AN ISO 9001: 2015 CERTIFIED

COMPANY

COMPANY PROFILE
 ABOUT US
SONU AUTO ELECTRICALS BRAND NAME IS AN ISO 9001: 2015 CERTIFIED
COMPANY IS A LEADING MANUFACTURER FOR AUTO ELECTRICAL PARTS IN INDIA FOR
MOTORCYCLES , SCOOTERS , ELECTRIC RICKSHAW & BIKES , THREE & FOUR
WHEELERS .

UNIT-1 & REGD. OFFICE

SONU AUTO ELECTRONICS
C-5 , DSIDC , ENGINEERING COMPLEX , MANGOL PURI INDUSTRIAL AREA ,
PHASE - 1 , DELHI-110083 , INDIA .
Tel: +91-11- 43860049
.

visit us: www.sonuauto.com

 ACHIEVEMENTS
1995   : Sonu Auto Electricals was started by Mr. Sonu Kohli ,Mechanical engineer + post diploma in tool design from trtc
with products Stop switches  
1996  : Business started with OEM’s Customers M/s Kinetic Honda motor ltd. With import substitute products like Auto by starter &
starter motor parts
2000
to : Expand their business with development of large range of products like handle bar Combination switches , Ignition
2005 switches & locks , fuse asslys , Combination switches for Cars , blinkers assly. , electronic Flasher E.t.c
           
2006  : Certified by ISO  9001 :2000 co.   
: installed fully automatic wire cutting stripping & crimping machine to produce wire harness for switches.

2007 : Business started with Mahindra & Mahindra ,Kinetic Engineering ltd . Kinetic Motor company ltd. Neolite Industries Ltd..
 
2008   : Certified by ISO/TS 16949 : 2002 and started exports.

2009   : Business started with HERO ECOTECH LTd., MAHINDRA TWO WHEELERS .,LOHIA AUTO INDUSTRIES , MINDA CORPORATION LTD.,
YOGENDRA ENGINEERING ( A UNIT OF MINDA GROUP ), PALSONS ( A UNIT OF AUTOPAL ),  

2010   : Business started with Alphatoyo Ltd. Ultra Motors Electric Vehicles.

2011 : Started wire harness Plant in imt manesar with fully automatic assembly line with latest machinery , ISO 9001:2008
certified by tuv south asia Started their plant In sitargunj uttrakhand ,ISO 9001:2008 certified started business with
alphatoyo for combination switches for cars .

2012 : Started business with M/s Standard Tractors for Tractor Parts .
: Started business with M/s Kuruksetra Auto Pvt. Ltd. , M/s Rasandik Motors, M/s API Motors Pvt. Ltd. and M/s Pashupati motors Pvt.
Ltd. For 3-Wheeler Parts
: Started business with Hella Lighting Limited .
2012 TO 2016 :DEVELOPED VARIOUS PARTS FOR THREE WHEELERS , FOUR WHEELERS ,TRACTORS & ELECTRIC RICKSHAW .
TO INCREASE BUISNESS SHARE IN ALL COMPANIES .
STARTED SUPPLIES TO ALL MAJOR COMPANIES FOR ELECTRIC VEHICAL MANUFACTURERS IN INDIA .
2016 TO 2018 : DEVELOPED ELECTRONIC PARTS LIKE USB MOBILE CHARGER & CIGRETTE LIGHTER ASSLY FOR MOTORCYCLES WHICH ARE OUR
PATENT ED PRODUCTS .

visit us: www.sonuauto.com

 VISION
To be recognized across the globe as a leading manufacturer and
supplier of High Quality Auto, Electrical and Electronic
Components

MISSION
Our Mission is to Continuously Strengthen And Upgrade Our
Manufacturing Processes, Quality Systems and People
Competencies to achieve our Vision

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 OUR BASIC VALUE ARE:
PERFORMANCE
Sonu Auto Electronics is a performance-driven company. Our performance is measured in all
areas and at all levels, and is based on our deep understanding and knowledge of our business. The
focus on performance is reflected in our management-by-objectives policy and in the
compensation paid to employees.

INNOVATION
Sonu Auto Electronics demanding business environment, where we mainly function as a
sub-supplier, innovation in the areas of product development, products and processes is a
necessity. We solve our customers’ (and their customers’) problems in a proactive manner,
through innovative product development combined with high-quality, cost-efficient processes.

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 QUALITY POLICY
We are committed for “Total Customer satisfaction’’ through
continual Improvement in order to fulfill the requirements of:-

QUALITY
COST
&
QUALITY OBJECTIVE TIME

.To reduce rejections.

