Amalgamations

Group
Engine components, batteries, clutches

Address Amalgamations Group is one of India's largest light

engineering groups consisting of 43 companies. Its
Amalgamations Private Limited operations include automotive components manufacturing,
861/862, Anna Salai
Chennai- 600 002 trading and distribution, services and plantations. The
Tamil Nadu automotive business comprises nine automotive
India components companies including diesel engines, forgings,
fuel-injection systems, gears, metal cutting tools, paints,
Tel: +91 44 2858 4918 pistons, transmissions and tyre retreading.
Fax: +91 44 2858 3179
Internet: In 1938, Amalgamations was established as a holding company for six companies,
http://www.amalgamationsgroup.com which have grown over time to 43 companies.
Its automotive supplier business consists of nine companies:
Senior Officers • Simpsons & Co Ltd: formed in 1840 to manufacture coaches, carriages,
motorcars, steam passenger buses, railway coaches and public service
A. Sivasailam, Chairman vehicles. In 1955, the company commenced production of diesel engines
A. Krishnamurthy, Vice Chairman through an alliance with Perkins, UK, and it now supplies diesel engine
K Sankaran, Executive Director, products ranging from 20 to 110 bhp. The company has two manufacturing
Operations facilities in Chennai (Tamil Nadu). The company manufactures engines
R Krishnan, Executive Director, Finance meeting Bharat Stage II norms for on-highway applications, Bharat Stage III,
& Marketing US Tier I and US Tier II norms for tractor applications.

Products • TAFE- Engineering Plastics Division: manufactures high precision tools and
custom-moulded engineering plastics from its two facilities in Bangalore
Amalgamations Repco : (Karnataka) and Maraimalainagar (Tamil Nadu). TAFE Engineering Plastics
Clutch driven plates, clutch cover Division supplies to domestic clients such as General Motors, HM Mitsubishi,
assemblies, clutch carbon release bearing Iveco, Kyoto, Tata Johnson Controls, Lear, Tata Toyo Radiators, Toyota
assembly Kirloskar Motors and Visteon.
India Pistons: • India Pistons Ltd: started operations in 1949 as India's first automotive
Cylinder liners, pins, pistons, rings ancillary manufacturing unit, in technical and financial collaboration with
Associated Engineering Plc (UK), a part of Federal Mogul. The company
IP Rings: manufactures cylinder liners, pins, pistons and rings. The company has three
Bevel gears, grey cast iron steel rings, manufacturing units located around Chennai (Tamil Nadu). IP Power Cylinder
nifflex expander based three piece oil Systems Ltd, a wholly-owned subsidiary of India Pistons, was established in
rings, nodular iron steel rings, pinions, 1994 for the production of cylinder liners.
special alloy steel rings, synchrocones
• IP Rings: supplies speciality steel piston rings and several transmission
Bimetal Bearings: components using orbital cold forming technology. The company has Ashok
non overlay plated engine bearings, Leyland, Eicher Motors, Ford, Hyundai Motors India, Mahindra & Mahindra,
overlay plated engine bearings, Maruti Udyog, Simpsons, Tata Motors and TVS Motors as its customers.
copper lead bearings,
large diameter bearings,
• Bimetal Bearings Ltd: supplies engine bearings, bushings and thrust washers
flange bearings,
to OEMs in the passenger car, HCVs, LCVs, tractors, industrial engines,
bushings,
defence and railway sectors. The company has a presence in the aftermarket
thrust washers
with its brand Bimite. Its manufacturing facilities are located at Chennai,
Coimbatore and Hosur (all three in Tamil Nadu).
Amalgamations Valeo Clutch Pvt Ltd:
Automated manual transmissions,
• Amalgamations Valeo Clutch Pvt Ltd: is a leading manufacturer of clutches in
automatic transmissions, CRC & CSC
the range from 160mm to 380mm and self-centring clutch release bearings for
(Metallic &Plastics), diaphragm clutches,
passenger cars, HCVs and tractors. The company supplies to Ford India,
dual mass flywheels, flexible flywheels,
Hyundai Motors India, Mahindra & Mahindra, Maruti Udyog, TAFE and Tata
hydraulic actuators- CMC, self adjusting
Motors.
technology clutches, self centring clutch
release bearings, solid flywheels • Shardlow India Ltd: incorporated in 1960 as a manufacturer of precision
forgings for crankshafts, axle beams, stub axles, gear blanks and steering
India Pistons Repco Ltd: Flywheel starter arms. The company operates two forging units one each in Chennai and Hosur
rings gears (both Tamil Nadu). Shardlow India supplies to Ashok Leyland, Kirloskar Oil
Engines, Simpsons, TAFE, Tata Motors and defence establishments.
Plants
• Amalgamations Repco Ltd: Incorporated in 1967, Amalgamations Repco
India (35) manufactures clutch and brake systems.

