Bajaj Auto Ltd.

Productivity improvement & conversion cost reduction in Balancer Driven & Idler gear through alternate process & Yield improvement.

Bajaj Auto, Chakan plant, achieved dramatic improvement of yield and cost savings by replacing forgings with sintered parts for balancer driven and idler gears. The sintered gears were near net shape with a yield of 95% against forgings with a yield of 70%. Process steps were also reduced, resulting in cost saving. The case study presentation will elaborate the approach used as well as the study carried out to address differences in the material properties of both processes.