.To deliver product on time.
.To enhance Customer Satisfaction.
.To upgrade skill to employees. s

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QUALITY MANAGEMENT SYSTEM

CCA QC
Control in process

Operation QC
Packing QC
Die making QC
Molding QC
Supplier Management

I QC
SQE
Quality Guarantee 100 percent testing
Survey & Audit
QC DEPARTMENT
Planning in advance
Customer service
QUALITY MANAGEMENT SYSTEM

ISO
ISO 9000
9000

Under customer’s requirement

Flexible Speedy Consistent

Do what customer need Limited lead time High quality

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 OPERATION SYSTEM

Shipment
Part Number Operation System
Quantity Payment Term

Lead time Unit Price

Leaded by customer requirement

Keep the balance of produce and sale

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 QUALITY PROCESS
Consistent Quality Requires Consistent upgrading Processes.
At Sonu Auto Electronics we take care of the quality of the product at every stage of
production:-

•Product Quality Planning

•Pre Production Feasibility & Commitment
•Quality Planning Processes
•Flow Diagram
•Failure Mode & Effect Analysis (FMEA)-Process
•Process Control Plan
•Process Capability Analysis
•Gauge calibration and gauge R&R study tool & fixture control
•Supplier selection and approval
•Production part level control plan process
•Production Parts Approval Process (PPAP) Validation

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ORGANISATION CHART

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 MAJOR CUSTOMERS
MAHINDRA DEFENCE LAND SYSTEMS

MINDA CORPORATION LTD.

ALPHATOYO LTD.

NEOLITE INDUSTRIES LTD.

PALSONS ( A UNIT OF AUTOPAL )

HELLA INDIA

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 MAJOR CUSTOMERS
Tractor , Combine & Crane Manufacturers

STANDARD TRACTORS

INDO FARM TRACTORS

ACE TRACTORS & CRANE

PREET TRACTORS

KARTAR COMBINE

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MAJOR CUSTOMERS
Two Wheeler and E-Bike Manufacturers
• MAHINDRA TWO WHEELERS
• KINETIC ENGINEERING LTD.
• HERO ECOTECH LIMITED
• LOHIA AUTO INDUSTRIES
• YO-BIKE
• SAVVY GO
• XS BIKES
• LECTRIX MOTORS

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SAERA ELECTRIC AUTO PVT. LTD.

MAJOR CUSTOMERS
E- Rickshaw Manufacturers

• LOHIA AUTO INDUSTRIES

• HERO ECOTECH LIMITED
• HBL POWER SYSTEM LIMITED
• SAERA ELECTRIC AUTO PVT. LTD.
• OTHER E RICKSHAW MANUFACTURERS LIKE :
• VICTORY , VOLMAC , RUHIN , YATRI ,
GOENKA , SHRI RAM , SKYRIDE , DD
MOTORS ,GKON , ETC

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 MAJOR CUSTOMERS
3-Wheeler Manufacturers

 Scooter India Limited

 Rasandik Motors Private Limited
 Kurukshetra Automobiles Pvt. Ltd
 Umbrella Corporation
 A.P.I. Motors Private Limited
 Pashupati Vehicles private limited
 Lohia Auto Industries
 MLR Motors Pvt. Ltd.
 ARD Exim

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MAIN WIRE HARNESS

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SUB/ PIG TAIL WIRE HARNESS

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BATTERY CABLES 3W , 4W & TRACTORS

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WIRING HARNESS,BATTERY CABLES
AND FUSE BOX ASSLYS.FOR 2 W
HANDLE BAR COMBINATION SWITCHES
HANDLE SWITCHES FOR SCOOTERS AND E-BIKE

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FRONT & REAR STOP SWITCHES, CLUTCH SWITCHES
FOR 2W ,3W & 4W

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IGNITION SWITCHES & LOCKS FOR 2W

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3WHEELER PARTS

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4 W, TRACTOR PRODUCTS

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E RICKSHAW PARTS

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FLASHER, BUZZER ,RELAYS

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COMBINATION SWITCHES FOR 4W

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PROCESS FLOW CHART OF MAIN WIRING HARNESS

MATERIAL
RECIEVING

INSPECTION
(Dim. Visual)
WIP +
WIRE
SLEEVE
TAPE INSERTION
STORE CUTTING, STRIPPING,
CRIMPING, PROCESSING

COUPLER SLEEVE

CRIMPING & JOINT

SOLDERING
TAPING
COUPLER WIRE ASSEMBLY &
ASSEMBLY SLEEVE INSERTION
JOINT
TAPING
ELECTRICAL
TESTING

ASSEMBLY
COVER CONNECTOR

FINAL INSPECTION
(Visual, Dim.)

