PRODUCTION DEPARTMENT

Clutch Plates

Clutch is a part which helps in transmitting power from engine to the gearbox for moving the
vehicle. The clutch is designed for the each model exclusive by NERO AIRFILTERS SPARE
PARTS as per the requirement of the vehicle manufacturer. The quality is tested through
latest R&D machines specially designed to test clutch plates at variable speeds and harsh
conditions so that there should be no problem after the fitment in the vehicle and driving is
safe and comfortable. The quality is so high that the durability and efficiency is comparable
to any other manufacturer in the world. Intermediate friction plate are made of high carbon
steel, and the core plates are made from aluminum, steel, high temperature resistant plastics,
or phenol resin based fiber depending on the design of the clutch. The friction material in wet
type clutch is made in three types rubber based, cork based or paper based and for dry clutch,
resin and fiber based material is used. This friction material is lined on the core plates to
generate the torque in the engine. There are different friction materials for different
applications to enhance the quality and performance of the vehicle i.e. more mileage, more
life, high pickup etc. The complete clutch is made inside the plant so that there should be no
defects at any stage; only the raw materials are bought from outside and checked at the time
of procurement. The process involved in making the clutch is so atomized with integrated
production line that there is no possibility of mistake. NERO AIRFILTERS SPARE PARTS
is producing clutch plates for vehicle starting from 50cc to 650 cc. NERO AIRFILTERS
SPARE PARTS is always working on quality and cost so that it can provide the best quality
at best price in international market. NERO AIRFILTERS SPARE PARTS the specialist in
friction material has spent almost 50 years in improving the clutch technology.
What is the function of Clutch?

In simple words the function of clutch is to move and stop the vehicle without damaging the
engine. The clutch is fitted inside the engine, to stop the power from being transmitted to
wheels clutch playas a key role. Clutch also has a major importance in smooth engaging and
disengaging of gears which ultimately stops engine from getting ruined.

MECHANISM

Transmission in automobiles is a systematically arrangement of parts connecting the engine

to the wheels. The simplest transmissions are manual transmissions, and consist of a system
of interlocking gearwheels; these wheels are arranged so that by operating a lever the driver
can choose one of several ratios of speed between the input shaft and the output shaft. These
ratios are called gears. To allow smooth shifting from one gear to another, a clutch is
provided to disengage the engine from the transmission. A clutch is a mechanism for
transmitting rotation, which can be engaged and disengaged. Clutches are useful in devices
that have two rotating shafts. In these devices, one shaft is typically driven by a motor, and
the other shaft drives another device. The clutch connects the two shafts so that they can
either be locked together and spin at the same speed or be decoupled and spin at different
speeds.

WORKING

On most 2-Wheelers, the clutch is operated by the clutch lever located on the left handle bar.
No pressure on the lever means that the Clutch plates are engaged (driving), while pulling the
lever back towards the rider will disengage the clutch plates, allowing the rider to shift gears.
These clutches are usually made up of a stack of alternating plain steel and friction plates.
one type of plate has lugs on its inner diameter that key it to the engine crankshaft, while the
other type of plate lugs on its outer diameter that key it to a basket that turns the transmission
input shaft. The plates are forced together by a set of coil springs when the clutch is engaged.

Racing Motorcycles often use slipper clutches to eliminate the effects of engine braking.

In a car the clutch is operated by the left-most pedal using Hydraulics or a cable connection
from the pedal to the clutch mechanism.
Manufacturing process of a 2 wheeler Clutch Plate
Clutch Friction Disc 2-wheeler

Two Wheeler clutch friction disc also called as friction lining is made up of a splined round
metal part plate covered with friction material (lining) .the Splines in center of the clutch disc
mash with splines on the input shaft of manual transmission. This makes the input shaft and
disc turn together. However the disc is free to slide back and forth in the shaft.

Clutch Friction Disc Cork and Paper Base

Cork base clutch is made up of Heat resistant non asbestos cork and fibers. Grooves are cut
into friction material to aid cooling and releasing Clutch disc. In 4 wheeler clutches the rivets
are used to hold the friction material to both sides of the metal body of the disc.

Paper base clutch friction disc is made up of heat-resistant cellulose based material molded
together. Cellulose is used to prolong life of the clutch and provide more torsional strength.
Paper Clutch friction disc has more life than cork base friction materials as it possess:

More heat resistant property

Low wear and tear characteristics
High endurance

At Nero Airfilters Spare Parts we make clutch as required by our customers with meeting
international standards in any design and with any friction material technology. Some of the
examples are displayed below:
Break Shoes

Clutch Shoes

DEFINITION & THEIR MECHANISM

A Device for decreasing the Speed of a moving body or for stopping its motion.

Most Brakes act on Rotating mechanical elements & absorb Kinetic Energy either
Mechanically, Hydraulically or Electrically.

Mechanical Brakes are the most common, they dissipate Kinetic Energy in form of heat
generated by Mechanical friction between a rotating metallic drum or disc & a stationary
friction element brought into contact with it by mechanical, hydraulic or Pneumatic means,
The friction elements for drum brakes may be bands or Shoes i.e. Blocks with one surface
concave.

It works on a mechanism where the drum Brake is actuated to contact with Internally
expending shoes in it, by pressure exerted on Brake Pad/ Lever directed on semi circular
brake shoe by a system of flexible Cables/ rods.

