Presentation ukay ashok 2-2015

Ukay Metal Ind.Pvt.Ltd.
Excel with Passion

Plastic Molded
parts & Assy.
NVH parts PU Foam Seats&
Head Rest
GROUP
STRUCTURE
UKAY METAL INDUSTRIES PVT.LTD.
MANAGEMENT
STRUCTURE
Mr. Rajendra Katore
MD
PRODUCT
CAPABLITY
Capability
Turnover
Ukay Metal Ind.Pvt.Ltd
OEM Supplier Rs. 1150 Million
 Technical center provides support for Design validation,, Testing, Tooling and Prototype
Precision
CNC
Machined
Parts
Integral Skin
PU foam molded parts
Excel with passion
TS16949,
ISO 14001,
OHSAS 18001
CRISIL A+ Rating
LMR-RIM
Parts
Head Liner

 Vision:
To be a global customer oriented mega organization,
driven by proactive people, unconventional innovation,
modern technology and simplified system.
 Mission
Total Customer Satisfaction through Continual
Improvement in its Products, Processes and Systems
through Optimization in Cost.
Excel with passion

 6 Plants at MIDC, Ambad, Nashik
 1 Plant at Gondhe, Nashik for Soft Luggage
 1 Plant at Haridwar
 1 Ware House at Chakan
 Corp.& registered office at MIDC , Ambad,
Nashik
Excel with passion

Locations – UMIPL & Customers
Haridwar
New Delhi
Zahirabad
Nashik (HO)
Pune
Bhuj
Mumbai
Ukay Metal
Manufacturing Location
& Customer Location
Customer Location
Excel with passion

8
7
6
5
4
3
2
1
2015 : Kaizen Winner State Level –CII
2014 : MSES B within a Six Month – M&M
2014 : Platinum Award - Godrej
2014 : Kaizen Appreciation Award – State Level CII
2013 : First prize in NPD - Godrej
2013 : Kaizen Winner State Level –CII
2013 : ISO14001/OHSAS18001 Certification – bsi.
2012 : Kaizen 2nd Runner-up - M&M
2012 : ISO/TS 16949 : 2009 Certification – bsi.
2012 : Fast Product Development Award - LEAR
2010 : Excellence Award - LEAR
2009 : ISO14001/OHSAS18001 Certification – bsi.
2009 : Best Product Unit Award - M&M
2009 : Best VAVE Award - M&M
2008 : Best VAVE Award - M&M
2004 : ISO/TS 16949 : 2002 Certification – bsi.
2000 : ISO9001 :2000
1999 : NIMA Award
1999 : Bhartiya Udyog Ratna Award
1997 : Established
1997 2000 2004 2008 2012 2015 2016 2017
TQM
Milestones
Excel with passion

Sales Performance
# projected
Excel with passion
Rs. Million

Sales Performance
Excel with passion
# Projection
Rs. Million
0
915
775
600
720
835
1000
515
355
660
1305
1800
2085
0
500
1000
1500
2000
2500
Sales 2012-13 2013-14 2014-15 2015-16 # 2016-17 # 2017-18 #
M&M
Non M&M

ISO/TS 16949:2009 , ISO 14001 & OHSAS 18001 Certificates
Excel with passion

Ukay Metal Ind. Pvt.Ltd.-Business Partners
Excel with passion

Injection Molded Products Assy.
Excel with passion

Injection Molded Products
Excel with passion

Vacuum Forming Products
Excel with passion

Liquid Molding Resin
Reaction Injection Moulding
-DCPD Creates Design freedom option
Excel with passion

Excel with passion
Liquid Molding Resin
Reaction Injection Moulding
-DCPD Creates Design freedom option

Head Liner
Excel with passion

Composites Products
Excel with passion

NVH Parts
 High Pressure PU Moulding machine from Italy
 Acoustic/ Viscos- elastic type foam with 130 kg/M^3 Density
 Used for Engine cover, Noise insulation;
Excel with passion

FLOOR CARPET, BONNET INSULATION ,PARCEL TRAY & UNDER TUNNEL ETC;
Excel with passion

NVH Parts
Excel with passion

PU Foam Seats Cushions,
Excel with passion

Head Rest
Excel with passion

Integral Skin PU Foam Products
Excel with passion

Precision CNC Machined parts
Excel with passion

Ukay -Manufacturing Facilities
 Injection Moulding
 1850 T -1machine
 1450 T -1machine
 660 T -1machine
 450 T - 1 machine
 125 T – 2 machine
Excel with passion

Injection Moulding Shop
Excel with passion

Reaction Injection Moulding- shop
Excel with passion

Ukay -Manufacturing Facilities
 Reaction Injection Moulding
 Low pressure process with low
viscosity liquids
 Tooling Options
 Cavity pressure of 15 to 30 psi
 Class A or Aesthetic parts( Nickel
shell or machined Aluminum)
 Industrial parts( Cast Aluminum )
 Prototype(Composite molds)
 Molded-In Inserts are an
option with liquid moulding
 Ribs & bosses can be
moulded in for stiffness and
attachments
Excel with passion

Head Liner
Excel with passion
Maxm. Size 2 m*3.0 m
Foam Slicing Line
Meyer Compression Forming
Lamination Line

Compression Forming
Excel with passion

Robotic Water Jet forTrimming
Excel with passion

Thermo Forming
Excel with passion
3 machines, can process part of 1200,1500 and 2200 mm

PU Foam Seats Cushions
 3 nos. High Pressure Foaming
Machines
 39 mould carrier continuous running
oval conveyor line.
 Automated clamps and mould
closing and opening system.
 Mould heating station on mould
carriers
 8 nos. Integral Skin Foaming
Machines
 Semi Rigid PU Foaming Line
 Vaccum Crushing equipment
 Roller crushing equipments
 Material Bulk Storage Racks
Excel with passion