P.D.I
PACKING F.G STORE DISPATCH
(Visual, Dim )
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 MANUFACTURING PROCESS- MAIN WIRING HARNESS

Automatic wire Semi Automatic Heat sealing Auto Joint Wire Assy
cutting ,stripping & Crimping Process Process Taping Process Process
crimping

Final Inspection Testing Process Taping Process Coupler insertion

Process

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MANUFACTURING PROCESS- MAIN WIRING HARNESS

Line--1 Line--2

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MANUFACTURING PROCESS- SWITCH AND ELECTRICALS PARTS

Line--1 Line--2

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 DESIGN RESOURCES & OUTPUTS
Auto Cad-R2004 & R2006
Pro-E-WILD FIRE
CATIA-V5R13
UNIGRAPHICS – NX-3

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 ENGINEERING / TECHNICAL

• Product Design Mold Design

• Mold Flow Analysis
• Project Management
• Supplier Managed Inventory
• Design for Manufacturing
• Value Analysis

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COMPETENCY LEVEL FOR MWH OPERATORS (STAGE WISE)
Cover Connector
Wire Assy. Coupler Assy. Taping Elect. Testing Final Inspection
Insertion
Sample Sample Sample Sample Sample Sample
Wire Details (Wire Wire Details (Wire Identification of In-
Wire Details (Complete Knowledge of Identification of Cover
Assy.& coupler Assy., coupler stage & Process Raw material
Wires) Fixtures Connectors
stage) Taping Stage) (All Stages)
Identification of Sleeve Identification of Appearance (Sample
Knowledge of Fixtures Knowledge of M/C Visual Insp.
(Size) Terminals Basis)
Identification of In-
Identification of Process Raw materials Identification of
No. of Wires Working Procedure a) Crimping Load
Couplers (Tape, Protector Cord Terminals
etc)
Knowledge of Identification of b) Condition of Terminals
Process Sequence Process Sequence Handling Procedure
Fixtures Couplers (Sample Basis)
c) Heat Sealing (Burn,
Knowledge of Branch &
Orientation of Wires Process Sequence Continuity Working environment Puncture,Existing
Taping Length
Strands)
Appearance (Sample Orientation of d) Overhanging length of
Reverse Taping Location Change  
Basis) Couplers TP Sleeve
e) Wires & Coupler
Working Procedure Wire Interchange Over Lapping of Tape Short Circuit  
Position
Handling System Terminal Back Out Naked Wires Open Points   f) Terminal Backout
Knowledge of KIT Re-Insertion of Appearance (Sample g) Taping Insp. (Naked
Orientation of Branch  
system (For Wires) Terminals Basis) Wires, Over Lapping)
Appearance (Sample
Working environment Working Procedure Working Procedure   h) Branch Length
Basis)
Knowledge of JOB Appearance (Sample i) Availability of raw
Working Procedure Safety Precautions  
CARD Basis) Materials
Knowledge of Conveyor
  Material Handling Handling Procedure   Working Procedure
Handling
  Working environment Material
visit us:Handling Working environment
www.sonuauto.com   Handling Procedure
 KIZEN

BEFORE AFTER

MANUAL TAPING AUTOMATIC M/c TAPING

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 KIZEN

BEFORE AFTER

MANUAL CRIMPING SEMI AUTOMATIC CRIMPING

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 KIZEN
BEFORE AFTER

NO DESIGN WIRE ASSY. STAND DESIGNED WIRE ASSY. STAND

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 KIZEN
BEFORE AFTER

NO DESIGN WIRE ASSY. STAND DESIGNED WIRE ASSY.STAND

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 KIZEN
BEFORE AFTER

NO DESIGN TAPING FIXTURE DESIGNED TAPING FIXTURE

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 KIZEN
BEFORE AFTER

BEFORE IMPROVEMENT AFTER IMPROVEMENT

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 POKA YOKE
BEFORE AFTER

1. NO DESIGN TAPING FIXTURE 1. DESIGNED TAPING FIXTURE

2. MEASURING LENGTH WITH THE 2. MEASURING SCALE NOT REQUIRED
HELP OF ENGG. SCALE 3. WIRE TAPING BOARD DESIGN AS
3. DOUDT OF LENGTH AND COLOR HARNESS DRAWING

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 POKA YOKE
BEFORE AFTER

1. NO DESIGNED OF COUPLER ASSY. 1. DESIGNED OF COUPLER ASSY. TABLE

2. MAXIMUM CHANCE FOR COUPLER MIXING 2. 100% FULL PROOFING IN COUPLER MIXING
3. EXTRA TIME FOR SEARCHING MATERIALS 3. SAVE TIME FOR COUPLER ASSY. STAGE
AT COUPLER ASSY. STAGE

