Next Generation Clamping Technology to rule the

manufacturing Industry

WARM WELCOME FOR A BRIEF INTRO

Kaizen.tools@gmail.com +91 9008133001
www.emergeindiafoundation.com
Innovative Next Generation Clamping system –
Technological Marvel now in India also

No Matter – What latest Finishing & CNC M/C’s you have –

it matters nothing in the absence of advanced tool / Work
holding technology
 Kaizen tools corporation

 Promoter Back ground

 Products – Specialty Hydraulic work holding
devices (Expansion mandrels ,Chucks & tool
holders)
 Services – Lean & six sigma consultancy –
Quality management
 Inventions ,Patents & copy rights
 Kaizen tools corporation – What is
this Patent & Technology all about ?

 Chemical technology of Hydraulic medium

 Metallurgy & Treatment Processes

 Speciality rare alloy – Expands & Springs back

like rubber – with Micron accuracy & Hardness

 Managing Torque Vs Clamping Pressure

 Miniature Hydraulic Power packs

 Pascal's law of Hydraulics

 Modulus of Elasticity

 Impossible for Copy cats

Kaizen tools corporation
 Kaizen tools corporation - Promoter
 Promoter Ramesh, a mechanical engineer having 35 yrs
of sound technical back ground in all fields of engineering
manufacturing, specially in Automotive & components .

 Lean & Six Sigma Black belt

 Appreciated by beloved Late

Dr. APJ. Abdul kalam for Patents & Inventions

 Worked at senior management positions at following

originations and running own Industry
 Sundram fasteners – Hosur – Tool room In-charge – 20 yrs

 Shetron group company – Plant General manager

 National Panasonic group company – AGM – Country Corporate

business Development and Quality Assurance

 Own Manufacturing Industry – Kaizen tools corporation since 2001

Kaizen tools corporation
 Kaizen tools corporation – Products

 Design & manufacture In the field of Hydraulic

work holding devices complete ranges

 Specialty Hydraulic Expansion Mandrels & chucks

 Hydraulic Inspection Fixtures & rotary assemblies
 Profile clamping mandrels & chucks
 Hydraulic Mutli components clamping systems
 Hydraulic Tool – holders
 Hydro nuts .

 Design & manufacture of jigs ,

Fixtures, welding fixtures ,
Inspection fixtures, gauges and SPMS

 Manufacturing & Job work on high precision

components & tooling elements
 Hydraulic Devices – The dear of
Customer complaints resolving - SLA
New product / Process Development
R&D
Production Engineering
Methods & Re Engineering
QA & QC
Micron accuracy requirement specifications
Cp & Cpk issues
Resolving R & R issues
Minimise or Eliminate CMM occupancy
Low cost - Line Inspection in par with standards room
Versatility by low /semi skilled man power
Poka – Yoke (Mistake Proof )
Greater EBITDA
Turn around Time
Value addition & Through put
Kaizen tools corporation – Hydraulic Devices

• GEAR PCD CLAMPING HYDRO- GRIP

CHUCKS , SPLINE CHUCKS , PROFILE
EXPANSION CHUCKS ,MASTER
GEARS CHUCKS
,PROCESS PERFORMANCE IMPROVEMENT
CHUCKS,CNC CHUCKS AND MULTI
COMPONENTS CLAMPING CHUCKS.

• APPLICATION AND ADVANTAGE :

• Used in to areas where ever accurate

centering, repeatability and positive
clamping are essential .gear teeth/profile
grinding and ID,OD and face grinding of
gears & pulleys. concentricity and
repeatability with in .003mm & .002 mm
T.I.R.we can adopt manual / auto
actuator screws where ever it is
convenient for usage. (Special cases .001
mm geometrical tolerances achievable)

• TYPE OF INDUSTRY USED :

• Precision gears manufacturing Industry,
mastergears, hobs manufacturers ,auto
components and OE manufacturers
,Transmission & pumps industry
,.machined gears manufacturers, forging
and powder metallurgy Industries .CNC
grinders etc.
 Why It is Revolution in Clamping System ?

