Hot Forging, Warm Forging, Cold Forging, 2800 Ton Forging Press, 8000 Ton Forging Press, Hobbing, Shaving, Grinding, Honing, Transmission Assembly, Gears, Shafts

1. Global Provider of Automotive Components
Corporate Presentation

2. Core Values
• Our values drives our businesses and has always been a
key enabler for our growth imperatives

3. The Group

4. Polymers Business
• Plastic Interiors
• Pillar Trims
• Door Modules
• Instrument Panels
• Centre Consoles
• Under body parts
• Charge Air Cooler
housing
• Radiator tanks
• Mirror Assembly
• Air filter assembly
• Seating assembly
• Varroc Polymers is one of the leading suppliers to Indian,
Japanese, European and American OEMs
• Pan‐ India manufacturing and paint shop footprint
• Invested in a state‐of‐the‐art Technical Center which
handles complex aspects of tool designing and
manufacturing
• Invested in R&D to build capabilities to provide solutions
for integrated modules, internal body parts, mirror
assemblies and advanced air filter solutions

5. Electrical & Electronics Business
• Electronics
• CDI controllers
• Regulators Rectifiers
• Digital Electronic
Clusters
• Handle Bar Assemblies
• Motors
• Starter Motors
• Wiper Motors
• Magnetos
• Emerging to be leading electrical and electronic
component supplier in 2W, Commercial Vehicles and
Passenger Car segments
• Dedicated R&D centre in India
• 5 manufacturing units

6. Metallic Business
• Leading supplier of engine valves globally
• State‐of‐the‐art simulation and validation testing facility
• State‐of‐the‐art fully machined forging components and crank
shaft facility to cater to the commercial vehicle space
• Forgings
• Transmission Assembly
• Connecting Rod
• Crankshaft
• Multiple Gear Assembly
• Camshaft and Crank
Pins
• Engine Valves
• Construction Industry
• Links & Rollers,
Segments
• Hubs
• Hydraulic components
• Cardan shaft, motor
cardan shaft, sleeve, etc.

7. 4‐Wheelers Lighting Business
• Varroc Lighting Systems (VLS) has a strong R&D and
manufacturing across North America, Europe and Asia
• Partner with major global OEMs to provide lighting solutions
that meet performance and aesthetic needs
• Head Lamps
• Reflectors, Halogen &
HID Projectors
• Adaptive Front Lighting
Systems
• AFS control electronics
• Day time running lamps
• High Intensity Discharge
Light
• Rear Lamps
• Fog Lamps
• Side Markers, Front & Rear
• Centre High Mount Stop
Lights

8. Tri.O.M 2‐Wheelers Lighting Business
• Head Lamps
• Tail Lamps
• Blinkers
• License Plate Lights
• Reflex Reflectors
• Side Markers
• Emerging global 2W lighting supplier
• Dedicated state of the art R&D centres in Italy and India
• 4 manufacturing units globally; serving Large Japanese,
European and Indian OEMs

9. • Varroc is well positioned to support Customer growth in all markets.
22-08-2014
Vietnam
Mexico
Italy
India
Czech
Location Plant R&D
Center
India 21 3
Europe 8 3
South
East Asia 1 -
US 1 -
Germany
China
France
Slovakia
United Kingdom
Unites States of America
Globally
Divisions Number of
Plants
Polymer 9
Electrical 12
Metallic 9
Integrated Plant 1
Engineering
Centers 6
Varroc Group – Global Footprint & Support