Sales • India Pistons Repco Ltd: Incorporated in 1962 for the production of flywheel
starter ring gears. The company has a total annual production capacity of 1.2m
Group: INR55bn (€869m, 31 March 2008) flywheel starter ring gears with two manufacturing facilities near Chennai
(Tamil Nadu). It was merged into Amalgamations Repco in 2005. The
Employees company supplies to Ashok Leland, Hyundai India and Tata Cummins.

c. 13,000 (2008) The Group is a conglomerate having 43 companies with 34 manufacturing facilities
and 12,500 employees. Amalgamations Group's major customers include all major
OEMs in the country.

Recent Developments
Corporate strategy
In recent years, Amalgamations has extended its alliances with new suppliers to
gain access to technology and customers while offering its extensive manufacturing
and supply expertise in the local market. The Group has developed a strong
relationship with almost all the OEMs in the country, facilitating the global one
ones to speed up their localisation programs. The Group is focusing on exports and
aftermarket to improve margins.

Acquisitions
• In July 2005, Amalgamations Repco merged group company India Pistons
Repco with itself.

Joint-ventures
• In December 2007, India Pistons entered into a joint-venture agreement with
Mahle, to make pistons for Euro IV compliant diesel and petrol engines. India
Pistons has hived off its facility at Maraimalai Nagar in favour of the new
entity where the two partners hold equal equity.
• IP Pins & Liners Ltd is a joint-venture within India Pistons Limited set up in
1988 at Maraimalainagar (Tamil Nadu, India) for the production of precision
heat treated and machined steel parts for the automotive industry.
• IP Rings Ltd is a joint-venture between the Amalgamations Group and Nippon
Piston Ring Company Ltd (Japan).
• IP Rings Ltd has a technical tie-up with MIBA (Austria) for carbon friction
lining of synchrocones and other synchronizer components.
• Bimetal Bearings is a joint-venture between Amalgamations Group, Repco
(Australia) and Clevite Corporation (USA).
• Bimetal Bearings shares an intellectual property and technology transfer
agreement with Daido Metal Corporation (Japan) for the production of a range
of high performance and Euro III compliant lead-free materials,
manufacturing process upgradation and introduction of contemporary
overplay plating process.
• Amalgamations Valeo is a joint-venture between Amalgamations Group and
Valeo (France).
• Shardlow India was formed as a joint-venture between the Amalgamations
Group and Ambrose Shardlow (UK).
• India Pistons Repco was formed as a joint-venture between the
Amalgamations Group and Repco (Australia).

Contracts
• India Pistons Repco is the single-source supplier of flywheel starter ring gears
to Ashok Leyland, Hyundai Motors India and Tata Cummins.

Infrastructure
• TAFE Engineering Plastics Division has an in-house tool room facility with
NC milling machines and EDMs for production of moulds suitable for
 injection moulding machines upto 3,200 tonnes. Additionally, the division has
a moulding shop with machines ranging from 50 tonnes to 3200 tonnes.
• Bimetal Bearings’ Coimbatore (Tamil Nadu, India) based facility specialises
in the the production of non overlay plated engine bearings, while Hosur
(Tamil Nadu, India) based plant specialises in overlay plated, copper-lead
bearings, large diameter and flange bearings. The Thoraipakkam (Chennai)
based facility manufactures bushings and thrust washers while Sembiam
(Chennai) based facility houses alloy powder facility, aluminium alloy
cladding line and sintering lines for the production of copper lead strips.
• Amalgamations Repco has the capability to manufacture clutch driven plates
from 160mm to 412mm. The company has a CAD centre and computer
controlled quality rigs to meet precise standards.
• India Pistons Repco is equipped for the production of ring gears with
diameters in the range of 190mm to 440mm.

Certifications
• Simpsons & Co. has been accredited with ISO/TS 16949:2002 and ISO
14001:1996 status.
• TAFE Engineering Plastics Division has been accredited with TS 16949, ISO
9001, ISO 14001 and UL status.
• Each of the three manufacturing units operated by India Pistons in
individually compliant with TS 16949-2002 and ISO 14000 requirements.
• IP Rings is certified for ISO/TS 16949:2002 and EMS 14001 requirements.
• All facilities operated by Bimetal Bearings are QS 9000 certified. The
Coimbatore plant is TS 16949 certified.
• Amalgamations Valeo Clutch Pvt Ltd has been acreditied with ISO/TS 16949
and ISO 14001 status.
• Shardlow India Ltd is ISO 9001:2000 certified.
• Amalgamations Repco’s Quality Management System is ISO 9001:2000
certified while its Enviroment Management System is ISO 14001:2004
certified.

Financial Overview During the financial year ended 31 March 2008,

Amalgamations Group recorded sales of INR55bn (€869m, 31 March 2008).

Outlook
The Amalgamations Group has an extensive product portfolio and strong
technology partners which help the company in securing supply contracts especially
when OEMs use a follow through source approach. Furthermore, Amalgamations
will benefit from the new OEMs who are in various stages of launching their
vehicle programs in India.