• Zero Defect Manufacturing

• Multiple components in a single set up
• Cp & CPk up
• Cycle time Improvements
• Cost reductions & ROI
• 6 Sigma level of Quality
• Patented & Technology Protected
• Poka – Yoke (mistake Proof)
• Less or No moving parts – No error
• Extra Long life
• Rs 6000/Cr Indian Market
• No Competition – Blue whale Strategy
• Impossible for Copy cats & Reverse engineering
• Unlimited Varieties
• Name a Precision manufacturing not applicable
• Mass Production in Microns no more a buzz word
Kaizen tools corporation – Hydraulic Devices

• HYDRAULIC EXPANSION INSPECTION

MANDRELS ,
DYNAMIC BALANCING MANDRELS A
ND FIXTURES INBUILT WITH HYDRO-
GRIP MANDRELS.
• APPLICATION AND ADVANTAGE :
• used in to areas where ever accurate
centering, repeatability and positive
clamping are essential .gear
teeth/profile grinding and ID,OD and
face grinding of gears. concentricity
and repeatability with in .003mm /
.002 mm T.I.R.most commonly held in
between centers while
inspection. (Special cases possible
with in .001 mm )
• TYPE OF INDUSTRY USED :
• Final inspection & standards room and
commercial toolrooms, hobs ,master
gears industry, transmission & gears
industry .forging and powder
metallurgy industries bearings
industry
Kaizen tools corporation – Hydraulic Devices

• GEAR GRINDING (SINGLE & MULTI

COMPONENTS ),
CNC AND SHAVING MANDRELS

• APPLICATION AND ADVANTAGE :

• Used in to areas where ever accurate
centering, repeatability and positive
clamping are essential .gear
teeth/profile grinding and ID,OD and
face grinding of gears &
pulleys. Concentricity and
repeatability with in .003mm / .002
mm T.I.R. we can adopt manual / auto
actuator screws where ever it is
convenient for usage. (Special cases
possible to maintain with in .001mm)
• TYPE OF INDUSTRY USED :
• Precision gears manufacturing
industry, master gears,hobs
manufacturers. Auto components and
Automotive OE M manufacturers.
Transmission & pumps Industry.
machined gears manufacturers,
forging and powder metallurgy
industries.CNC grinders etc
Kaizen tools corporation – Hydraulic Devices

• GEAR PCD GEAR GRINDING

HYDRAULIC CHUCKS (SINGLE &
MULTI COMPONENTS ) AND BLIND
HOLES CLAMPING CHUCKS FOR
CONVENTIONAL AND CNC MACHINES
APPLICATIONS.

• APPLICATION AND ADVANTAGE :

• Plain & taper mandrels are replaced
with hydro grip mandrels due to true ref
possibility on entire contact surface .
More accurate ,positive and exact
centering quick and secured clamping
.more durable. Concentricity and
repeatability with in .003mm / .002
mm T.I.R.most commonly held in
between centers while inspection High
light is the usage in case of blind holes
as ref area for inspection or for any
operations like machining or grinding.
(Special cases with in .001 mm)

• TYPE OF INDUSTRY USED :

• Conventional or CNC m/c shops of any
common industry standards room
,forging and powder metallurgy
Industries.
Kaizen tools corporation – Hydraulic Devices

• HYDRAULIC CHUCKS FOR SINGLE &

MULTI COMPONENTS MACHINING &
GRINDING FOR
CONVENTIONAL & CNC APPLICATIONS

• Application and Advantage :

• Used in to areas where ever accurate
centering, repeatability and positive clamping
are essential on batch production .Batches
volume can be large or small. mostly CNC
turning and ID,OD grinding of gear blanks
,bushes ,bearings ,sleeves ,valve seats and
valve guides. Mostly 2 or more identical parts
with in tolerance are clamped with single
mandrel or chuck to achieve repeatability,
productivity and reproducibility are essential.
Concentricity and repeatability with in
.003mm / .002 mm T.I.R. Special cases
possible with in .001 mm .

• Type of Industry used :

• Conventional or CNC m/c shops ,auto
components Industry, bearings and
transmission parts and powder metallurgy
industries and similar mass production
Industries like CNC turners or cylindrical
grinders.
Kaizen tools corporation – Hydraulic Devices

• GEAR PCD CLAMPING HYDROGRIP MANDRELS

(SINGLE & MULTI COMPONENT SYSTEMS ) ,
SPECIALTY REQUIREMENTS LIKE BLIND HOLE
MANDRELS ,SPLINE MANDRELS ,CYCLE TIME
IMPROVEMENT MANDRELS AND CP & CPK
IMPROVEMENT MANDRELS
.
APPLICATION AND ADVANTAGE
:
Used in to areas where ever accurate centering,
repeatability and positive clamping are essential on
mass production with geometrical tolerances
requirements with in .003mm or .002 mmT.I.R
.Mostly CNC turning and cylindrical grinding of parts
exclusively need for more reference surfaces to
achieve Cp & Cpk . Mountings can be according to
spindle/shanks or flange type so that the
components can be located and clamped at at most
convenience to reduce no of setting as well as
minimize cycle time for CNC machining & grinding .
Since there are no moving parts unlike chucks ,there
is no wear and no loss of geometrical tolerances .No
limiting factors for mounting, clamping or actuators
location.
TYPE OF
INDUSTRY
Conventional or CNC m/c shops ,auto components
industry, bearings and transmission parts and
powder metallurgy industries and similar mass
production industries like CNC turners or cylindrical
grinders. Aero space & aircraft industries. machine
tool industries.
Kaizen tools corporation – Hydraulic Devices
 Kaizen tools corporation – Services
 Being a Lean & six sigma Black belt – supporting
organizations as a consultant in the following domains.