ABOUT

Standard Drum Brakes were invented in 1902 by LOUIS RENAULT. His brakes worked by
using a CAM to force apart two hinged shoes . Drum Brakes are improved in many ways
over the years , But the basic Principle remains 20th century even with the advent of Disc
Brakes in 1970s , Drum Brakes remain the standard for REAR WHEELS.

TYPES

There are several types of Brakes used today such as Mechanical Brakes ,Hydraulic Brakes
,Pneumatic Brakes, Electro-Mechanical Brakes etc. ,The Brake Used today Commonly are
Drum Brakes with Mechanical and Hydraulic Systems.

We can categorize Brake Shoes as per vehicle requirements as 2 Wheeled & 3 wheeled.
Depending upon their Friction Material properties Brake Shoes are Organic , Metallic or
Ceramic type & Depending upon their Shoes they can be classified as Aluminium casting &
fabricated shoe.

Most Generally we can categorize Brake Shoes comparing their friction material
composition as:

MK has all type of brakes shoes with High Performance meeting with International quality
standards.

At MK GROUP we have facilities & a team of R&D People to work out for good &
functionality friction material Which is Eco-Friendly. Every New Development undergo full
Property , functional & Endurance check before Production at our labs to avoid any stage
failure.

MK R&D Team is always dedicated to improve Quality of the products.

Presently MK is involved in manufacturing a wide range of Asbestos base, Asbestos Free
both in Rigid and Rubberized friction material Brake Shoes for 2Wheeled as well as
3Wheeled Vehicles.

MANUFACTURING

At MK Group we only procure Raw materials for Manufacturing Friction material and Brake
Shoe Aluminium Part / Fabricated Part, Every operation after that is being carried out in
House. The process flow for the manufacturing is detailed below:

Manufacturing Process
TESTINGS & QUALITY

MK Group has a wide range of testing equipments and team of trained personals & technical
to fulfill Customer Requirements for good quality components. Our Specialized testing
facilities include :
 Universal Testing Machine
Coeff. Of Friction Test Rig
Profile Projector
Salt Spray Chamber

With the help of these special purpose machines the simulation testing is carried out to ensure
reliability & Performance of the component produced. The Chase type Coeff. Of Friction
Test Rig can be used as per National & International Standards.

A Team of Qualified Inspectors is involved for Process inspection during manufacturing to

produce quality Products with the help of QC Tools & Techniques. In Our Labs routine
checks for finished components is Carried out to help & ensure the performance.

Brake Disk Pads

MECHANISM

The Disc Brake is a Device for slowing or stopping the rotation of a wheel. A Brake Disc
(Rotor), usually made of Cast Iron / Ceramic, is Connected to the wheel or Axle. To stop the
wheel Friction Material in form of Disc Brake pads (Mounted in a Device called Caliper) is
forced mechanically, hydraulically or electromagnetically against both sides of the disc.
Friction causes the disc & attached wheel to slow or stop.

ABOUT

Disc type Brakes began in 1890s &Ist patented in 1902, though it took another half Century
for wide adaptation.

Modern style Disc Brake first appeared on low volume in 1949 & discontinued in 1950 due
to design problem .These Brakes offer better stopping performance than comparable Drum
Brakes, including resistance to Brake Fade caused by overheating of Brake component and
are able to recover quickly from immersion.

Unlike a Drum Brake, The Disc Brake has no Self-servo effect and braking force is always
proportional to the pressure placed on the braking pedal or lever. In the beginning Disc Brake
was most popular in Sports cars, since these vehicles are most demanding about Brake
performance. Now Disc brakes has become the more common form in most passenger
vehicles, although many use the Drum Brake on the rear wheels to keep costs & weight down
as well as to simplify the provision for a parking brake.

As the front brakes perform most of the braking effort, this can be a reasonable
compromise.

TECHNICAL

The Disc Brake System Consists of:

A Brake Disc
A Brake Caliper
A Brake Pad Set

Brake Disc

Disc Brake Discs are commonly manufactured out of a material called Grey Iron
.Specification for manufacture of grey iron for various applications is as mentioned in
standards. Which dictates the correct range of Hardness, Chemical Composition, Tensile
Strength & other necessary properties for intended use.

Historically Brake Discs were manufactured throughout the world with a strong
concentration in Europe and America. During the Period 1989 to 2005, manufacturing of
Discs has migrated predominantly to China. Today almost 60% of Brake Discs and Brake
Drums are manufactured in China & exported globally.

Caliper
The Caliper is the assembly which houses the Brake Pads and Pistons. Two Type of Calipers
are there.

1. Floating calipers
2. Fixed Calipers

Fixed Type Calipers have Zero movement related to Disc, It uses one or more Pairs of
Pistons to Clamp from each side of the Disc & is more complex and Expensive than a
Floating Caliper.
A Floating Type Caliper (also called a "sliding caliper") moves with respect to the disc, along
a line parallel to the axis of rotation of the disc; a piston on one side of the disc pushes the
inner brake pad until it makes contact with the braking surface, then pulls the caliper body
with the outer brake pad so pressure is applied to both sides of the disc.

