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Manufacturing
facilities
TSAL's 60,000-square-metre world-class facility at Chennai, India,
uses contemporary technology and a variety of business improvement
initiatives to ensure a quality level of less than 50 parts per
million (ppm). TSAL is the first vendor to receive the 100 PPM certification
from Hyundai.
With the Objective
of 020 and adoption of initiatives such as, TPM, TQM, Six Sigma,
5S, 3C and business excellence models, TSAL is fast approaching
zero PPM.
TSAL is TS 16949,
ISO 14001 and OHSAS 18001 certified.
Frequent exchange
of engineers and technicians between TSAL and SungWoo Hi-tech gives
TSAL personnel, hands-on experience on current Technology and Processes.
The facilities at
TSAL have a range of features that have won the customer's recognition:
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Plant layout
designed for a unidirectional flow of materials |
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Tandem operation
press lines with intermediate conveyors that ensure higher productivity |
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Dies with robust
design and a pneumatic ejection system that improve productivity
and reduces downtime |
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Implementation
of SMED concept, allowing heavy-line die change in less than
eight minutes |
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Intensive training
of engineers and technicians in South Korea |
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Skills and capabilities
for the design and maintenance of dies and jigs |
The plant contains
press lines, weld assembly lines and die/jig maintenance facilities
with a range of equipment.
Press shop
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Shearing Line
- 2 machines |
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Three heavy press
lines with 1000T to 300T and 2 light press lines of 200 T |
Weld shop
Welding Machines
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Projection welding |
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Riveting |
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Portable spot
welding |
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Portable spot
welding J-gun |
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Stationary spot
welding |
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Portable spot
welding X-gun |
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Automatic nut
feeders |
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Stud bolt welding |
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CO2 welding |
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Welding robots
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Spot-welding
robots |
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Under shuttle
to move the WIP from 1 jig to the next |
Die maintenance
shop
Machines
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Radial drilling |
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Lathe |
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Surface grinder |
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Arc-welding |
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Milling |
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Welding rod |
Advanced welding
technology
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Highly skilled
welding technology in die welding |
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Special welding
alloy electrodes used for castings, SKD, S45, etc |
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Die technicians
trained by Larsen & Toubro Eutectic welding sections |
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Inverter welding
machine and electrode drying oven for increased performance |
Hard
chrome-plating of dies
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Prevents die
material wear |
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Cost reduction |
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Improved productivity |
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Periodic chrome-plating of
dies done based on the annual chrome plating schedule |
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Improved panel
quality |
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High
pressure die washing
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Die maintenance
is equipped with hot and cold water high pressure jets for die
washing |
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This protects
the die from unwanted impurities sticking to the die and results
in improved panel quality |
Stores
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Die maintenance
is equipped with separate stores to cater to its needs |
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Optimum stock level and inventory
control is totally computerised |
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Direct import
of die maintenance spares |
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Testing laboratories
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Coordinate measuring |
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Salt-spray testing equipment |
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Universal testing |
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Durability testing machine |
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Hardness testing |
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All other basic measuring
instruments |
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