Welcome
To
Sun Vacuum Formers
Sun Vacuum Formers Pvt.
Ltd.
1. Our Quality Policy
2. Company Name Origin
3. Company Profile
3-1. Company Location
3-2. Company History
3-3. Group Company
4. Our Business Activity
5. Products Area Matrix
6. Main Products
Our Quality Policy
We are committed to satisfy our customer’s
requirement by producing quality product through
evolved systematic process and strive for continuous
improvement.
Company Name Origin
Sun Vacuum Formers was named after our starting
business activity, “Vacuum Forming”.
Company Profile
Company Name Sun Vacuum formers Pvt. Ltd.
Established 1987
Location Gurgaon & Manesar Haryana
Managing Director Subhash Sathe
Automobile, Motorcycle,
Business areas Home Appliance
Turnover (2016) 35 million USD
Number of Employees 700
International Standard ISO/TS 16949, ISO 14001,OHSAS
Maruti Suzuki, GM, TS Tech Sun,
Main Customers TRW Sun Steering, Daikin, TWD
Sun Acoustic
Gurgaon Plant Location
Plant- 1 : Plot No. 39-40, Sector 18, Maruti Industrial
Estate, Gurgaon
Maruti Suzuki
Sun Vacuum
Formers
Manesar Plant Location
Plant 2, Manesar : Plot No. 408, Sector 7, IMT, Manesar
Sun Vacuum Formers
Maruti Suzuki
Gujarat Plant Location
Plant 3, Kadi : Plot No., Sector, Kadi, Gujarat
Sun Vacuum Formers
• Construction Started: Feb 2017
• Completion: July 2017
• YSD-HB S.O.P. : Nov 2017
Company History
1987 Sun vacuum Formers was established.
1988 Vacuum forming business started with 2 German M/C.
1990 Injection molding business started with 3 M/C.
1995 Sun Steering Wheels was established. (PP steering wheel)
T.A. with TS Tech(Japan)
1997 Sun Petri was established with Petri Germany.
1998 PU foaming for crash pad started.
1999 TS Tech Sun was established with TS Tech(Japan).
2000 Painting business started.
2008 TRW Sun Steering Wheels was established with TRW.
Sun Alphatec Moulds was established with Alphatec (Japan)
2010 Manesar plant operation started.
2014 2nd Conveyorized paint shop installed in plant 1.
2016 Total of 70 injection molding M/Cs, Vibration welding M/C, Hot
stamping
3-3. Group Company
TS Tech Sun
Ownership 26%
Noida plant, Manesar plant,
Neemrana plant
Seat parts for 4W and 2W
TRW Sun Steering Wheels
Ownership 51%
Gurgaon plant, Pune plant
Steering wheels
Sun Alphatec Moulds
Ownership 62%
Gurgaon
Mold and jig
TWD Sun Acoustic Pvt. Ltd.
Manesar
Ownership 26%
Speakers for automobiles
Our Business
Activities
1
Design
Support
5
Mold 2
Maintenan
5 Testing
ce Business
Activities
4 3
Quality Production
Assurance
Sunvac is primarily involved in the business of manufacturing
plastic automotive components for Maruti Udyog Ltd. The
Components are produced by Injection moulding process
and Thermo-Forming process and painting process.
Schematic of Thermoplastic Injection Molding Machine
1. Design Support
Feasibility Study
C.A.E.
Poka-yoke proposal
2. Testing
Durability Test, Heat cycle Test,
Thermal Resistance Test,
Vibration Test, etc.
3.1 Injection Molding
60 Machines : 50t to 775t
Material : PP, PP-T, PP-GF, ABS,
PC, PA66-GF, POM, AES,
3 shifts production
3.2 Painting
Spray painting and Cubic painting
Material: Not specified.
Color : Not specified.
2 Conveyor zed paint shops
3.3 Plating
Bright chrome plating and Satin plating
Material : ABS, PC/ABS
Plating Thickness: 20μm to 30μm
3.4 Another Secondary Processing
Ultrasonic Welding, Screen Printing,
Pad Printing, Robo Printing, Hot Stamping,
Vibration Welding
3.5 PU Foaming
Rotary Production Process
3.6 Vacuum Forming
Sheet Size : Up to 2m x 1m
Sheet Thickness : 0.7～5.0mm
Material : PP, ABS, HIPS, HDPE, LDPE, PC
4. Quality Assurance
CMM, Profile Projector, UTM,
Color Comparator, Gross Meter
PPAP (FMEA, Initial supply report, etc.)