Floating caliper (single piston) designs are subject to failure due to sticking which can occur
due to dirt or corrosion if the vehicle is not operated regularly. This can cause the pad
attached to the caliper to rub on the disc when the brake is released. This can reduce fuel
effiency and cause excessive wear on the affected pad. Additional heat generated by the
constantly rubbing pad can lead to warping of the disc also.

Piston & Cylinder

The most common caliper design uses a single hydraulically actuated piston within a
cylinder; the hydraulic design also helps multiply braking force. The number of pistons in a
caliper is often referred to as the number of 'pots', so if a vehicle has 'six pot' calipers it means
that each caliper houses six pistons.

Failure can occur due to failure of the piston to retract - this is usually a consequence of not
operating the vehicle during a time that it is stored outdoors in adverse conditions. On high
mileage vehicles the piston seals may leak, which must be promptly corrected.

Brake Pad
The brake pads are designed for high friction with brake pad material embedded in the disc in
the process of bedding while wearing evenly. Although it is commonly thought that the pad
material contacts the metal of the disc to stop the car, the pads work with a very thin layer of
their own material and generate a semi-liquid friction boundary that creates the actual braking
force.

Of Course on depending properties of the material Disc wear may Vary, these are the
properties that determine material wear involved trade-offs between Performance &
longevity.

Screw
RAW MATERIALS

Screws are generally made from low to medium carbon steel wire, but other tough and
inexpensive metals may be substituted, such as stainless steel, brass, nickel alloys, or
aluminum alloy. Quality of the metal used is of utmost importance in order to avoid

The cold heading machine cuts a length of wire and makes two blows on the end, forming a
head. In the head slotting machine, the screw blanks are clamped in the grooves around the
perimeter of the wheel. A circular cutter slots the screws as the wheel revolves.

cracking. If a finish is applied to the screw, it must be of a compatible makeup. Steel may be
coated or plated with zinc, cadmium, nickel, or chromium for extra protection.

DESIGN

On a single thread screw, the lead and pitch are identical, lead is twice the pitch on a double
thread model, and three times as much on a triple thread. The pitch of a screw is the distance
between two threads (or grooves) from the same point on each thread. It is also more
commonly known as the number of threads per inch or centimeter. The lead of the screw
measures how far it is driven in for each revolution.
THE MANUFACTURING PROCESS

Machining is only used on unique designs or with screws too small to be made any other
way. The machining process is exact, but too time consuming, wasteful, and expensive. The
bulk of all screws are mass manufactured using the thread rolling method, and that is the
procedure described in further detail.

Cold heading

1 Wire is fed from a mechanical coil through a prestraightening machine. The

straightened wire flows directly into a machine that automatically cuts the wire at a
designated length and die cuts the head of the screw blank into a preprogrammed
shape. The heading machine utilizes either an open or closed die that either requires
one punch or two punches to create the screw head. The closed (or solid) die creates a
more accurate screw blank. On average, the cold heading machine produces 100 to
550 screw blanks per minute.

Thread rolling

2 Once cold headed, the screw blanks are automatically fed to the thread-cutting dies
from a vibrating hopper. The hopper guides the screw blanks down a chute to the dies,
while making sure they are in the correct feed position.
3 The blank is then cut using one of three techniques. In the reciprocating die, two flat
dies are used to cut the screw thread. One die is stationary, while the other moves in a
reciprocating manner, and the screw blank is rolled between the two. When a
centerless cylindrical die is used, the screw blank is rolled between two to three round
dies in order to create the finished thread. The final method of thread rolling is the
planetary rotary die process. It holds the screw blank stationary, while several die-
cutting machines roll around the blank.
 Threads can be cut into the blank by several methods. In the reciprocal method, the
screw blank is rolled between two dies. In the cylindrical method, it is turned in the
center of several rollers.

All three methods create higher quality screws than the machine-cut variety. This is
because the thread is not literally cut into the blank during the thread-rolling process,
rather it is impressed into the blank. Thus, no metal material is lost, and weakness in
the metal is avoided. The threads are also more precisely positioned. The more
productive of the thread-rolling techniques is by far the planetary rotary die, which
creates screws at a speed of 60 to 2,000 parts per minute.

SPEEDOMENTER

A speedometer is a device used to measure the traveling speed of a vehicle, usually for the
purpose of maintaining a sensible pace. Its development and eventual status as a standard
feature in automobiles led to the enforcement of legal speed limits, a notion that had been in
practice since the inception of horseless carriages but had gone largely ignored by the general
public. Today, no automobile is equipped without a speedometer intact; it is fixed to a
vehicle's cockpit and usually shares a housing with an odometer, which is a mechanism used
to record total distance traveled. Two basic types of automobile speedometer, mechanical and
electronic, are currently produced.

HISTORY

The concept of recording travel data is almost as old as the concept of vehicles. Early
Romans marked the wheels of their chariots and counted the revolutions, estimating distance
traveled and average daily speed. In the eleventh century, Chinese inventors came up with a
mechanism involving a gear train and a moving arm that would strike a drum after a certain
distance. Nautical speed data was recorded in the 1500s by an invention called the chip log, a
line knotted at regular intervals and weighted to drag in the water. The number of knots let
out in a set amount of time would determine the speed of the craft, hence the nautical term
"knots" still applied today.

