Avasarala extends automated assembly lines to carmakers

Avasarala Technologies will soon begin providing automated main assembly lines for carmakers. The Bangalore-based automation solution company has been making automated feeder and main assembly lines for four-wheeler and two-wheeler makers respectively.

This new foray will call for better product capabilities and talks are on with potential global allies. “We are looking at companies in the US, EU and southeast Asia for either technology transfer or equity participation,” said managing director, TT Mani.

Avasarala is also setting up a Rs 20 crore facility in Somanahalli which is not too far away from one of its units in Bangalore. This will have four modules including one dedicated to an automated main assembly line for cars. The company has three facilities in Bangalore, two in Pondicherry and one in Mysore. It recently opened its first overseas office in Chicago to support its export businesses. Avasarala exports customised machines like conveyors and automation systems to the US, UK and Australia.

Mani said share of exports to turnover was less than ten percent and tipped to cross 25 percent in three years with existing overseas customers planning to increase their outsourcing. According to him, the company’s core strength lies in its engineering capability and innovative processes which assure solid customised solutions. It recently re-jigged its verticals and defined a distinct focus on each segment is has been operating in.

FOUR VERTICALS

Avasarala has four business verticals: nuclear power, space, factory automation and outsourced manufacturing. For the first, it offers critical reactor systems for nuclear power plants besides taking up their installation and refurbishment. Under the space division, it makes heat pipes for satellites, offers special coating services, develops systems for satellites and launch vehicles, installation and relocation services. In factory automation, it supports automation needs of automotive and consumer goods manufacturing segments.

The company makes medical equipment, engineering subassemblies and specialty metals like tungsten and molybdenum. At present, share of revenue from automotive business is less than 20 percent of turnover and targeted to increase to 25 percent in two years. During 2005-06, the company reported turnover of Rs 140 crore which could touch Rs 300 crore in 2007-08.

##### Though it has largely catered to large companies, Avasarala has standardised modules like flexible rollers and free flow conveyors for small and medium enterprises. As Mani said, under its redefined approach, it will focus on SMEs to offer low cost automation and other supportive services. “We provide appropriate solutions while looking at constraints like investments,” said executive director, BM Renukaprasad.

The company feels that it is better to participate from the concept stage itself for providing solutions. It makes most modules and subassemblies including software inhouse and this gives enough flexibility and speed in executing projects, he added.

KEY PROJECTS

Some of Avasarala’s projects include designing, developing and commissioning an assembly line for an AC compressor maker. It has also relocated four plants in Malaysia and Singapore and refurbished Madras Atomic Power System. For Suzuki Powertrain, Avasarala recently supplied free flow conveyor system to assemble diesel engines with pneumatic stoppers, pop-up units, pallets with RFID units, cross transfer units, end lifters along with PLC and electrical control panels.

This line handles cylinder blocks, upper/lower cylinder heads and finally the total engine. The equipment uses pallets moving along a free flow chain conveyor to assemble various parts to short/long blocks and the cylinder heads. The system also facilitates final dressing of the engine. The components are placed on the pallet which is moved on the chain. There are pneumatic stoppers provided at each station, which operates automatically when the operator presses the push button at each station.

For Tata Motors, Avasarala offered free flow conveyors for pallet transfer with seats of passenger cars. The system, being a free flow conveyor, handles car seats on pallets. Seats come from vendors and arranged in two tiers inside the truck. They are pushed into the receiving conveyor manually from trucks. The pallet with the seat is transferred from receiving area to assembly area without operator intervention.

Avasarala has also completed projects for Hyundai Motor India to extend the engine assembly line during shutdown without affecting production. Interestingly it has designed 65 varieties of stillages for Ford India which helped reduce inventory at its Chennai plant. Similar solutions were given to Mahindra & Mahindra for its Scorpio project. Avarsala caters to a host of bearing manufacturers etc and big OEMs and vendors. Recently former president of Hyundai Motor India, BVR Subbu joined its board.

T MURRALI