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status of indian foundry industry

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h sundara murthy status of indian foundry industry

h sundara murthy status of indian foundry industry

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  • 1. The Institute of Indian Foundrymen..Status of Indian Foundry Industry By President The Institute Of Indian Foundrymen
  • 2. The Institute of Indian Foundrymen.. GDP Forecast – UN Report 2011 2012 2013India 7.6 7.7 7.9China 9.3 8.7 8.5EU 1.6 0.7 1.7USA 1.7 1.5 2World 2.8 2.6 3.2
  • 3. The Institute of Indian Foundrymen.. Location of Major Clusters There are approx 4600 units in the country located in the areas marked in the map engaged in various types of metal castings
  • 4. The Institute of Indian Foundrymen.. Indian Foundry Industry At a Glance Approx Units : 4600 Production: 9 Million MT PA Employment: 500,000 Directly 150,0000 indirect Major Clusters: 19 Productivity Per unit : 1950 MT/PA Avg Productivity/Man/PA: 20 Max Productivity /Man/PA: 90
  • 5. The Institute of Indian Foundrymen..Castings Production Trends in Million MT-India Casting Production Trends in Million MT-India 10 9.0532 9 7.7711 8 7.1793 7.4432 6.8405 7 6.055 6 5 4.623 4.038 4 3.215 3.12 3.155 3.509 2.767 2.895 3 2 1 0 Grey C.I. SG Iron Malleable Steel non ferrous TOTAL
  • 6. The Institute of Indian Foundrymen.. Growth in Production of Castings in 2010-11 vs 2009-10 Type % Growth Grey Iron 23 Ductile Iron 26 Steel 21.6 Non Ferrous 13.5 Overall 23.8
  • 7. The Institute of Indian Foundrymen..Exports Total engg exports during 2011 was USD 59.78 Billions ie an increase of 83.65% over previous year Castings export was approx Rs 6500 Cr in 2010-11 Vs Rs 4200 in 2009-2010 The trend may not be sustainable next year as most Asian economies have increased interest rates to curb inflation & Coupled with rising commodity prices & crude will dampen demand However, most respondents expressed stagnant export market
  • 8. The Institute of Indian Foundrymen..Export Trends :
  • 9. The Institute of Indian Foundrymen..Sectorwise Consumption of Castings
  • 10. The Institute of Indian Foundrymen.. Product Mix‘
  • 11. The Institute of Indian Foundrymen..Share of Major Casting Producing Countries Brazil, 3.24 Germany, 4.79 India, 9.05 Italy, 1.97 Others, 11.63 France, 1.96World, 91.67 China, 39.6 USA, 8.24 Korea, 2.23 Japan, 4.76
  • 12. The Institute of Indian Foundrymen..Top 1-6 Casting Producers Top Six Casting producers of Castings ‘ 45 40 35 ChinaFigs in Million MT 30 India 25 USA 20 Germany 15 Japan 10 Russia 5 0
  • 13. The Institute of Indian Foundrymen..Growth of Metal castings by –MajorCountries by Production While World production in 2010 grew by 14% as compared to previous years, Brazil emerged as fastest growing country as per census by Modern Castings Brazil 40.87% Germany 22.82% India 22.3% Italy 17.96% China 12.18% USA 11.35% Japan 8.18%
  • 14. The Institute of Indian Foundrymen..Top 15 Produce >13% Name of Unit Production of Castings T/Year Year : 2010-11ELECTROSTEEL CASTINGS LTD 275284LANCO INDUSTRIES LTD. 123422RAIL WHEEL FACTORY 106525HINDUJA FOUNDRIES 88545NELCAST LTD. 83469TATA MOTORS JAMSHEDPUR + Pune 81274BRAKES INDIA LTD. 75886DCM ENGINEERING PRODUCTS 62327SAKTHI AUTO COMPONENT LTD. 50000COOPER FOUNDRY, SATARA 49200MAHINDRA- HINODAY + Mahindra Auto 48719JAYASWALS NECO LTD. +NECO CASTINGS 48085ASHOK IRON WORKS 45112KIRLOSKAR FERROUS INDUSTRIES LTD. 41905WELCAST STEELS LTD. 38241
  • 15. The Institute of Indian Foundrymen..Various Types of Castings Producedin India
  • 16. The Institute of Indian Foundrymen..Various Types of Castings Producedin India
