AIS Repair Services India
AIS (Autobacs India Pvt. Ltd.) is India's largest automotive safety glass and related components manufacturer, headquartered in Mumbai with manufacturing facilities across India. They produce laminated windshields, tempered glass, adhesives, and integrated glass-based systems for passenger cars, commercial vehicles, and two-wheelers. AIS supplies OEM and aftermarket segments, dominating India's automotive glass supply chain with exports to 50+ countries.
AIS (Autobacs India Pvt. Ltd.) is India's largest automotive safety glass and related components manufacturer, headquartered in Mumbai with manufacturing facilities across India. They produce laminated windshields, tempered glass, adhesives, and integrated glass-based systems for passenger cars, commercial vehicles, and two-wheelers. AIS supplies OEM and aftermarket segments, dominating India's automotive glass supply chain with exports to 50+ countries.
Synchronics repairs and maintains AIS adhesive dispensing systems, glass handling automation equipment, curing ovens, and production line control electronics. Our 180+ engineers understand the precision requirements of automotive glass manufacturing—tolerances, thermal cycling, and safety certifications. We service AIS production facilities across Gujarat, Maharashtra, Tamil Nadu, and Telangana, ensuring zero downtime in glass lamination and tempering operations.
Expert repair of AIS automotive glass manufacturing and adhesive application systems nationwide.
AIS Product Lines We Repair
Our engineers are trained on the full AIS product range. Below are the major product families we service.
Adhesive Dispensing Systems (ADS)
Automated two-part polyurethane and epoxy adhesive mixing and application equipment used in laminated glass bonding. Common issues include dispenser clogging, pressure sensor failure, and metering ratio errors causing glass bond failures.
Glass Handling & Conveyor Automation
Vision-guided robotic glass sheet positioning and transport systems for windshield and side-glass production. Failures include vision camera misalignment, servo motor stalling, and pneumatic actuator leaks affecting production throughput.
Curing & Thermal Processing Units (CTU)
Programmable ovens for adhesive curing, tempering, and annealing processes with precise temperature and humidity control. Common faults: thermocouple drift, PLC recipe corruption, humidity sensor failure, and heating element burnout.
Quality Control & Inspection Systems
Automated optical and mechanical inspection equipment detecting glass defects, adhesive voids, and dimensional variances. Issues include camera calibration loss, light source degradation, and data logging system failures.
Production Line PLCs & HMIs
Industrial controllers and touch-screen interfaces managing glass cutting, washing, adhesive application, curing, and packaging sequences. Faults include firmware corruption, I/O card failure, and communication protocol breakdowns affecting entire production lines.
Why Choose Synchronics for AIS Repairs?
PCB-Level Expertise
We repair down to the component level — not just swap boards. Our engineers identify root causes, replace failed IGBTs, capacitors, processors, and gate drivers on AIS equipment.
Fast Turnaround
Standard 7–10 working days. Express 3–5 days available for critical breakdowns. Emergency same-day/next-day service for unplanned downtime.
6-Month Warranty
Every repaired unit ships with a 6-month comprehensive warranty on parts and labour. Our repair success rate is over 94% across all brands.
All-India Service
Couriered repairs accepted from any city in India. Doorstep pickup available in Vadodara, Mumbai, Pune, Ahmedabad, Surat, Chennai, and more.
Common AIS Equipment Faults We Fix
Based on 30+ years of repair data, these are the most frequent failure modes we see in AIS equipment arriving at our workshop.
- ✓Adhesive dispenser ratio imbalance or incomplete cure — Polyurethane/epoxy metering pump wear or pressure transducer miscalibration causes incorrect 1:1 ratio, resulting in weak glass bonds, delamination, and structural failures in windshields. Common in high-volume production facilities running 16+ hours daily.
- ✓Vision-guided glass handler positioning errors — Camera calibration drift due to thermal expansion, lens contamination, or servo encoder degradation causes ±5-10mm positioning variance. This leads to misaligned adhesive application and defective lamination.
- ✓Curing oven temperature overshooting or undershooting — Thermocouple sensor failure, PLC temperature loop gain misconfiguration, or heating element resistance drift causes ±10-15°C temperature variance, resulting in incomplete adhesive cure or glass stress fractures.
- ✓HMI touchscreen unresponsive or freezing during production — Flash memory degradation in AIS-IPC controllers, corrupted production recipe files, or insufficient CPU thermal dissipation during sustained 20+ hour runs causes interface lockups and production line halts.
- ✓Void detection camera false positives or missed defects — LED light source aging (50-70% intensity loss after 10,000 hours), camera sensor pixel drift, or incorrect image threshold calibration causes false rejection of good glass or acceptance of defective product.
