2 Greaves Cotton & 3 Product Profile

Greaves : An Analysis of Product Quality & Customer Satisfaction

2.1 HISTORY

The history of Greaves Cotton opens as a family saga starting from the enterprise of one man – JAMES GREAVES & GEORGE COTTON. In 1868 the two joined forces & the firm of Greaves Cotton & Co. was formed. They together set up Head quarters in Bombay & for almost 90 years the head office of Greaves Cotton & Co. had been established at 1 Forbes Street, Bombay.

The partners always seeking fresh spheres for expansion & progress turned to cotton – spinning & no- sooner the firm of Greaves cotton controlling no less than 10 cotton-spinning mills. Finally it was the year 1947 when the company was taken over by Lala Karamchand Thapar (Thapar Group). Thapar from the very beginning of his connection with the company was anxious to encourage its active participation in the manufacturing field.

2.2 PRESENT STATUS

The company acquired its name Greaves Limited in 1993 and thus today the GREAVES GROUP forms a significant part of the Thapar Group of Companies. That was the birth of greaves we know today a pioneer in Engineering Products.

Starting as a trading concern, it has since Independence quickly diversified into manufacturing and marketing high technology engineering products and systems. The Company has Regional and Branch Offices covering all major states of India and also has offices overseas in U.K., Singapore and Russia. Today Greaves is a major force in the Indian Industrial Scenario.

Offering its demanding clientele a wide range of products and systems geared to meet the highest performance standards. Commanding an emphatic presence in core competence areas such as IC engines, power generation equipment, power transmission systems, oilfield, construction, mining and materials handling equipment, pumps, integrated systems and electronics, and polymers. In fact, offering tailor – made solutions to specific customer requirements has always been, and always will be the reason of Greaves, the moving force behind its every endeavor. This is precisely what makes Greaves the premier choice of discerning

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customers around the world, making it a truly world class company in every sense of the world.

Greaves has also entered into strategic joint ventures overseas which will enable the company to consolidate its presence in the international market. In order to have clear customer focus, business operations of the Company are strategically structured into several Business Groups.

Over the years GREAVES has brought to India state of art Technologies in various Engineering Field through setting up of manufacturing units and Subsidiary and Associates Companies. The GREAVES GROUP currently employ about 6000 people and Greaves turnover for the year is about Rs. 500.00crores

2.3 ORGANIZATION STRUCTURE

The Company has a Board of Directors consisting of eight Directors with Mr. Karan Thapar as its Chairman and Mr. Pravin Sachdev as Managing Directors along with Executive Director Along with team a of Executive Vice President and Vice Presidents.

Greaves limited has organizational structure based on Business Group concept where each Business Groups are responsible individually for its Sales, Production & Profitability. Above structure create sense of responsibility and emphasis is on Team Work.

B/G organization helps in rapid decision-making, Vice President & Marketing managers are empowered to take decision of the group. The employees feel highly motivated when the Targets to be met with are known to them right from the beginning of the year. The entire working of Greaves is based on the Budget, which is prepared at the beginning of the year for each Business Group. Such a method of functioning also ensures that there is discipline for achieving Sales & Production targets.

The Greaves Group consist of Corporate Office, Business Groups, Business Centers Subsidiary and Associates Companies.

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2.4 MILESTONES

YEARACHIEVEMENTS

2004Greaves Cotton, part of the B M Thapar group has appointed Karan Thapar as the chairman of the company

2003 Solaris Chemtech Limited acquires 950,000 equity shares of Rs 10 each of Crompton Greaves Limited from Greaves Ltd., stake increases to 10.83% in the company

2002 Italian auto firm Same Deutz Fahr Group SPA has taken over its Indian partner, Greaves Ltd, for Rs 26.9 crore from its two tie-up, one to manufacture tractors and the other for tractor engine

2000 The Greaves engineering arm of Thapar Group, has entered into a technical collaboration with Italian Construction equipment giant Cifa Spa for manufacturing ready mix concrete equipment.

The capacity of petrol/kerosene engines manufactured at Chennai will be increased to 120,000 engines from the current capacity of 80,000 engines.

1999 Greaves Ltd has joined hands with Piaggio S. P. A. of Italy to locally produce in India compact engines with in-built gearboxes for the three-wheelers, which the two Companies would be manufacturing under their joint venture.

Greaves Ltd, engineering arm of the Thapar group, has launched a new range of industrial gearboxes for the industry, making it the only company to offer a wide end unique range of gearboxes for different industries.

