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Advancements in engine technology have increased overall torque rating of engine and demanded further improvement in transmissions to sustain higher input torque. Conventional brass synchronizers have proved inadequate for these torque and gear inertia. It becomes necessary to use advanced material science and enhanced technology to synchronizer capabilities. Multi-cone compact synchronizer with carbon composite friction material technology has been tested successfully for these more demanding applications. This paper will focus on some of the key challenges in modern synchronized transmission, and way forward to address those. Some of the key areas delivering highest impact are being discussed. A combination of various techniques has enabled a significant reduction in overall transmission length along with enhancement in shift effort, life and overall performance.

In traditional manufacturing processes a lot of material is wasted in hidden ways. These can be identified through Lean Manufacturing systems. It is proven that the Lean Approach eliminates waste and improves value. This reduces excessive investment in working capital and improves Return on Invested Capital (RoIC). As a result, the shareholder's value is maximized through simultaneously reducing costs and increasing capital efficiency. To demonstrate this we analyzed the production process of the Upper Output Shaft , a key component in a typical drive train assembly like a Four Wheel Drive transfer case, used in a pickup truck or SUV. Value Stream Mapping (VSM) is used to identify and reduce non value-added activities.