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 IMPROVEMENTS

Visual Incoming Scrap area

adds inspection identified

Master Training Material Handling

sample room system

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 EQUIPMENT FOR MAIN WIRING HARNESS

S. No. Section/Machine/Station  
Production 300/Day
1 Automatic Wire processing M/C 2
2 Semi-Automatic M/C 2
3 Applicators 24
4 Manual die for crimping 24
5 Heat Sealing 1
7 Joint Taping 1
8 Electrical Testing 3

9 Assembly Table (Coupler, E/T & Visual insp.) 3

10 Taping Boards 110

11 Wire assembly Hangers & WIP hangers & Harness hanger for PDI 12
12 Sleeve Insertion Tables 3
13 Electrical Testing Fixture 80

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TYPE OF MACHINE / DESCRIPTION CAPACITY MAKE & MODEL LIST OF TESTING INSTRUMENT
HIGH VOLTAGE TESTER   SIGMA

MEGGER   SIGMA

SALT SPRAY TESTING   AUTO TEST

PUSH PULL TESTER FOR LOAD TESTING DIGITAL IMPORTED

MULTI METER   RISHABH

POWER SUPPLY   SIGMA

ENDURANCE TEST RIGS FOR SWITCHES   INHOUSE

VERNIER CALIPER  DIGITAL MITUTOYO

MICROMETER DIGITAL MITUTOYO

IMMERSION CONTAINER TESTER   INHOUSE

HOT AIR CHAMBER   AUTO TEST

COLD CHAMBER   AUTO TEST

ENVIORMENT CHAMBER   SARASWATI

WATER SPRAY TESTER   INHOUSE

DOUBLE KELVIN BRIDGE TESTER    

SHORE HARDNESS TESTER   EXCEL

COMPRESSION SPRING LOAD TESTING    

VIBRATION TABLE   SARASWATI

MAGNIFY LAMP   BLUE SKY

 MAKE & NO. OF

LIST OF MACHINERY
TYPE OF MACHINE / DESCRIPTION CAPACITY MODEL MACHINES
ASSEMBLY SHOP
WIRE CUTTING STRIPPING & CRIMMPING FULLY
MACHINE AUTOMATIC IMPORTED 3

CRIMMPING MACHINE   YP HYDERABAD 4

PNUEMATIC CRIMMPING MACHINE     4

HAND PRESS     12

HAND PRESS     4

SOLDERING STATION     10

SOLDERING POT     10

TAPING MACHINE     2

ULTRASONIC COPPER WELDING MACHINE   IMPORTED 1

SPIRAL TAPING MACHINE   IMPORTED 1

CONTINUTY TESTING MACHINE   FUTURA 3

CONTINUTY TESTER     10

CONTINUTY TEST BOARDS WIRE HARNESS     82

HEAT SEALING MACHINE     4

ASSEMBLY LINES     10

RIVETING MACHINE PNEUMATIC     2

TOGGLE PRESS     2

ELECTRIC SCREW DRIVER     50

CONTINUTY TESTER WIRING     5

COMPRESSOR 500 POUND   1

IMPORTED APPLICATORS FOR TERMINALS     12

APPLICATORS INDIAN FOR TERMINALS     20

BELT GRINDER     3
 TYPE OF MACHINE / CAPACIT MAKE & NO. OF
DESCRIPTION Y MODEL MACHINES
LIST OF MACHINERY SOFTWARE AUTO CAD
DESIGN & DEVELOPMENT
     
SOFTWARE CATIA      
MAGNIFY LAMP      
PROFILE PROJECTOR      
MEASURING INSTRUMENTS      

TOOL ROOM
LATHE MACHINE 6 FEET D.S TOOLS 1
LATHE MACHINE 6 FEET EVEREST 1
SURFACE GRINDER 9 X 18 INCH RAMANNA 1
SURFACE GRINDER 7 X 14 INCH GURU ARJAN 1
MILLING MACHINE 225 X 1075 SAGGU VGM 1.5 1
MILLING MACHINE 280 X 1200 SAGGU VH 2 1
DRILL MACHINE 1/2 INCH MATCH LESS 2
SPARK EROSION EDM ELECTRONICA S
MACHINE 400 X 250 MM 425 1
SURFACE TABLE   APEX 1
BENCH VICE     4
VERNIER CALIPER   MITUTYO 5
VERNIER HEIGHT GUAGE   MITUTYO 1
MICROMETER   MITUTYO 4
RADIUS GUAGE     2
SLIP GUAGE     1
ROTARY TABLE     1
SINE GUAGE     1
GRINDING VICE     2
V BLOCK     2
ANGLE PLATE     2
 Thanks For Your Kind Attention
Team,
.
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