The first patent for a rotating-shaft speed indicator was issued in 1916 to inventor Nikola
Tesla. At that time, however, speedometers had already been in production for several years.
The development of the first speedometer for cars is often credited to A. P. Warner, founder
of the Warner Electric Company. At the turn of the century, he invented a mechanism called
a cut-meter, used to measure the speed of industrial cutting tools. Realizing that the cut-meter
could be adapted to the automobile, he modified the device and set about on a large
promotional campaign to bring his speedometer to the general public. Several speed indicator
concepts were introduced by competing sources at the time, but Warner's design enjoyed
considerable success. By the end of World War I, the Warner Instrument Company
manufactured nine out of every 10 speedometers used in automobiles.

The Oldsmobile Curved Dash Runabout, released in 1901, was the first automobile line
equipped with a mechanical speedometer. Cadillac and Overland soon followed, and
speedometers began to regularly appear as a factory-installed option in new automobiles.
Speedometers in this era were difficult to read in daylight and, with no lamp in the housing,
virtually illegible at night. The drive cable in early models was attached to either the front
wheels or the back of the transmission, but the integration of the drive cable into the
transmission housing wouldn't happen for another 20 years. After that improvement was
made, the basic technical design of a speedometer would remain untouched until the advent
of the electronic speedometer in the early 1980s.
RAW MATERIALS

Materials used in the production of speedometers vary with the type of gauge and intended
application. Older mechanical models were entirely comprised of steel and other metal alloys,
but in later years about 40% of the parts for a mechanical speedometer were molded from
various plastic polymers. Newer electronic models are almost entirely made of plastics, and
design engineers continually upgrade the polymers used. For example, the case of a
speedometer's main assembly is usually made of nylon, but some manufacturers now employ
the more water-resistant polybutylene terephthalate (PBT) polyester. The worm drive and
magnet shaft are also nylon, as is the speedometer's gear train and spindles. The glass display
lens of the recent past is now made of transparent polycarbonate, a strong, flexible plastic that
is resistant to heat, moisture, and impact.

DESIGN

In a mechanical speedometer, a rotating cable is attached to a set of gears in the automobile's

transmission. This cable is directly attached to a permanent magnet in the speedometer
assembly, which spins at a rate proportional to the speed of the vehicle. As the magnet
rotates, it manipulates an aluminum ring, pulling it in the same direction as the revolving
magnetic field; the ring's movement, however, is counteracted by a spiral spring. Attached to
the aluminum ring is the pointer, which indicates the speed of the vehicle by marking the
balance between these two forces. As the vehicle slows, the magnetic force on the aluminum
ring lessens, and the spring pulls the speedometer's pointer back to zero.

Electronic speedometers are almost universally present in late-model cars. In this type of
gauge, a pulse generator (or tach generator) installed in the transmission measures the
vehicle's speed. It communicates this via electric or magnetic pulse signals, which are either
translated into an electronic read-out or used to manipulate a traditional magnetic gauge
assembly.

THE MANUFACTURING PROCESS

STEEL COMPONENTS

1 To form molten steel, iron ore is melted with coke, a carbon-rich substance that
results when coal is heated in a vacuum. Depending on the alloy, other metals such as
 aluminum, manganese, titanium, and zirconium may also be introduced. After the
steel cools, it is formed into sheets between high-pressure rollers and distributed to the
manufacturing plant. There, the individual parts may be cast into molds or pressed
and shaped from bar stock by large rolling machines.

PLASTIC COMPONENTS

2 The various plastics that arrive in an instrument manufacturing station were first
created from organic chemical compounds derived from petroleum. These polymers
are distributed in pellet form for use in the injection-molding process. To make the
small parts for a speedometer assembly, these pellets are loaded into the hopper of a
molding machine and melted. A hydraulic screw forces the plastic through a nozzle
and into a pre-cast mold, where the plastic is allowed to cool and solidify. The parts
are then gathered and transported to assembly stations.

ASSEMBLY

3 The manner of assembly and degree of human interaction depends on the quality of
speedometer. Some inexpensive speedometer systems are made to be "disposable,"
meaning that the instruments are not built for easy disassembly or repair. In this case,
the hardware is fastened using a process called riveting, in which a headed pin is
inserted and blunted on the other end, forming a permanent attachment. Higher-end
speedometer systems consist of two major assemblies attached by screws; the
advantage is that the inner hardware of the gauge is accessible for repair and
recalibration.
4 The inner shaft and speedometer assembly are then fused into place with rivets or
screws. The permanent magnets used in mechanical speedometers are compressed and
molded before arrival at the plant, and therefore only require mounting onto the worm
drive. In the case of electronic speedometers, fiberglass-and-copper circuitry is also
manufactured by vendors, and does require programming before it is screwed into the
larger system. These larger components are transported to a separate assembly station,
where they are mounted into the housing with stud-terminal or blade-terminal plastic
connectors. Beyond its primary
 The inner mechanisms of a speedometer.

Duty as a protective case, the housing also serves as a platform for attaching exterior
features such as the dial face, needle, and display window. Again, these processes
require automation due to large output, but human effort is needed at every step to
inspect and ensure product consistency.