1996 The company entered into a technical collaboration with

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Spa, Italy for the manufacture of agricultural tractors and signed a joint venture agreement with them for the manufacture of diesel engines for tractors and other uses.

1994 The company undertook a project for the manufacture of rolling cutter rock bits, used largely in oil well drilling and also for waterwell drilling in collaboration with Smith Tool Company, a division of Smith International, Los Angeles, U.S.A. For this purpose a new factory was set up in the MIDC Industrial Estate at Nasik..

1993 The company entered into a joint venture agreement with a few parties in Singapore for trading in Vietnam and other parts of the world. A new company was registered in Singapore in the name of Pacific Greaves Pte. Ltd.

1990 The company introduced Greaves portable light weight diesel Genset viz., Greaves-GD3000.

The company undertook to increase existing capacity of the light weight engines unit at Aurangabad to 32,500 units from the existing 22,500 units

1984 Greaves Lombardini Ltd., was merged with Greaves Cotton & Co. Ltd.

1975 Greaves Lombardini Company in collaboration with Lombardini Motor of Italy promoted Greaves Lombardini Ltd., for the manufacture of diesel engines. Greaves Lombardini Ltd., was incorporated on 21st May, under the name and style of Greaves Diesels Ltd., and the name was subsequently changed to the present one.

1947 Lala Karamchand Thappar ( Thappar Group ) took over the company

1922 The company was incorporated as a Private Ltd. company

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2.5 GREAVES PRODUCTSGreaves Limited is divided into five Business Groups & the products under them are as follows

Group no. BUSINESS GROUP

PRODUCTS MANUFACTURED BY

Group I (BG I) Power Generation

Diesel EnginesGreaves Limited Diesel Engines Unit Pune

GensetsDual Fuel Engine/GensetsGas GensetsC.I & S.G Iron Castings

Greaves Limited Foundry Unit Pune

Group II (BG II) Power Transmission

Worm Gears Greaves Limited Power Transmission Unit – I & II Pune & Falta, West Bengal

Helical Gears & Bevel Helical Gears

Fluid Coupling Pembril Eng Pvt Ltd Aurangabad.

Group III (BG III) Portable Engines Light Diesel Engine

Greaves Limited Light Engines Units I & II at Aurangabad & Ranipet

Group IV (BG IV) General Engineering

Concrete Pump Greaves Limited Heavy Eng Unit Gummidipuni, Chennai

Transit MixersConcrete Batching plantSingle Drum CompactorsTandem CompactorsRock Roller Bits Greaves Limited

Nashik PlantSilicon Carbide & Clay Graphite Crucibles

Greaves Morganite Crucible Ltd, Aurangabad

Group VII (BG VII) Agro Equipments

Diesel EnginesThoraipakkam - Chennai

Self Priming PumpsLight weight 4 stroke engines

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Power Tiller Imported from ChinaReaper

3.1 INTRODUCTION TO BUSINESS GROUP – I

Greaves leads the field in the manufacture of diesel engines (15-816 HP) used for diesel generating sets, barges, pilot launches, compressors, construction equipment, cranes, forklifts and various defense applications. Built in the true tradition of Greaves, each engine is a marvel of engineering excellence in itself- made of the best materials and conforming to the highest standards.

3.2 DIESEL ENGINE , GENERATING SETS

Diesel Engines are one of the prime movers which is basically a source of energy. The most common prime mover is Electric Motor. Places where Electric Power is not available Diesel Engines are used. Following are the places where Diesel Engines are used :

At a very remote place where electric power is not available.In case of emergency or breakdown in a factory.

3.2.1 WORKING OF GENSET

Gensets or Generating Set is complete equipment, which comprises of Diesel Engine & Alternator. Here Diesel Engine provides drive to the alternator.

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3.2.2 WORKING OF DIESEL ENGINE

Diesel Engine works on compression ignition principle. In cylinder because of the compression, when diesel is injected high pressure & high temperature is generated (because of Compression). Diesel is then ignited & gives thrust to piston & thus power is transmitted from piston to flywheel & is taken to the equipment to be driven.

3.2.3 WORKING OF ALTERNATOR

Alternator works on the principle that whenever a moving object cuts a magnetic field then electricity is generated. In alternator stator is wound with magnetic coil having FERRO MAGNETIC property. Between the coils magnetic field exists. Rotor driven by a prime mover – Diesel Engine cuts the magnetic Field. Electricity is thus generated. Brushes kept outside the alternator then take it out. Depending on the size of the magnetic coil in stator and that of Rotor various capacities of alternators are available.