Integral Skin PU Foam Moulding
Excel with passion

Paint Booths
Wet Paint Booths-2 nos Dry Paint Booth-2 nos.
Excel with passion

Seat CoverTrims
 Digitizer Equipment
 CNC cloth spreading Machine
 CNC cloth cutting Machine
 High Speed Industrial Sewing
Machine
 High Frequency PVC welding
 Jigs For Stitching & Inspection
CNC spreading Industrial Sewing
Machine-150 nos.
CNC Cloth Cutting
Excel with passion

Tool Room & Machining Shop
 DMG Mori SeikiTurn mill
Centre
 ACE Make CNC Lathe
 Makino VMC Machine (4 Axis)
 TAL Make VMC
 Jyoti Machine
 CNC Router
 Ultra 3D Printer (Prototype
Machine)
 Conventional Milling
Machines
 Conventional Lathes
 Radial drilling machines
Excel with passion

Tool Room
DMG Machine
Jyoti VMC Machine
LT-20 CNC Lathe
Water Jet Machine
Makino Machine
EDM
Excel with passion

Assembly Work Station- Sunvisor Line
Assembly Work Station- Bolero Line
WSS AT SHOPFLOOR
Excel with passion

Operator Meeting Plant Indicators for DWM
 Operator Meeting and DWM implementation resulting the PPM reduction
from 724 to BELOW 100 PPM in last 2 years.
Daily Work Management
Excel with passion
Excel with passion

Operational Efficiency Monitoring
Excel with passion

Firewall Work Station
PDI Inspection Defect Sample Display
Master Sample
QUALITY MANAGEMENT
Excel with passion

Metrology & Quality
 Auto Melt flow Indexer
 Shore A Hardness Tester for
Integral skin foam & rubber parts
 Portable Hardness Tester
 UTM Machine for checking Foam
Indentation, Hardness & Tensile
Test
 Spectro Photometer Gloss Meter
 DFT Meter
 Gloss Meter
 Flammability Tester
 Salt Spray Cabinet
 Digital Stormer Viscometer
 Anemometer Air Velocity
 Digital Thickness Meter
 Lux Meter
Excel with passion

Metrology & Quality
 CMM Machine- Cimtrix AEH
Germany
 Video Measuring Machine-
AEH Germany
 Surface Roughness Tester-
Carl Zeiss
 Height Gauge-Mitutoyo
 3D Bases Arm Type CMM
AEH Germany
Excel with passion

Design & Development
 All the members in Design are engineers.
 Senior members having experience more than 25 years in
Molding and PU Foam industry
 Custom designed design software available for design
calculations
 3D CAD Stations supported by Software:
 UG NX3
 Magic's 9.45
 Auto CAD
 Art CAM /Dell CAM for CNC Programming
Excel with passion

APQP Review Meeting Project Progress Tracking
Timely Review of the projects are resulting to In-time development & First
time right Quality products. One of the example is W105.
PROJECT MANAGMENT
Excel with passion

Logistic Management
Storage Despatch
Excel with passion

Supplier Meet Supplier Audits – M/s.Jindal
 STA team works upon supplier up-gradation for Improving PPAP ,
Reducing PPM level etc.
 55 out of 107 Suppliers have undergone through trainings and our STA
team is monitoring the effectiveness at supplier end through audits.
SUPPLIER UP-GRADATION
Excel with passion

MSES B
SBCB – Aon HewittKaizen Appreciation Award – State Level CII
ACHIEVEMENTS
Excel with passion

Customers Appreciation
Excel with passion

Training & Development
 Behavioral training for Managers and executives
 Goal Setting for Managers & Executives.
 Competency mapping
 Reforms in Operational area through TQM techniques
 Career and succession Planning for Staff
 Empowerment initiative for employees
 Talent Development and Retention initiatives
Excel with passion
TRAININGFORSTAFF
TrainingNeed
Identification
TrainingPlan
Training
(Execution)
PostTest
Evaluation
Effectiveness
Monitoring
GapAnalysis(Skill
PersonalCard)
Input
CompetencyMatrix
Pre-Test
(IfApplicable)
IfGapObserved

Class Room Training
Gurukul Work station
Practical- Assembly station
 Till Date 381 Operators have Completed Gurukul Training.
Gurukul
Excel with passion

CSR Activity & Employee Motivation
 Participate in customer CSR activities (blood donation, Nanhi
Kali, Providing Helps to Adharashrams, AIDS awareness)
 Kaizen Awards
 Awards for Best Kaizen from all Plant , Best Kaizen from Individual
plants , Highest Kaizen Plant & Certificates to all participants.
Excel with passion

ENVIRONMENT
 Tree Plantations are organized jointly Management and
employees.
 ETP at place to reuse the coolant water and Paint shop waste
water for gardening
 Rain Water Harvesting in all our new plants.
 Energy Conservation -Solar Energy for lights, Energy Audits.
 Sewerage Treatment plant.
Excel with passion

Health & Safety
 Regular and periodical check-ups for employees
 First Aid provided at work Places with proper visibility
 Ventilators installed at all plants
 Fire Hydrant and Fire extinguishers System at designated
places.
Excel with passion

 Contact:
Ashok Chandak
Executive Director- Business Development
Ukay Metal Industries Pvt. Ltd.
F-139, MIDC Ambad,
Nasik -422012, Maharashtra, INDIA
Tele fax : +91 253-6695508
Phone: +91 253 6629460
Mobile:+91 9819920011
Email: chandak.ashok@ukayindutries.net
www.ukayindustries.co.in
Excel with passion

Presentation ukay ashok 2-2015

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