION CAPACITY MAX gms 336 125
THEORETICAL DISPLACEMENT cc 353 132
INJECTION PRESSURE MAX bar 1731 1639
INJECTION RATE(With open Nozzle) cc/sec 158
140
INJECTION SCREW STROKE mm 180 130
SCREW DIAMETER mm 50 36
SCREW L/D RATIO 20 20
SCREW SPEED rpm 222 298
SCREW TORQUE @172 bar NM 1080 671
PLASTICIZING RATE gm/sec 28 14
PLASTICIZING RATE (BARRIER) gm/sec 33.6
NO. OF THERMOCOUPLES(BRL+NZ) 3+1
3+1
TOTAL HEAT CAPACITY KW 15 7.3
HOPPER CAPACITY kg 29.5 29.5
NOZZLE ORIFICE mm Φ3.5 Φ3.5
NOZZLE RADIUS mm R15 R15
CLAMP UNIT SPECIFICATION
CLAMPING FORCE kN 1500 800
CLAMP STROKE mm 440 310
MAXIMUM DAYLIGHT mm 950 710
MINIMUM MOULD HEIGHT mm 150 150
MAXIMUM MOULD HEIGHT mm 510 400
PLATEN SIZE (H X V) mm 740 X 740 610 x 565 (H X V)
DISTANCE BETWEEN TIE ROD mm 510 X 510 405 X 360 (H X V)
TIE ROD DIAMETER mm 85 70
EJECTOR SROKE mm 130 120
EJECTOR FORCE kN 44 34
MOLD WEIGHT CAPACITY kg 1500
EJECTOR ROD THREAD M16 M16
Newly Added Molding Machine

KLT Logo
India
GLOBAL DELIVERY
For global distribution Konzert has no boundaries. Products / Tools can be shipped to America, Europe or Africa, On-time, every time with the support of global
carriers such as UPS, FedEx, DHL,TNT express company, and other global freight forwarders. We can assist you in determining which one will be best suited for
your cost and timeline needs

Konzert Toolings Pvt. Ltd.
Regd. Address: Plot No. EL-21/1/3, | M.I.D.C., Bhosari.,
Pune, Maharashtra, India. 411 026.
CONTACT
Mr. R. Rajiv Seshadri Head – Business Development
Phone: +91 7507 999 503, Mail to: marketing@konzertonline.com

MAKE IN INDIA @ KONZERT_ATD_PTD_04_AUG_2015

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