CALIBRATION

5 Calibration is the process of determining the true value of spaces in any graduated
instrument. It is an especially vital process in the manufacture of speedometers
because driver safety is reliant on an accurate readout. In a mechanical gauge,
magnetic forces produce the torque that deflects the indicator needle. When
calibrating this type of gauge, an electromagnet is used to adjust the strength of the
permanent magnet mounted in the speedometer until the needle matches the input
from the rotating cable. When calibrating an electronic gauge, adjustments are made
when calibration factors are written into the memory of the meter. The system can
then refigure the balance between input from the transmission and output of the
needle. New automated systems for calibrating both mechanical and electronic
speedometers are now available, saving an immense number of the man-hours usually
required for this process.
QUALITY CONTROL

Probably the most direct method of quality control is the calibration process. Auto parts
manufacturers work under the measurement standards developed by International Organization
for Standardization (ISO), which ensures that universal guidelines between gauge
manufacturers are used. In-house quality assurance teams develop specifications for each new
product before it moves to the assembly line, and the same teams later report whether those
guidelines are adhered to on the factory floor. Gradual levels of assembly also involve
inspection by factory personnel to make sure that the automation is working smoothly.

Byproducts/Waste

No byproducts result from the manufacture of gauges. Waste materials include scrap metals
and plastics, some of which can be reused in later production runs. Because the raw materials
involved are prepared outside of the factory, no significant amount of hazardous industrial
waste results from manufacture. Emissions from factory automation are government-
regulated and surveyed by environmental protection groups.

The Future

Design firms are currently experimenting with improvements in speedometer readout, an

effort to eliminate the moment of distraction needed for a driver to look down and gauge his
or her speed. Digital readouts projected onto the windshield appear to be the next
developmental step. Some proto-types for these speedometers actually make the readout
appear as though it is floating over the engine hood. Because this type of display looks as
though it is several feet beyond the steering wheel, drivers will be able to continually monitor
speed without having to take their eyes off the road. The mirrors and projection devices used
in this system could also be adjusted to suit the driver's position, much in the same way that a
rear-view mirror does. In addition, speedometer projection systems will eventually be
integrated with navigation tools, allowing directional information to appear with gauge
readouts.
Two Wheeler Dust Tube
We are manufacturing, supplying, and exporting wide collection of Two Wheeler Dust Tube
and allied parts to our esteemed clients. These are made by using high end technologies in
our modern manufacturing facilities. We maintain stringent norms of quality by complying
with international standards. These are extensively used and highly acclaimed for optimum
performance and durability. Our valued patrons can avail these at leadingindustry prices.

Features:

Dimensional accuracy
Reliable and long lasting

Plug Cap
We are considered as one of the most prominent organizations engaged in manufacturing and
supplying optimum grade Plug Cap. We manufacture these holders using high quality
material sourced from our highly authentic market dealers. Professionals working with us
also make sure to follow all laid quality guidelines while manufacturing these center holders.
We have also ensured that these holders are made available to our customers within
predefined time frame. Plug Cap offered by us is reckoned for the following quality features:
 Easy fitting
Rust resistant
Accurate dimensions
Fine finish

Cush Rubber

Backed by rich industry expertise, we are engaged in manufacturing and supplying a

superlative assortment of quality approved Cush Rubber. These rubbers are manufactured in
our state-of-the-art unit using high grade material and innovative technology. We have been
following all stated set regulations of this domain so as to ensure that our offered rubbers are
in line with international product range. Cush Rubber offered by us are appreciated for their
following quality features:

Longer service life

Easy maintenance
Perfect shape
Accurate dimensions

Clutch Lever

Established in the year 1997, we are one of the most trusted organization engaged in
manufacturing and supplying supreme quality Clutch Lever. This lever is made using
optimum quality material in our state-of-the-art manufacturing plant. After manufacturing,
these levers are passed through a series of testing so as to ensure that only high grade and
defect free range is delivered at our clients. Clutch Lever manufactured by us are made
available to the clients within predefined time period.
Special Key Features:

Durability
Ruggedness
High stability
Rust resistance
Excellent finish
Sturdy construction
Dimensional accuracy
Longer service life
Corrosion resistance
Application specific design

Side Stand

To suit the variegated requirements of our valued patrons, we have been able to manufacture
and supply superior grade Side Stand Foot. These stands are manufactured in our highly
sophisticated manufacturing plant using optimum grade material and hi-tech machines. With
the assistance of our highly prompt and diligent transportation department, we have been able
to deliver these stands at clients' ends within predefined time frame. Side Stand Foot offered
by us is made available to the clients at best market price.

Features:

Robust construction
Optimum service life
 Durable
Accurate design

FUNCTIONS OF HR DEPARTMENT:
1) HR ACQUISITON
Recruitment
Selection

2) HR DEVELOPMENT
Training and development
Organization development
3) PERFORMANCE AND COMPENSATION
Performance appraisal
Incentives and benefits
4) MOTIVATION
Creating motivation environment
Empowerment and participation
HR Mobility

1) HR ACQUISITION

RECRUITMENT
Recruitment is the process of finding and attracting capable applicants for employment. The
process begins when new recruits are sought and ends when their applications are submitted.
The result is a pool of applicants from which new employees are selected.

SOURCES OF RECRUITMENT
The following are various external sources of recruitment:
1. Consultancies
2. Campus recruitment
3. Lateral entries
1. CONSULTANCIES
The department heads where requirements are needed informs to the HR department about
the requirement. The concerned persons for recruitment get approval for filling the vacancies.
Then the consultancies are approached telling the requirements. The fit applications are
mailed to attend the interview. If satisfied, they are called for the personal interview.