APPLICATION

Winches , Compressors , Pump sets , Fire Fighting Pumps , Marine & Defense Vehicles .

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3.3 INTRODUCTION TO BUSINESS GROUP – II

Greaves manufactures an exhaustive range of helical and worm reduction gearboxes and are leaders in this field. Standardized designs and large volume output make for complete interchangeability and unmatched economy. The wide usage of these gear units by leading names around the globe bears testimony to their quality and reliability. Made at Greaves ISO 9000 certified units, that is only to be expected. Greaves range of power transmission products includes Worm and Helical Gearboxes, Bevel Gears, Custom Built and Special Gears for Coal mills, Windmills, Rolling Mills, Cooling Towers and a host of other applications that cater to almost every industry.

Greaves also supplies a range of Fixed and Variable Speed Fluid Couplings manufactured at Pembril’s ISO 9001 certified manufacturing unit, Greaves EC Variable Speed drives and Gear couplings. Greaves is truly a one-stop shop for all power transmission systems.

3.4 GEAR BOX

Gears are used in tons of mechanical devices. They do several important jobs, but most important, they provide a gear reduction in motorized equipment. This is key because, often, a small motor spinning very fast can provide enough power for a device, but not enough torque. For instance, an electric screwdriver has a very large gear reduction because it needs lots of torque to turn screws, but the motor only produces a small amount of torque at a high speed. With a gear reduction, the output speed can be reduced while the torque is increased. Greaves has a wide variety of Gears. The different types of Gears available are Worm Gears, Helical Gears & Bevel Gears.

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3.4.1 WORM GEAR

Worm Gear Box

Enlarged View of Worm Gear

Worm gears are used when large gear reductions are needed. It is common for worm gears to have reductions of 20:1, and even up to 300:1 or greater. Many worm gears have an interesting property that no other gear set has: the worm can easily turn the gear, but the gear cannot turn the worm. This is because the angle on the worm is so shallow that when the gear tries to spin it, the friction between the gear and the worm holds the worm in place.

Limitations: Low efficiency. The worm drives the drive gear primarily with slipping motion, thus there are high friction losses.

Advantages: Will tolerate large loads and high-speed ratios. Meshes are self locking (which can be either an advantage or a disadvantage).

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3.4.2 HELICAL GEARS

Enlarged View of Helical Gear Helical Gear Box

The teeth on helical gears are cut at an angle to the face of the gear. When two teeth on a helical gear system engage, the contact starts at one end of the tooth and gradually spreads as the gears rotate, until the two teeth are in full engagement. This gradual engagement makes helical gears operate much more smoothly and quietly than spur gears. Helical gears may be used to mesh two shafts that are not parallel, although they are still primarily use in parallel shaft applications. A special application in which helical gears are used is a crossed gear mesh, in which the two shafts are perpendicular to each other.

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Limitations: Helical gears have the major disadvantage that they are expensive and much more difficult to find Helical gears are also slightly less efficient than a spur gear of the same size .

Advantages: Helical gears can be used on non-parallel and even perpindicular shafts, and can carry higher loads than can spur gears.

3.4.3 BEVEL GEAR

Bevel Gear

BoxEnlarged View of Bevel Gear

Bevel gears are useful when the direction of a shaft's rotation needs to be changed. They are usually mounted on shafts that are 90 degrees apart, but can be designed to work at other angles as well.

The teeth on bevel gears can be straight, spiral or hypoid. Straight bevel gear teeth actually have the same problem as straight spur gear teeth as each tooth engages, it impacts the corresponding tooth all at once. Just like with spur gears, the

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solution to this problem is to curve the gear teeth. These spiral teeth engage just like helical teeth: the contact starts at one end of the gear and progressively spreads across the whole tooth.

On straight and spiral bevel gears, the shafts must be perpendicular to each other, but they must also be in the same plane. If you were to extend the two shafts past the gears, they would intersect. The hypoid gear, on the other hand, can engage with the axes in different planes.

Limitations: Limited availability. Cannot be used for parallel shafts. Can become noisy at high speeds.

Advantages: Excellent choice for intersecting shaft systems.

APPLICATION – (Worm Gears , Helical Gears , & Bevel Gears) Agitators, Conveyors , Crushers , Cranes , Elevators , Feeders , Oil Industry , Paper Mills , Sugar Industry , Textile Industry , Cooling Towers.

