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Casting process - sand casting, molding, steels
- 1. Aerospace -Defense - Fluid Handling - Infra - Rail and Locomotive - Off-Highway - Oil and gas Machined Cast parts - Machined Forged parts - Precision Components Contract Assembly Services - Engineering Design Support & Prototyping Testing & Validation Casting Supplier
- 2. Presentation Outline Corporate Overview Background Vision & Mission Why XXXX Leadership team Milestones What we do Capabilities Manufacturing Facilities Castmetals Division QA Infrastructure - Castmetals Division Manufacturing Facilities Engineering Division QA Infrastructure - Engineering Division Certification and Approvals - Castmetals Division & Engineering Division Customers
- 3. Background, Vision & Mission The leadership team at XXXX has been at the forefront of the foundry industry in India since 1967. The leadership at XXXX has over 50 years of experience in working with leading international OEMs To build long term sustainable relationships with global manufacturing companies such that we become true trusted goal sharers for their specific product and service requirement. Vision : Past Experience & Expertise of the management group : To be a Great Trusted Place to Work with for employees, customers, suppliers and service providers committed to delivering excellence in the build-to-print complex and core manufacturing space. Mission :
- 4. Why XXXX One stop source for diverse components From precision components weighing a few grams to large castings and forgings weighing up to 5000 Kgs. Variety of processes Investment /Sand castings, Forgings and bar. Small by Design Large enough to be reliable and small enough to be agile and customer focused. Flexible and highly responsive culture. "Goal Sharers" and solution providers instantly aligning to customer goals. We embrace complexity and challenging materials Tight geometrical tolerances, difficult to produce materials and critical Non destructive testing (NDT) requirements form part of our regular production. Proficiency, precision and accountability We simplify complex supply chains Single line POs to 100 lines POs- Low volume high variety to repetitive scheduled deliveries. Ex-Works /FOB/ CIF coupled with warehoused Just-in-Time Supply as per customer requirement. Single Point of Ownership for diverse components in variety of materials and sizes. Serviced by XXXX A Team Manufacturing and metallurgical expertise built over 5 decades. Senior Management commitment, involvement and accessibility Dedicated Focused manufacturing Cells for key product / customer groups. Trust Track record Stability 100% referable clients. 5 decades of customer service, dedication and protection of customer IP ingrained in XXXX culture. Family owned & professionally managed by 3rd Generation entrepreneurs. Financial stability with high credit rating willing and ready to make investments in
- 5. 2000 Set up of facilities and commencement of business (Machining & Test Unit 1) 2003 CNC Machining Capability added. 2005 Supply of Valve kits and precision components & Contract Assembly 2007 2nd manufacturing site at Coimbatore- Focused factory with dedicated manufacturing cell for volume, repetitive products. 2009 XXXX Cast metals Division Set up (Captive Steel Foundry) in Chennai. 2010 New Machining facility Plant III started production in Chennai. 2012 2015 2017 2019 2020 Upgradation of Quality Infrastructure In house Radiography factory for high integrity parts. Unit I - Upgradation Set up of Prototyping Division with 5 Axis Machining facilities in Chennai Set up of Aluminium Sand & Gravity die casting foundry in Chennai. 2018 Set up of On demand manufacturing . XXXX Milestones EN 15085-2 Welding of railway vehicle and components certification for Cast metals division. & Aerospace AS9100 Certification for XXXX Unit II Coimbatore 2022 Large Casting Capabilities