2. CAMPUS RECRUITMENT
The recruitment panel goes to the reputed colleges to select the candidates.
On the following basis they recruit the candidates
GETs - Graduate Engineer Trainees
DETs - Diploma Engineer Trainees
ITI- Industrial Training Institute

3. LATERAL ENTRIES
They pick the experience candidates or people from other companies. The
Following is the process of lateral entry recruitment:
1. Sourcing
2. Interview
a. Written test
b. Technical round interview
c. Personal Interview

PROCEDURE FOR LATERAL RECRUITMENT

Pre-Selection
Selection
Post-Selection
PHASE 1: PRE-SELECTION

REQUIREMENT
FUNCTIONAL HEAD
REQUISITION

HR APPROVING AUTHORITY

IDENTIFICATION OF
PROSPECTIVE CANDIDATE
Job site search
Internal references
Hiring consultants
Direct applicants
 PHASE 2: SELECTION

Initial hr screening

Screened resumes
Sent for further
Short-listing to the
Functional head

personal interview

Discussion and final

Interview by the
interview panel

PHASE 3: POST SELECTION

 Salary and grade fixation by approved
authority

Initial offer communicated

to the candidate

offer Negotiation with the not accepted

offer accepted candidate
hr informs the
Functional head hr issues offer letter

and
Closes the case

Hr informs the
Functional head
about probable doj

new hires

joining formalities

SELECTION
The selection procedure is concerned with selecting the right candidate at right time for right
place. The selection procedure saves a lot of time and money by eliminating candidates who
are not eligible for the post.

STEPS IN SELECTION
Receiving of application
 Preparing of shortlist by the department
Verification of resume by department head
Interview (one round)
Psychological test
Reference/Background information
Final selection
Placement

2) HR DEVELOPMENT
TRAINING
Training is an on-going process aimed at capability-building of the employees at all levels. In
todays competitive mileu, organizations are increasingly turning to training to capture the
cutting edge. As they manage growth in a constantly changing environment. Purposive
training and planned re-training have an acquired priority status on the corporate agenda.
Training programmed is classified into
Skill
Knowledge
Attitude

TRAINING PROCESS

Business Plan
Performance Priority Needs

Appraisal of depts./ units

3600 Feedback Competency

Mapping

Quad 1 Yes Initiative

Executives Training Need

TRAINING PROGRAMS:
Quad 1 executives
Competencies and priority needs of departments/ units
E-learning
Induction for DET (2 years) GET (1 year), Laterals (7 days)
GENMOD training program.
General-Planning for retirement
Budget spent for training (8hrs- 1day) middle managers (3 to 4 persons) is 3-4 lakhs
WORKMEN CAPABILITY BUILDING
Training & Development for the unionized employees at the manufacturing units is focused
on skill development. Both internal and external training is given for associates. Guest
lecturers of external faculty and various other industrial visits will be arranged for associates.
In addition to some programmers like engineering drawing and waste elimination are also
conducted.

TRAINING FOR SENIOR/ MIDDLE LEVEL MANAGEMENT

Both external and internal training is given for the executives. Faculty from outside agencies
will be arranged for training them. They also get faculty from corporate level.
Training for senior/middle level management is done on the following basis:
1. Technical
2. Behavioral
3. Functional
MANAGEMENT DEVELOPMENT PLAN
Management development plan of Nero air filter corportation limited focuses on the
following competencies
People leadership
Transformational leadership
Project management capability
Result orientation
Entrepreneurial perspective
HR processes such as job evaluation and competency mapping will be dovetailed into the
development plan to enhance objectivity and effectiveness.
DEVELOPMENT ACTIVITIES
The following are the developmental activities:
TEI Total Employee Involvement
CFG Cross Functional Group
QC Quality Circles
SS Suggestion Scheme
Re-deployment

3) PERFORMANCE AND COMPENSATION

PERFORMANCE APPRAISAL
Performance appraisal is the systematic evaluation of the individual with regard to his or her
performance on the job and his potential for development
In Nero air filter corportation limitedgraphical scale method is followed, it is also known as
linear rating scale. In this, a printed appraisal form is used for each appraise. The form
consists of various employee characteristics and his job performance. Various characteristics
include initiative, leadership, dependability, creative ability, analytical ability etc..,
The rating is done on the basis of scale which is in continuum representing various degrees of
particular quality. Nero air filter corportation limiteduse numbers say 5, 4, 3, 2 and 1 to
denote points for various degrees of excellent-poor, high-low, good-bad and so on.
The appraisal form is divided into 8 parts where under each part separate sections are being
covered.
Part I- Performance in the present job (Employees achievements, goals)
Part II- Work behavior (Plans, objectives, activities, execution of plans)
Part III- Abilities (Job knowledge, commitment to achieve results at work)
Part IV- Potential ( Areas of interest, personality traits, strength, weakness)
Part V- Overall performance rating ( Based on assessment of part I, II III)
Part VI- Training need (To improve performance in present job, to assume higher
responsibility)
Part VII- Development plan (Job rotation, job enlargement, special assignment/
reputation)
Part VIII- Other comments
The appraisal form also consists of customer satisfaction survey where the need, service
provider and period of assessment are all identified. It also follows graphical scale method
using a five point scale based on the criteria
1) Quality ( Customer needs, service information, quality works, complaints etc..,).
2) Delivery (Delivery time, point of use, use or parts/service information)
3) Communication (Interaction with customers, listening to customer views, timely
feedback, and review changes with the customer)

