Forging industry acts as a key link between critical manufacturing segments. Today, deployment of cutting-edge technology is crucial for forging companies to adhere to the clients' changing quality requirements. Moreover, as each industry moves into its niche zones, it is important to provide a customized forging solution that is dedicatedly blended to meet the unique criteria. Not to mention, with increasing price of the raw materials, cost remains a daunting challenge for the industry. In this complex environment, it is imperative to opt for an experienced and customercentric forging entity that excels in all the three domains of technology, quality and price.
With more than a decade of experience in the forging domain, Sunstar Precision Forge has been diligently meeting all the requirements of its clients with complete assurance. The firm excels in supplying only the finest quality forging service that meets the niche application. Moreover, the team specializes in high-volume production runs, with short lead time for developmentat ultra-competitive prices. Owing to the firm's dedication for quality and customer centricity, it has now evolved as one of the largest producers of shifter forks & companion flanges in the country.
“Today, the major expectations of all customers are not only parts but technology service providers along with customised one stop solutions for all automotive assemblies", says S. S. Verma, CEO at Sunstar Precision Forge.
“Sunstar Precision Forge, we have majorly invested in technology improvements to work on cold & warm forging projects covering all areas of the forging industry. Today, we have an integrated facility spread across 20 acres for forging & precision machining providing customised solutions of precision machining , broaching , induction hardening & various metal finishing like coating, plating etc as per customer needs".
TQM Practices Assuring Quality
Sunstar Precision Forge has been stringent on the quality of the products that they deliver to the clients. “We are dedicated to fulfilling customer needs and ensuring their satisfaction by delivering high-quality items on schedule while also implementing and improving the quality management system", states Verma. Owing to this effort of the firm, it is now a EMS 14001: 2015 ISO 9001 : 2015 and IATF 16949 : 2016 certified company.
Since inception, Sunstar has worked on two unique levels of quality policy and employee training to be on par with the requirements of its clients. To start with quality policy, the firm has now equipped a comprehensive range of advanced measuring & inspection equipment in its total operations including the shopfloor, Metallurgy Lab &Standard room. Today, each product manufactured at Sunstar is produced adhering to the global TQMpractices.
“Delivering the glob¬al standards of quality within competitive prices has always been our topmost priority. With advanced machinery and inspection equipment on the line, we produce only best-in-class products", points Verma. Along with equipment, Sunstar has also been diligent about continually upskilling the skills with the latest
industry standards. “We are working on continuous growth & development of all employees along with organisation growth, so that technology improvement is a continuous journey with best global standards of manufacturing practices", mentions Verma.
The continuous training and knowledge process of Sun¬star, has helped to develop the best design & engineering teams with best & experienced talents from all across the forging & machining industry.
State-of-the-art Infrastructure
The infrastructure of Sunstar has been its X-factor in the forging industry of India. Starting from design to development and inspection, the firm utilises the most advanced equipment and machinery, allowing the firm to attain a superior quality product.
Beginning with the design phase, the company develops its dies utilising cutting-edge technologies, such as DeForm 3D v10. The tool and die manufacturing plant is also outfit¬ ted with high-speed milling equipment from DMG and other cutting-edge equipment including CNC wire cut, CNC EDM machines, CNC engraving, Plano miller, and more, enabling it to create forging dies of the highest calibre with the greatest accuracy. The company offers a high degree of technical sup-port using CAD, CAM, and PRO-E.
Moreover, Sunstar also has a total of seven press lines & are working on enhancement of capacity by adding 2 to 3 more press lines. The team is also working on robotic operation on presses by implementing advanced technology in production lines. “Our machine shop is equipped with German & Japanese CNC turning centres, HMCs, VMCs , Vertical Broaching Machines, High, Low & medium frequency induction hard¬ening machines along with metal finish coating facility for all one stop customised needs", shares Verma.
The company also has a well-equipped metallurgical laboratory with a mobile spectrometer, programmable microvickers, hardness tester, eddy current sorter, tensile strength testing machine, image analyzer with an updated microscope, and other internal facilities are used to inspect both raw materials and finished components. For dimensional validation of fixtures, gauges, machined components, and many more, CMM from Zeiss is used.
Environmental Policies
As an environmentally conscious responsible entity, Sunstar walks an extra mile to prevent pollution, through continual improvement in its environmental performance and its demonstration.
To achieve the same, it has always put its best foot forward towards sustainable direction. As a result of its efforts, Sunstar now complies with applicable EMS legislation and other requirements. Furthermore, it has institutionalised effective waste management through recycling and reuse of materials as far as possible while ensuring to eliminate, minimize and control its environmental parameters. The team at Sunstar is also dedicatedly trained to optimize the utilization of natural resources, in particular fuels, energy and water.
“Through ongoing training, we make sure to increase the environmental knowledge and skills of our staff members and essential subcontractors in order to ensure sound environ¬mental management is everyone's duty", points Verma.
Anooj Dharam Garg, MD
Climbing the Growth Ladder
Starting its operations in 2009, Sunstar has witnessed a massive year on year growth. The growth has been both in the domains of geographical expansion and customer addition. Today, Sunstar has all major Domestic & overseas OEM & Tier 1 Customers on board. In terms of geography, it is now supplying to all leading global players in the US, Mexico, Brazil, UK, Italy, Germany, Sweden & China.
“Our company is located in the best industrial township of Greater Noida at a 20 acre plot with best support infrastructure to cater all customers logistic needs. We believe in investing into future upcoming technologies and collaborations if needed by any OE customer as we have opportunity to expand", marks Verma.
“With an average production of around 24 million vehicles annually and an employer of over 29 million people (direct and indirect employment), the automotive sector in India is one of the largest in the world. With this growth, we are also seeing huge multiple growth for us in next 3-5 years ”, he concludes.
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