Delivering Optimum Quality for Safe Driving and Flying is Sansera’s daily business
In the wake of recent recalls in the automotive industry to the tune of billions of dollars and the resulting damage to the manufacturer‘s image, quality assurance in the manufacturing process is becoming more and more relevant. Quality assurance plays a pivotal role at Sansera Engineering, an Indian company that has been producing components such as connecting rods, rocker arms, gear shifter forks and crankshafts since 1987. “Engine components have particularly narrow tolerances. Our customers‘ specifications are strict and, not surprisingly, they expect optimum quality. Meeting these standards requires the best metrology products and solutions,” says P.V. Sudheer, Quality Manager at Sansera Engineering.
“Thousands of different components must be perfectly matched to ensure that a vehicle’s engine works without a hitch. Design errors can sometimes have serious consequences. Ensuring component accuracy is the be all and end all in both the automotive and aerospace industries.”
Over the past 30 years, Sansera headquartered in Bangalore, India has become a trusted partner in the automotive industry. Today, approximately 4,500 employees work to complete orders from around the globe at the company‘s sites in India. Sansera‘s customers include numerous well-known two wheeler manufacturers such as Suzuki, Harley Davidson, Yamaha and Ducati as well as automotive sector customers like Volkswagen, General Motors and Toyota. For the past several years Sansera has also been providing the aerospace industry with seating and cargo systems. “Ensuring component accuracy is the be all and end all in both the automotive and aerospace industries,” explains P.V. Sudheer
“The requirements have continued to increase in the past years and change almost daily. That is why we needed to invest in our Quality Assurance department.”
Increasing and daily changing requirements
Sansera uses random sampling for the mass production automotive parts. The required tolerances are often around just three micrometers. “The requirements have continued to increase in the past years and change almost daily. That is why we needed to invest in our Quality Assurance department. We simply could not meet our customers‘ requirements by performing manual measurements,“ says quality manager P.V. Sudheer. While primarily stencils and gauges were used in the past, these days highly precise measuring machines are at work. “A friend of mine from college works at ZEISS here in Bangalore. This was one reason we started looking into their measuring technology,” says S. Sekhar Vasan, Founder and CMD of Sansera. “Of course we also considered ZEISS‘ competitors, but we wanted cutting-edge technology and that is what we got.
“A friend of mine from college works at ZEISS here in Bangalore. This was one reason we started looking into their measuring technology,” says S. Sekhar Vasan, Founder and CMD of Sansera. “Of course we also considered ZEISS‘ competitors, but we wanted cutting-edge technology and that is what we got.
Meeting customer requirements and increasing efficiency
Sansera acquired its first ZEISS measuring machine about twelve years ago, and, thanks to a few updates, the company is still using this machine. It works along side twelve other measuring machines in the measuring lab on Sansera’s premises in Bangalore. All are supported with ZEISS software. “The software is a great help because it enables us to capture and document data quickly and easily as well as trace our results. The resulting quality reports are easy for our customers to understand,” says Quality Manager P.V. Sudheer.
“Thanks to the metrology solutions from ZEISS, we can observe the stipulated tolerances, deliver the quality our customers expect and even increase production efficiency with faster throughput times.”
Quality assurance is an attitude, not just a product
The relative proximity of the ZEISS site in Bangalore also plays a key role, because it is only 30 minutes away from Sansera’s premises. “Of course an excellent product is important and for most people is probably the most important factor. But it is also important for us that we have a good partner on our team who is on-site quickly when whenever we need them. Thus it is not just a question of the product, but also of the software, service and consultation,” says S. Sekhar Vasan. It all comes down to the entire package that Sansera requires for quality assurance.
These days, Sansera manufactures around seven million connecting rods annually, and the number is expected to increase to approximately 18 million by 2018 because of a large order. “Our ongoing challenge is figuring out how to manufacture our products at a good price even as our customers‘ requirements and tolerances are becoming ever stricter,“ says S. Sekhar Vasan. Reliable measuring results lay the foundation for achieving this goal.
Sansera Engineering Pvt. Ltd develops and produces precision-manufactured components for the automotive and aerospace industries. Founded in 1987, the company is headquartered in Bangalore and serves both Indian and international customers. The product portfolio comprises aerospace components such as seating and cargo systems as well as precise, forged and machined automotive components such as connecting rods, rocker arms, gear shifter forks and crank shafts along with other components for heavy commercial vehicles as well as two- and three-wheelers. Today approximately 4,000 employees work at the nine Sansera Engineering sites.