4) Responsiveness (Responding to customer complaints, changes to customer needs)

5) Improvement (Positive attitude for improvement, implementation & effectiveness of
improvement and improvements at the customer end)

Overall Customer Rating = 1+2+3+4+5

5

EMPLOYEE RETENTION
Performance linked pay
The company has an annual appraisal system in place and pursuant to this system,
performance linked pay, annual variable pay and/or commission is paid to the employees.
Employee motivation
Nero air filter corportation limitedtargets 100% of its employees to be involved in its
continuous improvement activities. Reward systems such as IMPROVE, RISE, BITES, 100%
CLUB and GEMBA passport scheme motivates people to contribute their ideas.
INCENTIVES
1) Surcharge on Direct Booking Incentive.
2) Special Incentive Scheme.

Employee welfare schemes

The following are the welfare schemes available to the employees.
Canteen facilities
Medical claims
Transport facilities
 Nero air filter corportation limitedschool for their children
Scholarship schemes
Recreation facilities

BENEFITS
1) Tuition fee refund:
Reimbursement of expenses related to course fees, examination fees and purchase of books
is allowed up to 75% of amount spent per academic year subject to a maximum amount as
given by personnel administration.
2) Major medical plan:
Benefits will be available within the laid down overall limits for self dependants viz.
reimbursement of medical expenses and interest free loan
3) Medical reimbursement:
Domiciliary expenses incurred on domiciliary medical treatment shall be reimbursed subject
to the annual limits fixed from time to time.
4) Domestic travel:
Boarding and lodging expenses per diem allowance, when an employee opts to makes his
own arrangements , out of pocket expenses, other expenses such as local conveyances, office
phone calls.
5) Conveyance reimbursement:
It is made on self certification of expenses by the executives. This will stand withdrawn in the
event of company transport being provided.
6) Vehicle loan:
Interest free loan upto 100% of the cost of a new two wheeler subject to a maximum limit
stipulated from time to time.
7) Group term insurance:
It is in addition to the accident insurance cover provided by the company for executives. In
the event of accidental death, the beneficiaries will receive benefit under both policies.
8) Sixth day compensation (ie. Saturday):
Executives in CG 25 (Corporate Grade) and below will be paid 7.5% of basic salary for every
6th day (optional) worked. The 6th day compensation as indicated above will be considered as
salary for the purpose of contribution to PF and eligibility for bonus/ Ex-gratia.
Maternity leave:
Total period: 12 weeks leave with pay (6 weeks before delivery and 6 weeks immediately
following the delivery) for lady executives.

10) Leave:
All executives are eligible for privilege leave (PL)-30 days, sick leave (SL)- 7 days, casual
leave (CL)- 7 days, national and festival holidays. All leave will be credited in January, every
year.
11) Retirement age:
The age of retirement from companys service will be the last day of the calendar month in
which the executive attains the age of fifty eight years.

EMPOWERMENT AND PARTICIPATION

IMPROVE
Improve is an annual company- wide event to record, recognize and award employees for
their positive involvement in organizational growth innovation and customer satisfaction.

RISE
The expansion for RISE is Reward for Individual Search for Excellence. It is an integrated
award and is given to the associates. If an employee does some good activity or work apart
from his usual one he is being awarded with RISE.

TQM Total Quality Management

The main objective of the TQM cell is to set human in a good manner to achieve the goals.
The quality circle includes 6 people which include 5 associates and 1 executive. Their main
function is to identify the problem, find the solution and to implement it.
HR MOBILITY
PROMOTION OPPORTUNITIES
Promotions is based on the seniority, eligibility for post , efficiency, skill, qualification etc..,
The management decides whether to fill a post of outside recruitment or through promotion.
Workman shall be considered for promotion to a post based on certain rules.
He has rendered a minimum period of qualification service of five years.
He possesses the qualification prescribed for the post to which he is to be considered.
Fulfills prescribed attendance.

SEPARATIONS
Separation involves cessation of services of personnel from an organization. When people
leave the organization, Exit interviews are usually conducted to know the reasons for leaving.
The common reasons given are:
Better opportunities
Lack of growth

ALLOWANCES
House rent allowance
Washing allowance
Uniform and stitching allowance
Night shift allowance
Conveyance allowance
Milk and vitamins allowances
Flexibility allowance
Quality certification allowance
Direct production allowance

FINANCE DEPARTMENT
 Finance is considered as the life blood of business. This is because in the modern money-
oriented economy, finance is one of the basic foundations of all kinds of economic activities.
Finance function may be defined as the procurement of funds and their effective utilization.

RESPONSIBILITIES OF FINANCE DEPARTMENT:

The pricing department is responsible for the fixing of prices for sales of the vehicles
and for buying of raw materials and semi finished goods.
Treasury section is responsible for all kinds of funding managements such as
investments.
Taxation section is responsible for remittance of tax, filing of returns, handling of
litigations etc..,
Costing and Budgeting department is responsible for the unit costing of each product
in particular, such as spare parts and a vehicle as whole.
The FSG (Finance account Service Group) deals with the payables and receivables at
regional offices.
The Explore finance department deals with the FSG exporting of items.