10. Varroc Group – India Footprint

11. Key Customers

12. Key Customers

13. Varroc Engineering Pvt. Ltd.
(Forging Division)

14. Plant - V
Plant - VIII
Plant – VII

15. CERTIFICATIONS
TS/ISO 16949:2009 OHSAS 18001:2007 ISO 14001:2004

16. Engineering Infrastructure

17. Engineering Infrastructure
The Design & Engineering facility comprises of:
 CAD/CAM/CAE infrastructure for 3D modeling, NC tool path generation and FEA analysis to accelerate
response time in developing new parts.
 Metal flow simulation software "FORGE 3“ from M/s. Transvalor, France used for virtual manufacturing,
Process validation, die stress analysis, to estimate forging load, grain flow, tool life, Material life and design
optimization to develop new parts right the first time.
 High-end CAM software, like “Delcam“ and "UG-NX" for generating NC tool paths for high-speed die cutting,
to reduce turnaround time in die manufacturing.
 Software include • FORGE 3 Ver. 2011 on 9 CPU Cluster
• Finite Element Analysis (Ansys 11.0)
• Hyper mesh 21HWU
• 3D Modeling (Unigraphics NX-5)
• 3D Modeling (Pro Engineer)
• 3D Modeling (Catia V5 R18)
• Machining Program (Power shape 7.2)
• Machining Program (Power Mill 8.0)
• Drafting (AutoCAD)

18. Metal Flow Simulation
Steering Knuckle
Cam Shaft 2 port Flange
Kidney Gear Starter Clutch 4 Cyl. Crankshaft

19. Product Lines

20. Product Line
Transmission Assembly (Range from 100 cc to 1000 cc)
690 cc Bike (Export) 675 cc Bike (Export)
690 cc Bike (Export)
135 cc Bike (Domestic)

21. Product Line – Finished Parts
Boss Buffer Gear Kick Wheel Ratchet
Weight 1 Gear 2 Starter Clutch Gear Idler 2

22. Product Line – Forged Gears
Gear 4th Pinion Gear 4th Wheel Gear 1st Wheel Gear 2nd Wheel
Gear 3rd
Pinion
Gear Primary
Drive
Gear Drive
Gear 3rd Wheel Gear 5th Wheel Gear 5th Pinion

23. Product Lines
Crankpins
(Seven varieties)
Production Capacity – 2.75 Lakhs/month
Connecting Rods
(Two varieties)

24. Product Line
Hub Reduction – Sun & Planetary Gear

25. Product Line
Inlet Exhaust Valve Camshaft Fuel Injection Pump Camshaft
Single Cylinder Diesel Engine Camshafts

26. Product Line
Steering Spindle Assembly
Front Wheel Hub Assembly

27. Product Line – Hydraulic Parts for Steering Assembly & Pump
Valve Cardan Shaft Motor Cardan Shaft Cardan Shaft Idler Shaft
Piston Sleeve Danfoss Shaft Coupling

28. Product Lines – Parts for Heavy Commercial Vehicles
Six cylinder Crankshaft ‐
Machined
Four cylinder Crankshaft ‐
Machined
Six cylinder Crankshaft ‐
Forging
Front Axle Beam Knuckle
Ring Gear Blank Spindle

29. Manufacturing Infrastructure

30. Key Manufacturing Equipments: Forgings
Hot Forging
* 6 Press Lines from 500 T to 8000 T
with dedicated Induction Billet
Heaters
* (500T, 1000T (2 nos.), 1500T,
2800T & 8000T)
Warm Forging
2800T Forging Press Line
Warm Forging Press Line
* 3 Press Lines of 300 T with
dedicated Induction Billet Heaters
8000T Forging Press Line

31. Key Manufacturing Equipments: Forgings
Cold Forging
Hydraulic Cold Forging Presses
* 11 nos. Hydraulic Press Lines from
100T To 500 T
* (100T, 150T, 200T, 300T, 400T,
500T)
* 4 nos. Mechanical Press Lines from
150T To 650 T
* (150T, 400T, 500T, 650T)

32. Key Manufacturing Equipments: Soft Machining
1. Gear Cutting Machines
A. Gear Hobbing Machines
i. Liebherr Make LC150 - 6 nos.
ii. Mitsubishi Make (GD 30) - 1 nos.
iii. Mitsubishi Make (GD 15) - 4 nos.
B. Gear Shaping Machines
i. Lorenz Make - 4 nos.
ii. HMT Make WS1 – 9 nos.
C. Gear Shaving Machine
i. Hurth Make – 1 no.
ii. SICMAT Make – 1 no.
2. Broaching Machine: 3 nos.
Liebherr LC 150 – Gear Hobbing
Mitsubishi – Gear Hobbing
SICMAT – Gear Shaving