- ✓Pneumatic actuator slow response or complete failure — Air system moisture contamination, solenoid coil burnout, or internal spool valve sticking in glass-handling robots causes delayed gripper release or inability to position glass sheets, halting lamination operations.
How We Repair Your AIS Unit
Receive & Log
Your unit is logged into our tracking system with a unique job number. You receive WhatsApp / email updates at every stage.
Fault Diagnosis
Board-level diagnosis using oscilloscopes, LCR meters, and thermal cameras. Root cause identified before any repair begins.
Component Repair
Faulty ICs, capacitors, MOSFETs, IGBTs, and gate drivers replaced with genuine or equivalent-spec components.
Full-Load Test
Unit tested under rated load with original or equivalent motor. All parameters verified. 6-month warranty issued.
Industries Using AIS Equipment
We serve plant maintenance teams across all major industries where AIS automation is deployed.
Frequently Asked Questions — AIS Repairs
Do you repair AIS equipment anywhere in India?+
Yes. Synchronics repairs the full AIS automotive glass production range—adhesive dispensers, glass handlers, curing ovens, vision systems, and production line PLCs. We offer PAN India door pickup from all major manufacturing hubs including Mumbai, Pune, Vadodara, Ahmedabad, Hyderabad, Chennai, Bangalore, and Kolkata. All repairs are processed at our 25,000 sq.ft. facility in Vadodara, Gujarat.
What is the typical turnaround time for AIS adhesive dispenser repair?+
Standard AIS dispenser repairs (metering pump replacement, pressure sensor recalibration, solenoid valve rebuild) are completed in 3-5 business days. Urgent breakdowns receive same-day diagnostics and priority processing. We maintain stock of OEM-equivalent pump seals, transducers, and solenoid coils to minimize downtime. Complex firmware issues may require 7-10 days including PLC recalibration and adhesive flow validation.
Can Synchronics repair AIS vision-guided glass handling systems if the original OEM support has ended?+
Absolutely. We specialize in reverse-engineering obsolete AIS glass handler vision systems. Our team can replace legacy camera modules with modern high-resolution alternatives, reprogram servo motion logic, and re-validate positioning accuracy. We've successfully restored 15+ year-old AIS AutoLoader systems to ±3mm repeatability without requiring expensive full-system replacement.
Do you offer preventive maintenance contracts for AIS production lines?+
Yes. Synchronics offers tiered preventive maintenance (PM) contracts for AIS facilities covering quarterly inspections of adhesive dispensers, thermal profiling of curing ovens, vision system calibration, and pneumatic system health checks. PM customers receive 20% faster emergency response and spare parts discounts. Customized PM schedules based on your production volume and equipment age are available.
What is your experience with AIS PLC firmware corruption and data loss recovery?+
Extensive. We've recovered 25+ AIS-IPC production control systems from complete recipe file loss, corrupted firmware, and I/O module failures. Our cleanroom-equipped electronics lab performs EEPROM extraction and binary data reconstruction, then re-programs secure PLC backups. We also implement automated daily backup protocols to prevent future data loss in your glass production systems.
How do I send my AIS unit for repair?+
Pack the unit securely and courier it to our Vadodara workshop. Include a note with the fault description and your contact details. We will log it into our system and WhatsApp you a job number within 24 hours of receipt. Doorstep pickup is available in Vadodara, Ahmedabad, Surat, Mumbai, and Pune.
What is the cost of repairing a AIS drive or PLC?+
Repair cost depends on the model and the fault. We offer a free diagnosis — once we identify the fault, we provide a fixed quotation before proceeding. Typical repairs cost 20–40% of the new unit price. We will never repair without your approval.
What warranty do you provide on AIS repairs?+
All repaired units carry a 6-month comprehensive warranty covering the same fault and related issues. If the fault recurs within the warranty period, we repair it free of cost.
Do you provide a no-fix, no-fee guarantee?+
Yes. If we cannot repair your AIS unit after diagnosis, you pay only the diagnosis fee (₹500–₹1,500 depending on the product). The unit is returned to you at no additional charge.
AIS Repair Catalog
No products found for AIS
Don't See Your AIS Model Listed?
We repair the full range of AIS industrial electronics — even if the specific model is not yet in our catalog. Send us the unit details and we'll confirm repairability within 24 hours.
Free evaluation • 6-month warranty • PAN India pickup
Get Your Equipment
Back in Action — Fast
Send us your faulty industrial electronics. Our engineers will diagnose it and provide a detailed quote within 24 hours — with no obligation to proceed.
Free Evaluation
No obligation
48hr Turnaround
Fastest in India
6-Month Warranty
Every repair
No Fix, No Charge
Zero risk policy
Pan-India Pickup
Doorstep service