5. Mold Maintenance
2 CNC Milling Machines
1 EDM, 1 Laser Welding Machine
Conventional machines
(New Tooling Room)
OUR
PRODUCT
RANGE
BEZEL FRONT FOG LAMP BOOT COMP SHIFT LEVER COVER STEERING JOINT
CASE EPI CONT COVER ASSY STEERING COLUMN SHROUD AIR INTAKE
LOUVER COMP CTR VENT
BOOT COMP SHIFT LEVER ORNAMENT I/P CTR
GARNISH RADIATOR UPPER
COVER ASSY STEERING COLUMN
BOOT COMP SHIFT LEVER
LOUVER COMP CTR VENT R/L (HOT STAMPING)
CASE DIESEL ENGINE
PIPE AIR CLNR SUCTION (VIBRATION WELDING) CAP SOCKET BRACKET EPI CONT
BOOT COMP SHIFT LEVER
MODEL – YL7 , YE3 , YRA , YBA ,
YJC , YSD ,YHB & YHA
BOOT – YL7 BOOT - YE3 BOOT - YBA BOOT - YJC BOOT - YSD
BOOT - YRA BOOT - YHA
LOUVER COMP CTR VENT
MODEL – YL7 , YE3 , YBA , YSD ,
YJC ,
LOUVER – YL7 LOUVER – YE3 LOUVER – YBA
LOUVER – YSD LOUVER – YJC
THERMO - FORMING PARTS
TRIM FLOOR SIDE
TRIM SEAT RISER CENTER
MARUTI 800 TRIM STRISER
TRIM DASH SIDE
GARNISH FRONT DOOR TRIM UPPER TRIM REAR WHEEL HOUSE
COVER TRIM REAR PILLAR
COVER TRIM CTR PILLAR
MINI CONSOLE
COVER TRIM DASH LINER INNER FRONT FENDER COVER IP FLOOR
COVER TRIM QTR PLR UPPER
COVER TRIM QTR PLR LOWER
COVER TRIM CTR PLR UPPER
COVER TRIM ASSEMBLY LEG
PAINTED PARTS
PAINTED PARTS
GARNISH IP CTR WAGON-R GARNISH IP CTR ZEN ESTILO GARNISH IP AUTO SX4
GARNISH DOOR TRIM
SPEAKER SWIFT KNOB GEAR GARNISH IP MANUAL SX4
PAINTED PARTS
ORNAMENT FRONT DOOR TRIM SWIFT ORNAMENT RR DOOR TRIM SWIFT
GARNISH HEAD GARNISH FRONT CTR OMNI GARNISH HEAD
LAMP OMNI LAMP OMNI
Garnish Back Door With Hole Garnish Back Door W/O Hole
MATERIAL FEEDING & PAINTING
FEEDING ON CONVEYOR IPA CLEANING OF PARTS
AIR CLEANING OF PARTS SPRAY PAINTING
PAINTING BOOTH
PARTS TRANSPORT FOR BAKING
FLASH OFF ZONE COOLING ZONE
ROBO PRINTING MACHINE
DEVELOPMENT &
TOOL ROOM FACILITY
Conventional Tool Room with EDM CNC Milling
CNC Milling
Product & Mould Design Facilities & CAE
Sunvac has entered into a Techno Financial Joint Venture with Alphatec, Japan for tool making &
development. The Company SUN ALPHATEC MOULDS INDIA PVT. LTD. shall manufacture moulds and
tools with design support from Alphatec Japan & Tool Making support from Alphatec, Shanghai.
TOOL ROOM FACILITY ALPHATEC CHINA
Conventional Tool Room inside view TOOL ROOM BUILDING
DIE SPOTING PRESS CNC EDM
Products Area Matrix
Product
Engineering Injection Molding
Vacuum
PU Forming
Foaming
Area +Painting +Plating +Assembling +Other
Fog lamp Garnish Radiator
Front Emblem
Cover Head Lamp Grill
Exterior
Out Side Out Side Fender
Side Mud Flap
Door Handle Handle Liner Inner
Automobile
Cover Rear Garnish Garnish
Rear
Fog Lamp Back Door Back Door
Air Bag Garnish IP Gear Knob
Interior Horn Pad Boot/Louver CTR Pillar
Cover Center Cap
Under hood
Shroud Cover Timing
Condenser Belt
Seat
Scooter Seat Base Emblem
Cushion
Home Appliances Blade Drain Pan
Our Products
Emblem
Radiator Grill
Corner Trim
Outside Door Outer Fr, Rr.
Handle
Grill Lower
Garnish Back Door
Fog Lamp Cover
Fender
Guard Fr, Rr.
Trim Tail End Member
Door Splash
Fr, Rr. Mud Flap
Center Louver Garnish IP
Center
Ornament Trim Front Pillar
Panel Cluster
Cover Str.
Air Bag Cover Column Center Pillar
Garnish IP Grip Assistant
Horn pad
Nozzle
Demister
Louver Side
Garnish Door
Trim Speaker
Glove Box
Console
Box
Gear Knob Corner
Trim Inner
Reclining Case Bezel
Leather Boot Cover
Trim Dash
Reclining Knob
Scuff Front
Foot Cover Scuff Rear
Engine Cover Spacer water Jacket
Shroud Condenser
Cover Timing Belt
Oil Channel Input Emblem
Shaft
Seat Base
Seat Cushion
ARIGATO GOZAI MASHITA