33. Key Manufacturing Equipments: Soft Machining
3. Facing & Centering SPM: 4 nos.
4. Twin Spindle Gun Drilling machine
A. Widma Make – 3 no.
B. TBT Make – 1 no.
5. Face teeth Milling Machine
A. BFW Make – 2 nos.
6. Thread Rolling Machine
A. Praga Make – 2 no.
B. MTE Make – 1 no.
7. Liquid Honing (Sand blasting) – 1 no.
.
8. Vertical Machining Centers - 3 nos (AMW & BFW Make)
9. CNC Lathe – 14 nos. (Electronica, ACE, etc. Make)
Bird’s eye view of Machine shop

34. Key Manufacturing Equipments: Post Heat Treatment
Machining
1. Bore Honing Machine
A. Nagel Make – 8 nos.
2. Super Finishing Machine
A. Nagel – 2 nos.
3. CNC Straight Plunge Cylindrical Grinding Machine
A. Parisudh Make – 7 nos.
B. Micromatic Make – 2 nos.
C. AWH Spectra Make – 1 no.
4. Hydraulic Center less Grinding Machine
A. HMT Make – 2 nos.
B. Palmary – 1 no.
C. Parisudh – 1 no.
5. NC Controlled Center less Grinding machine (Parisudh Make) – 1 no.

35. Details of Six Cylinder Crankshaft Machining Line:
Key Machines Specs & Makes :
 Turning Machines – George Fischer
 Journal & Pin Milling – Heller RFK 4
 Induction Hardening – Alfing
 Pin & Journal Grinding – Naxos Union
 End Operations – HMC – Heller BEA2
 End Grinding - Naxos Union
 Dynamic Balancing – Hofmann & Shenck
 Super-finishing – Nagel
 Washing Machine - Durr

36. Heat Treatment Facilities
• Multi-Chamber Continuous Gas Carburizing
Furnace
•Designed by Holcroft & Mfd. by BGL
•Sealed Quenched Furnace (With Hot Oil Quenching)
• 1 no. – Designed by Holcraft & Mfd. by BGL
• 3 nos. – WELMECH Make

37. Heat Treatment Facilities
Heat Treatment Furnace (Polymer Quenching)
With capacity of 4Ton/Hr

38. Heat Treatment Facilities
Pit Type Annealing Furnace
6 nos. – WELMECH Make
Continuous Mesh Belt Normalizing Furnace
3 nos. – WELMECH Make

39. Heat Treatment Shop – USP
SCADA Software display on
Plasma TV
• Entire facility is supported by SCADA software
• Sub-Zero Treatment (up to -73 degree) facility
• 63 variety of parts handled every month
• Specialty in Case hardening of Gears, Shafts & Crank
Pins in the range of 0.3 mm to 1.6 mm
• Hi-Tech Metallurgy Lab with following equipments;
• Micro Hardness Tester
• Shimadzu (Japan) Make Optical Spectrometer
• Portable energy dispersive X - ray fluorescence
(EDXRF) spectrometer

40. Automated Phosphating Plant
Special Processes

41. Shot Blasting Facility

42. Tool Room Facility
Fadal High Speed Vertical Milling m/c
ACE CNC Hard Turning m/c
Joemars Spark Erosion Joemars Wire Cut

43. Key Quality Assurance: Standard Room
Profile Projector with
Data Processor
Gear Tester (Hofler Make)
Gear Tester (TTI Make)
Co‐ordinate Measuring Machine
(CMM)
Roughness & Contour Measuring
Equipment

44. Key Quality Assurance: Standard Room
Roundness Tester 2D Height Master
Form Tracer / Contracer (Mitutoyo Make)
Hardness Tester Shimadzu (Japan) Make Optical
Spectrometer
Metallurgical Microscope with Image
Analyser – ZeissMake

45. Thank You