Profile
Profile

Dense traffic and high speed characterises everyday life on roads. This puts increasing demands on the field of vehicle engineering for higher vehicular safety and comfort.And the steering system plays a major part in fulfilling this requirement.

 

 ZF Steering Gear (India) Ltd (ZFINDIA)  was incorporated in the year 1980 as a joint venture  zf friedrichshafen ag.

 

ZF Steering Gear (India) Ltd (ZFINDIA)  a Pioneer in Manufacturing and Supply of  Ball and Nut  Integral Hydraulic Power &  Worm and Roller Mechanical Steering System in  India and having joint venture with M/s. ZF Lenksysteme GmbH. The plant is located at village Vadu Budruk, Taluka- Shirur, 28 Km away from Pune on  Pune - Ahmednagar Highway, in the western part of India. Pune is a major automotive hub with OEM like  Force Motors ,General Motors, Mercedes Benz,  Mahindra Trucks & Bus Ltd, TATA Motors, etc.

 

Present installed capacity is 2,00,000 units of  Worm and Roller Mechanical Steering Gears and 2,50,000 units of   Ball and Nut Integral Hydraulic Power Steering Gears and 60,000 units of Mechanical Rack & Pinion Steering Gears per annum.  

 

We have the state of the art technology in Design & Manufacturing various types of Power  Steering Systems and Mechanical Steering Systems based on customer’s need.

 

We are continously in the process of widening our product base to meet the increasing demands of automotive market and are keen to diversify in appropriate product lines.

 

We have an established business management system with certification for QMS vide ISO: TS: 16949:2002 and ISO: 14001. We have created service and spare parts network of around 60 dealers uniformly spread all over India ,Nepal, Middle East , South Africa and Bangladesh to address to all our customer’s needs.

 

The company has an established structure for carrying out various facets of manufacturing functions as per business process defined by ISO: TS: 16949:2002.We had adopted to lean manufacturing systems and have an employee strength of around 1000 personnel.

 

The company’s Product Range:

  •  Ball and Nut Integral Hydraulic Power Steering Gears for Heavy Commercial vehicles.
  • Integral hydraulic Power Steering Gears for Medium and Light Commercial Vehicles.
  • Power steering gears for SUV and off road vehicles.
  • Vane pumps.
  • Oil reservoirs.
  • Steering columns.
  • Drop arms.
  • Intermediate shafts.
  • Universal joints.
  • Bevel gear boxes.
  • Worm and roller mechanical Steering systems for Tractor and Light Commercial Vehical and all accessories for the same.
  • Power Rack and Pinion Steering system for Passanger Car.  
  • Mechanical Rack and Pinion Steering System for One Toner Passanger and Goods Carrier.

 

Manufacturing Equipments:

  • 31 HMC’s including state of the art machines such as Mazak, Mori Seiki etc.
  • 19 VMC’s.
  • 18 Turning centers.
  • 50 SPM’s.
  • 200GPM’s.
  • 5 Generator Sets.
  • 4 Compressors.
  • An automated conveyor Paint shop with seven tank dip system.

 

Heat Treatment Equipment and facilities : 

We have state of art heat treatment facility comprising,

  • 20  nos. Heat Treatment furnaces.(Gas fired Sealed Quench, Drip feed carburizing furnaces, and controlled atmosphere continuous hardening and tempering furnaces) with continuous data logging facility for process control and monitoring.
  • Nitrogen plant  - 30 M3/Hr capacity.
  • LPG.Storage installation.
  • Vibro finishing machine for super polishing of steering parts.
  • Shot blasting machine - Schlick make, Germany
  • Brinell, Vickers hardness testers.
  • Micro hardness testers - Zwick Germany  and Future tech Japan.
  • Metallurgical Microscope and Image Analyzer- Zeiss, Germany.
  • Stereo Microscope - Zeiss Germany.
  • Universal testing machine.

 Heat treatment processes carried out include :-

  • Annealing.
  • Gas carburizing ,hardening and tempering- From 0.1m to 1.3mm case depth requirements.
  • Bright hardening and tempering

 

The Products Manufactured by us are duly designed and developed as per our customers requirement. The products are manufactured with at most care for cleanliness, smooth function in operation, easily accessible fitment and long life cycle.
We have a zero defect (with Pokayoke Concept) assembly line for assembly of Steering systems for HCV, LCV, MUV/SUV, Passenger Cars, Tractors etc.
 
We have a self sufficient in house Tool Room for supporting and maintaining various services like tool Re-sharpening, Grinding etc; required for conducting the manufacturing activity continuously. We have all necessary material handling devices to ensure safe and smooth transportation of material within the plant.
 
Manufacturing concepts:
1.Lean cellular manufacturing.
2.Adaptation of principles of 5S. (link 5S to http://en.wikipedia.org/wiki/5S_(methodology))
3.Continuous Improvements - Kaizen. (Link Kaizen to http://en.wikipedia.org/wiki/Kaizen)
4.Kanban, First In, First Out (F.I.F.O.).
5.TQM and TPM.

 

The processes are monitored, controlled and qualified as per the set parameters and all production and quality assurance  activities are managed by  team of qualified and experienced  engineers and workmen under the leadership of the chief metallurgist. The steering system of an Automobile falls under category of Safety critical part and essentially very special steels and other materials of unique compositions are selected and used after proper heat treatment operations. Hence, we have created  the necessary infrastructure for heat treating up to 300T/Month, including a modern metallurgical laboratory and special process techniques that are required to achieve the desired Metallurgical performance standards. 

 

All key equipment have been provided with complete power back up to ensure the uninterrupted process which is essential for excellent metallurgical properties.

 

Quality Control Equipment in Standards Room :

  • CNC Three Coordinate Measuring machine.
  • Contour Tracer.
  • Form Tester.
  • Surface Roughness Measuring machine.

 

In House design facilities for:

  • 2D and 3D Modeling.
  • Pro E, IDEAS, Auto cad software.
  • Finite Element Analysis.
  • SAP ECC 6.0 ERP System

 

The main features of our products are easy operation, compact, trouble free steer ability, easy adjustments, positive road feel.

Our valuable customers  are:

 

 Power Steering Gear :

  • AMW Motors Ltd.
  • Ashok Leyland Ltd.
  • Daimler India Commercial vehicles Pvt. Ltd.
  • Force Motors Ltd.
  • KAMAZ Motors Ltd.
  • Mahindra Trucks & Buses Ltd.
  • MAN Trucks India Pvt. Ltd
  • SML Isuzu Ltd
  • Tata Motors Ltd.
  • VE Commercial vehicles Limited
  • Vehicle Factory
  • Volvo Group

 Mechanical Steering Gear :

  • Action Construction Equipment Ltd.
  • Bajaj Auto Limited
  • Escorts Limited
  • Force Motors Limited
  • International Tractors Ltd.
  • Mahindra & Mahindra Ltd
  • New  Holland Fiat india Pvt. Ltd.
  • Piaggio vehicles Private Limited
  • Same Deutz-Fahr India Private Limited
  • TAFE Motors & Tractors Ltd.
  • Universal Construction Machinery