DEPARTMENTAL STRUCTURE:

ROLE OF FINANCE:
Recorder (accounting) of all Financial Transactions
Reporting of Financial Performance
Arranging long and short term funds Capital and Debt
Working Capital Management
Compliance of tax and other corporate laws
Risk Management
Controllership function
Audit coordination
Investor Relations

PROCESS & ACTIVITIES OF FINANCE:

a) Financial Accounts
 Quarterly, Half-yearly and annual results published as per listing requirements
Limited Review / audit coordination.
Annual Reports Disclosures made are comprehensive; complied much before they
become mandatory
Early completion of accounts, audit process; forefront in adherence to accounting
standards & other guidelines.
Audit Committee comprises of Stalwarts from the profession.
Automation of processes
b) Financial Planning & Control
Financial Planning includes estimating the amount of capital to be raised and laying
down the policies as to administration of the financial plan.
Monthly MIS: Very Comprehensive with wider coverage and highly informative.
Monthly review covers business volumes, market share, physical and financial
parameters including alerts on laggards, exceptions in all fronts.
Exception reporting and Profit management measures form integral part of this
process

c) Treasury Management
- Raising of Funds
- Funds Management
- Debt Servicing
- Risk Management
Financial instruments for Funds raising would depend on end use of funds; de-risking
is an important consideration in deciding the instrument.
Capex and long term working capital requirements are funded through share capital
and long-term debt.
Financial Instruments used include
- Long term funds: Shares, GDR, ECBs, Debentures, term loans etc.
-Short term Funds: Cash credit, Demand Loans, Commercial paper, FCNR,
etc.
Major funds raising in AL include GDR of US$134 Mn. in 1995 & ECB of
US$315Mn incl. US$ 200 Mn. in Dec 2007.
Level of debt (Long-term): Rs. 2280.44 cr as on 31/3/10
 Banking relationships for working capital is managed through Consortium of banks
comprising of 14 banks Fund based Rs.600 cr & Non-fund based Rs.750 cr.
Funds Management includes managing collections and outflows and surplus/deficit
management. Closer working with Marketing and Units is vital.
Surplus management includes investment in Fixed Deposits, Mutual Funds, etc.,
Direct investment in equity avoided.
Debt Servicing includes repayment of principal and payment of interest on due dates
and ensuring that commitments made are adhered to.
Risk Management is vital since organization is exposed to both currency as well
interest rate risks. Risks offer both threats and opportunities (can increase income or
reduce expenditure). Results depend on how well they are managed.

d) Costing & Pricing

Strategic pricing of products, quotes for various tenders.
Special pricing for export contracts.
Monitoring of cost of production of various models and for make or buy decisions
Project / capex evaluations for optimization and for making commitment decisions
e) Taxation
Compliance with Direct (Income Tax Act, Wealth Tax) & Indirect Taxes (Excise,
Customs, Service Tax, Sales tax etc).
Tax planning is an important component of business decisions.
Recent major developments include introduction of Service Tax legislation and VAT
across many States.
Aligning the business process across the organization and maximizing the benefits
against such legislations is a major task handled by Finance.
Regular tasks include remittance of tax, filing of returns, handling of litigations etc.
f) Investor Relations
In AL, Mutual Funds, FII etc.., hold 32% of shareholding besides public who hold
10%.
FII & Mutual Funds represent investment community who track companys
performance continuously very closely.
Dissemination of data relating to companys performance and developments very
important and sensitive.
 Handled through presentations in periodic investor meet, web-cast, tele-conferences,
individual meets, address in TV etc.
Presentations made are hosted in companys website

PLANNING & MANAGING CASH FLOWS:

1. Planning cash flows
Rolling Quarterly cash forecast prepared and monitored weekly seeking
explanation for variance in order to control and direct operations.
2. Management of daily funds
Collections from 49 locations pooled under cash management system in to
centralized accounts with consortium banks at Chennai.
Various payments reported are collated and funded for in the various bank accounts
depending on the expected debits.
Surplus for the day, if any, invested for tenor which is based on requirement of funds
back in to the system.
Deficit funded through short term loans from banks, availed based on best product
available / rate offered

STRATEGIC GOALS:
Raise resources to the tune of roughly US$ 1.8 billion for funding expansion plans of
AL, Nissan and other JVs over the next 3 years
Achieve optimum funding mix / restructuring of companies to minimize the cost of
raising of funds.
Maximize tax efficiencies to improve cost competitiveness of products and improve
viability of projects.
Make globalization a reality through acquisitions and setting up of new ventures
abroad by leveraging ALs strengths.
Bench mark financial processes to the best in the world and improve the bar; maintain
high standards of financial discipline.
Maintain excellent relations with international investor community through effective
communication for international offerings.

FINANCIAL CHALLENGES AHEAD:

Global slowdown challenging break even.
 Decrease in Margins due to inability to pass on cost increases due to competitive
pressures partially compensated by increase in volumes.
Profitability pressures due to changes in business mix and commodity price
movements.
Forex management unforeseen volatility in major currencies; particularly important
with forex loans
Supporting inorganic growth evaluation & funding of emerging options.
Need to fund major capex & investments Rs.2400 cr in the next 3 years; major
investments in JVs
Tackling financial covenant breaches.
Increase in interest rates
Business integration of overseas units.
Managing expectations of stakeholders