- 6. What we do Description What we do Industries Served Aerospace Defense Locomotive & Rail Off Highway Power Sector Oil & Gas Machined Cast Parts Ferrous and Non Ferrous using Sand and Investment castings, High Precision machining and value added services including hard facing and ground / lapped finish. Weight Range from 0.01 Kgs to 5000 Kgs Machined Forgings Open die, closed die and ring rolled forgings fully machined in a variety of alloy steel and stainless steels. Weight Range from 0.5 Kgs to 3000 Kgs Precision Components High precision machined components in a variety of materials grades including alloy steels, stainless steels, Inconel. *Flatness 0.0005 *Deep hole position tolerance 0.003 *Concentricity/ Perpendicularity with in 20 Micron Contract Manufacturin g Services Complete assembly and testing services for pumps , valve and sub assemblies using machined cast, forged and fabricated components - - - Materials Carbon Steel, Alloy Steels, Stainless Steel Grades, Duplex Stainless Steel, Exotic alloys ( Monel, Inconel, Hastelloy), Aluminium, Aluminium Bronze, GCI and Ductile Iron. Value Added Supply Chain Consolidation Integrating customers existing supplier base for higher value addition / inventory consolidation / Kanban / assembly in order to deliver better efficiencies Engineering Support Services . Working with customers for design support services including Fab to cast conversion, cast to forge, improve manufacturability
- 8. Capabilities - Machined Casting Traction Motor End Cover Frame Heads Engine parts Exhaust transition section
- 9. Capabilities -Machined Castings Rail parts Tight lock Couple Coupler Head Casting Draft Gear Housing Knuckle Yoke Herbert Mounting Plate End Plate Air Coupler Draw bar U-Tube Transom Anchor Bearing Bracket Centre Plate
- 10. Capabilities -Machined Castings Traverse Middle Welded Spring Cup Joint Head Joint Fork Rail parts Spring Pot LDG Joint Eye
- 11. Capabilities -Machined Castings Rail parts Flexi Shoe Holder Brake Shoe Holder Brake Shoe Support Hanger Piston Wedge Inferior Support Knuckle
- 12. Capabilities -Machined Casting Flow Meter Pumps Knife Gate Valve
- 13. Capabilities -Machined Casting Butterfly / Triple Off set Valves Ball Valve Dual Plate Check Valves
- 14. High Integrity Lite metal parts High Integrity Lite metal parts
- 16. Capabilities - Precision Components
- 17. 5 Axis machining Finished part Patterns core & Cavity Flexicam CNC - Router - Work Area is 3,080 x 2,040 (XxY) - Z clearance 900mm - Z stroke 1,000mm Rapid tooling shop
- 18. XXXX - Manufacturing Facilities Castmetals Division
- 19. Castmetals Division Current Capacity and Capabilities Description Current Capacity Capacity Planned for 2022-2023 Sand Casting Phase -II ( Investment Foundry) Max Single Piece weight 3.6 Tons 50 (Kgs) Monthly Capacity 450 Tons/Month 60 Tons/Month Capacity Utilized 220 Tons/Month 30 Tons/Month Spare Capacity 230 Tons/Month 30 Tons/Month
- 20. Castmetals Division - QA Infrastructure Magnetic Particle Inspections Spectro Meter UTM Machine Impact test Machine In-house RT Facility Faro Arm
- 21. XXXX - Engineering Division Manufacturing Facilities Unit 2 Unit 1 Head Office 2
- 22. Engineering Division - QA Infrastructures Flatness check Air Gauge Kings Hardness Tester Portable Hardness Tester Fluorescent dye penetrant (Zyglo) Zeiss CMM Trimos Height Gauge Faro CMM Arm Romer
- 23. XXXX - Certifications and Approvals Castmetals Division ISO 9001 : 2015 NORSOK Approval EN 15085-2 CL- 1 ASNT NDT Level III Certificate DNV Marine Approval Transportation and Power Generation ISO 14001:2015 and ISO 45001 : 2018 Engineering Division ISO 9001 : 2015 Aerospace Quality Management System AS9100 API
- 24. XXXX is committed to growing its businesses in a responsible, planned manner. Our goal is inclusive growth considering our team, our customers, our immediate environment. All plants focused on operator and plant safety. Investments made for environmental protection measures that exceed statutory requirements in the Castmetals Division. State of art Sand reclamation system RO plant STP ETP Ultra filtration Acid pickling wet scrubber, DM Water plant All power used by the company is from our green power ( Wind mill). Health, Safety and Environment
- 25. Corporate social responsibility Little Drop old age homes Isolation ward Udhavum Karangal donation for Library Carl Zeiss make Ophthalmic micro scope to VHS Chennai
- 26. Few of our valued customer Off Highway, Power sector & Infrastructure Fluid Handling Rail & Locomotive
- 27. Thank You for your time 1 committed team backed by diverse, world-class, manufacturing capabilities focused on consistently delivering value to the customer.