 Inculcate culture of Quality by forming Lean & sigma

teams and leading them to achieve organizational goals .

 Kaizen Initiatives ,
Value additions & eliminating variations

 Independently taking up complex quality Issues ,

 productivity Improvements (Multi components systems ) ,
 Cost reductions, Process performance Improvements ,
 Smooth flow from Design to production shop ,
 cycle time improvements ,
 FMEA ,
 Issues related to service quality agreements (SLA ).

 Quality control to Quality Assurance

Kaizen tools corporation – Inventions
– Patents – Copy rights
Patents Ref
Kaizen tools corporation – Achievements
 We feel delighted to share with you that we are the only
Hydraulic work holding devices manufacturing company In
India who felt qualified to enter in to patenting with our
Innovative & proven designs .

 when ever there is a complex requirement,

we are Invited as a first person. Hence, we
started more focusing on super specialty
requirements and gained experience for proven results. you
name any design , we have made that already In hydraulic
work holdings

 We are the only one who imports & uses super specialty
material “Nitinol “ for specialty expansion mandrels in India.

 Saved Rs 100/- Cr for National Panasonic group company by

successfully executing an Individual six sigma black belt
project.


Kaizen tools corporation – Criteria's of your
requirement – From our vast experience
 Nitinol is the only recommended material – Whose ultimate
tensile strength is 80+ Gpa, where as material used by other
manufacturer’s is below 20 Gpa.
 Indigenous material will burst / shoot out like a bullet .Life
risk . Major safety hazard . You may say, it has not happened to
us. No:1 you are lucky . No 2 .It is happening and covered up.
 Have you ever asked liability cost? . We sign cost of risk, for
our export orders.
 Nitinol landed cost with Import duty is Rs 50,000/- per kg
for small qty .
 We alone holistically follow Vacuum heat treatment + Sub
zero + shrink fitting + Vacuum brazing + stage vice stress
relieving + finally PVD Titanium nitride coating, for which I
have to make multiple visits to mumbai .
 It takes the manufacturing cost 10 ordinary mandrel for
making one specialty mandrel.
 If you don’t ask questions ,mandrel manufacturer will not
reveal voluntarily.
 Hence MOQ need to be considered
 Kaizen tools corporation – Some questions
which you would not have asked ?
 Have your ever seen in the disclosure / web sites of other
manufacturer on Hydraulic calculations , Actuating pressure ,
Clamping pressure ? Torque ? Why they have not shared ?

 Not many knows it . Most goes on trial & error.

 Many present mandrel manufactures are our ex-employees ,

good for trial and error method . Not subject matter specialists.

 Have you ever tested their jelly on Burn test as well as shore
hardness ? Because in India we are the only manufacturers of best
quality jelly (it takes life )– The market is dominated by Chinese
jelly , whose quality you will know very well.

 We take of Hydrogen de-embrittlment on our all

types of Hydraulic work holding devices – which other
manufacturers does’nt even know about such criteria's specially
castings ? Ask some one if you have doubt in my word .
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
Kaizen tools corporation – Innovations
 Next Generation Hydraulic Devices applied at

Auto OEMs Railways & Metro Rails Mfg

Starters & Motors R & D centres
Refrigeration & AC Power plant
Compressors Mfg Textile machinery Mfg
Air craft Industry Off set printing press Mfg
Defense Gen sets
CNC machine tools All Pumps Mfg
Analog Machine tools Photo copying M/Cs Mfg
SPMS Inspection Fixtures Mfg
Gauges & QA Commercial Tool - rooms
Cutting Tooling Mfg FMCG
Computer hardwares Tractors Mfg
Home appliances Agro & Farm Equipts Mfg
Automation Instruments Mfg
Auto Tiers 1 & 2 Satellite & Launch vehicles Mfg
Robotics Mfg Name any Mfg environment
Kaizen tools corporation
MILLION THANKS FOR YOUR
VALUABLE TIME –
PLEASE GO THROUGH
TRAILING DETAILED
PRESENTATION -
We will be delighted to share
our expertise on Hydraulic
work holding devices by
Licensing / Transferring our
technology