3.5 FLUID COUPLING

FLUID COUPLING

Fluid Coupling is used for the transmission of torque through fluid flow. The torque developed by the electric motor is converted by the primary side of the coupling that is directly connected to the motor shaft, into kinetic energy. It is then converted back into mechanical energy by the secondary side of the coupling. No wear occurs; no mechanical contact of the power transmitting parts occurs. The fluid coupling behaves according to

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the propeller law. The torque transmitted increases with the square and the power transmitted with the cube of the input speed.

There are three essential parts to a fluid coupling: the driving (input) section known as the impeller the driven (output) section known as the runner and the casing which bolts to the impeller enclosing the runner providing an oil tight reservoir. Both impeller and runner each represents half of a hollow torus with flat radial vanes. The operation of the fluid coupling requires mechanical input energy, normally provided by a standard electric motor which is connected to the impeller and casing.

Advantages

Motor soft start: standard motors of any voltage or characteristic can be started with very little load. This allows the time of the current inrush to be reduced and also for the motor to have the maximum speed and torque available for accelerating the load.

Applications : Ball Mill , Conveyor & Crushers , Fans , Pumps & Crushers.

3.6 INTRODUCTION TO BUSINESS GROUP - IV

To meet the challenges of the recent increase in construction activity, Greaves manufactures a complete range of concrete and road making equipment like Concrete Mixing and Batching plants, Transit mixers, Concrete pumps, etc. in technical collaboration with leading construction equipment manufacturer, CIFA SPA of Italy.

In collaboration with yet another world leader, Bomag GmbH of Germany, Greaves manufactures compactors for Soil compaction and Asphalt tandem rollers. Greaves also markets the entire range of CIFA and Bomag machines which include Shot Crete pump, Tunnel forms moulds, etc. The Bomag range also includes tampers, Plate compactors, Pneumatic tyre roller, Recyclers and Refuge compactors amongst many other machines. These are mainly used for Power Plant construction of roads, bridges, expressways, and highways. To help in India’s quest for self-sufficiency in oil and for a host

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of mining requirements, Greaves manufactures an entire range of trustworthy rock rollers bits. For the demanding non-ferrous foundry industry, Greaves provides the Greaves Morganite range of silicon carbide crucibles that are better resistant to thermal shocks, erosion by molten metal and chemical attack by flux and slag.

Greaves also represents Sheffield, U.K. internationally renowned manufacturer of rolls for cold rolling and hot rolling steel mills. Further, Greaves represents Special Metal, U.K. for nickel alloys used in process and chemical industries, U.K. for titanium alloys used in petro-chemical industries.

3.7 TRANSIT MIXER

TRANSIT MIXER

Transit Mixer has a rotating drum mounted on a Truck. The drum keeps on rotating continuously at a steady speed so that the concrete mainly Ready Mixed Concrete brought from the batching plant does not settle inside. Also various admixtures are added in the concrete so that setting of the concrete does not take place. Transit mixers are mainly used when concreting on large scale has to be done & concrete is brought from the batching plant.

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3.8 CONCRETE PUMP

CONCRETE PUMP

Concrete pump is used mainly for transfer of concrete. When concreting has to be done on heights or for longer spans of slabs Concrete pumps are used. It can be connected to the transit mixer which will provide the input & concrete can be transferred by connecting pipes to the concrete pump. Mainly when continuous concreting work has to be done for flat slabs concreting by means of concrete pump is carried out. It proves to be a costly option compared to the conventional means of concreting as the cost of the equipment itself is very high & is used where speed & more quantity of concreting is to be done.3.9 TANDEM ROLLER

TANDEM ROLLER

In a Tandem Roller the front wheel is used for steering , while the two rear wheels are used for driving the unit. It has three drums & three axles. It is mainly used for compacting granular soils , such as sand , gravel , & crushed stone , & they are also effective in smoothing surfaces of soils that have been compacted by tamping rollers. Also they are effective in compacting the top layer of asphalt & bitumen in roads. The movement of such rollers for compaction is known as “Pass”.

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3.10 VIBRATORY COMPACTORS

VIBRATORY COMPACTOR

Certain types of soils such as sand , gravel , & relatively large stones respond quite well to compaction produced by a combination of pressure & vibration. When these materials are vibrated , the particles shift their positions & nestle more closely with adjacent particles to increase the density of the mass. The manually operated vibratory compactor by BOMAG is used for consolidating soils & asphalt in locations where larger units are not practical. These gasoline or diesel – powered units are rated by centrifugal force , exciter revolutions per minute , depth of vibration penetration , feet per minute travel , & area of coverage per hour.

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2 Greaves Cotton & 3 Product Profile

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