April 18, 2021

The journey of Kay Jay Forgings

The forging trade in India is intently linked to the success of the Indian vehicle sector and using the wave, a homegrown part maker has efficiently made the transition from being a bicycle components producer to one of many main auto part producer on the planet.

Dwelling to many of the forging trade, Ludhiana-based Kay Jay Forgings Pvt Ltd’s title was integrated in 1988, however its roots will be traced to 1975 when it produced cycle components like pedal cranks. The primary auto half that the corporate made was in 1983, when it did the crankshafts for Majestic Auto.

“The marketplace for us was static until about 1992, after which the actual increase occurred. Regardless of Hero Honda being current since round 1984, the market was primarily scooter pushed. Solely when the likes of Bajaj and TVS entered the motorbike market, did we see a increase” says Amit Kothari, Joint Managing Director, Kay Jay Forgings Pvt Ltd.

India is immediately the fourth largest automotive market on the planet and the gamers within the manufacturing value-chain replicate the strides it has taken. When the Indian automotive market opened up after liberalization within the early 1990s, the worldwide auto makers set base within the nation in each two and 4 wheelers. Slowly and steadily because the localization wants of those OEMs grew, a powerful auto part manufacturing base began to take form.

The auto part makers needed to meet the worldwide requirements, which in the end meant they turned aggressive on a global stage. At the moment, Kay Jay Forging has a whole in-house facility to carry out the diversified features of producing, machining, processing, warmth therapy and testing. In addition they have precision sheet metallic elements just like the gas tank, software field, engine cowl, facet faring, gear shift lever, and brake pedal.

In accordance with the Affiliation of Indian Forging Trade (AIFI), primarily based on their put in capability, the forging models could also be labeled as very giant (capability above 75,000 MT), giant (capability above 30,000 to 75,000 MT), medium (capability above 12,500 to 30,000 MT), small (capability above 5,000 to 12,500 MT) and really small (capability as much as 5,000 MT).

In India it’s clear {that a} majority of the models, or 83%, falls underneath the small and really small, whereas solely about 8% will be labeled as very giant and huge models; the steadiness of about 9% represent the medium sized models.

Forging-3ET On-line

Supply – AIFI

When it comes to geographic unfold AIFI states main forging clusters will be discovered within the states of Maharashtra, Punjab, Gujarat, Tamil Nadu, Haryana, Delhi, Karnataka, Jharkhand, West Bengal and Andhra Pradesh.

Present share of the auto sector is about 58% of whole forging manufacturing whereas the remaining is with the non-auto sector. It’s no marvel that the fortunes of Kay Jay Forging are, thus, intently linked with the expansion of the auto trade.

Greater plans

Handwringing over the decline of producing isn’t solely new, neither is it distinctive to a state like Punjab. In a landlocked place all the things must be transported by way of roads and one doesn’t have the benefit of a port. Whereas the prepared availability of has expert labour and metal, which is the primary uncooked materials for the sector, are essential benefits, the forging firm has to beat challenges.

Kay-Jay-1ET On-line

The largest drawback based on Kothari for Kay Jay immediately is the space from the auto hubs of the nation. Within the vehicle trade within the state it has gamers like SML Isuzu (previously Swaraj Mazda), Punjab Tractors, ICML and within the north gamers like Escorts, Maruti Suzuki, and JCB, that are comparatively nearer. Authentic Gear Producers (OEMs) have additionally come up in areas like Pant Nagar, the place Ashok Leyland and Hero Honda function. Gujarat with its hub in Sanand is about 1000 km away.

Kay Jay, nevertheless, has larger plans within the home market- one thing that appears to nullify the problem posed by distance. The corporate setup a plant in Hosur ten years in the past to satisfy the calls for of one among its largest customers- TVS Motors, which ultimately grew to a 60,000 sq. toes facility. Buoyed by the success of the plant, the corporate is now constructing a second plant, pushing its manufacturing presence to over 100,000 sq. toes.

“The Hosur plant was began for crankshaft and connecting rods. Earlier than this we had been doing the forging for crankshaft for TVS Motors in Ludhiana, which had been then despatched to TVS for meeting. Nevertheless, for the previous couple of years we’ve got began making these components for a number of of their fashions in Hosur and we hope to slowly and progressively do for all of the fashions of TVS in Kay Jay Hosur. We’re additionally doing the entire machining for Beneath Bracket. We’re additionally doing a whole lot of elements for TVS-BMW,” says Kothari.

The corporate can be establishing a brand new plant Ludhiana which is able to cater to calls for from each home part and exports.


Kay Jay began exports within the yr 2004 and for the abroad market it’s robust within the Steering Yoke area and is in actual fact the Tier 1 provider to Bosch. “This implies we additionally provide steering assemblies to firms to the likes of Mercedes, Audi, Mazda, Jaguar, and Renault-Nissan. We’re additionally Tier II suppliers to firms like Rane, ZF Lenksysteme and NSK Steering Programs,”stated Kothari.

AutoComp-2ET On-line

Supply – ACMA

When it comes to nations, the auto part maker provides to the US, France, China and Hungary. “European automakers are upbeat about Indian auto part maker. Our merchandise are good in high quality and priced nicely, which makes us very aggressive. This implies we’ve got a whole lot of scope in exports,” says Kothari.

For vehicles, Kothari says it’s doing Cast & Machined Steering Yoke. “Kay Jay was a small group some 25 years in the past, however a whole lot of modernization in equipment helped us develop in the previous couple of years,” says Kothari.

Whereas Kay Jay has been primarily engaged within the two wheeler phase of the market domestically, it has not too long ago diversified supplying elements for high-end luxurious vehicles. “Home marketplace for vehicles is sweet, however the two- wheeler market was so thrilling for us domestically that we by no means checked out vehicles. At the moment, we’re at a stage the place we’ve got diversified and are searching for new clients and the 4 wheeler trade is an effective market to discover,” says Kothari. Being a provider to Bosch is a large shot within the arm for the corporate, a feat not many companies have been in a position to obtain.

The corporate that forges 3000 tonnes of metal each month immediately employs 2400 folks throughout its vegetation. Final fiscal the corporate clocked revenues of Rs 394 crore and Kothari says the corporate is rising at nearly 20% this yr.