  • 17. The Institute of Indian Foundrymen..Foundry Industry -Foundries 50% respondants reported + 5-10% % growth in production in Q2 Vs Q1 2011-12 .While other 50% reported growth of + 10-15% in same period Exporters reported growth of + 5-10% in Q2 Vs Q1 2011- 12 Most reported order books + 5-10% in Q2 Power availability improved in 2011-12 Vs 2010-11 though still unsatisfactory .The gap between demand & supply reduced in TN,AP,Punjab Rajasthan & Haryana Power generation grew by 9.3% in Apr-Sep 2011-12 Vs 4.1% in 2010-11
  • 18. The Institute of Indian Foundrymen..Equipment Manufacturers• Most respondants reported growth of +10-15% in Q2 11-12 Vs Q1• Order books were Up by 5-10% reported by 50% respondants & up by 10-15% by balance in Q2 Vs Q1• Reported raw material & power availability as satisfactory• 75% Respondants reported export markets still growing while balance reported as stagnant
  • 19. The Institute of Indian Foundrymen..Foundry Material Manufacturers Most respondants have reported - ve growth of 5- 10% in Q2 Vs Q1 while a few reported + ve growth during above period of 10-15%. Domestic markets for most is still growing @ 5-10% & satisfactory while exports are going down.
  • 20. The Institute of Indian Foundrymen..Auto Industry Sales of passenger vehicles has been very weak & registered modest growth in Nov after falling for last 4 months & the annual growth in sales of cars likely to be 2- 4% this fiscalSales Growth in Nov 2011 Vs Nov 2010 Cars +7% Motorcycles +23% Scooters +38% Commercial Vehicles +35% Three Wheelers +6% Total + 22%
  • 21. The Institute of Indian Foundrymen..Auto Industry Single Largest Conumer .Consumes approx 32% of total production Growth in 2011-12 to be weaker Vs 2010-11 SIAM Forecast 11-12% in 2011-12 Vs 26% in 2010-11 Cars will register lowest growth of 2-4% ;LCVs are likely to grow 20-23%;CV & two wheelers @ 13-15% The slow down is attributed to higher interest rates ,commodity & crude oil prices
  • 22. The Institute of Indian Foundrymen..Tractors Growth in 2011-12 is likely to be lower in 2011-12 Expected growth this FY is 10%
  • 23. The Institute of Indian Foundrymen..Machine Tools Registered growth of 12.24% by volume in Apr-Dec 2011 Vs Apr-Dec 2010 Registered Growth of 18.4% by value during corresponding period as above
  • 24. The Institute of Indian Foundrymen..Power & Infrastructure Govt of India plans a target of USD one trillion of investment during 12th plan ( 2012-17) Power sector’s share n above likely to be USD 300 Billions for addition in capacity of 100,000 MW during the plan period This will pull demand from sectors such as Earthmoving, Power Generation, Electrical Machinery & Transport
  • 25. The Institute of Indian Foundrymen..Vision For Indian Foundry Industry‘ Production In Million MT/PA 30 25 20 15 10 5 0 2010 2015 2020
  • 26. The Institute of Indian Foundrymen..Vision For Indian Foundry Industry‘ Avg productivity /unit in MT PA 5000 4500 4000 3500 3000 2500 2000 1500 1000 500 0 2010 2015 2020
  • 27. The Institute of Indian Foundrymen..Vision For Indian Foundry Industry‘ Avg Productivity/Man in MT PA 60 50 40 30 20 10 0 2010 2015 2020
  • 28. The Institute of Indian Foundrymen..Vision For Indian Foundry Industry Savings in Sp Energy Consumption in % 10% 5% Base Line 2010 2015 2020
  • 29. The Institute of Indian Foundrymen..Govt. Initiatives Current share of Manufacturing in GDP has been 15- 16% since 2005-06 Govt plans to increase share of manufacturing in GDP to 25% in next 10 years As per Planning commission India needs 250 million new jobs in next 15 years & therefore focus on manufacturing NMIZs being planned spread over 2000 Hectares( 8 Sq Km) NMIZs will be combination of production units, public utilities, logistics, environmental protection mechanisms & residential area
  • 30. The Institute of Indian Foundrymen..Govt. Initiatives Contd….. Two Automotive Manufacturing hubs planned one each in Central & Eastern India spread over 10,000 Acres each in addition to 3 existing at Haryana, Maharashtra & Tamil Nadu Setting up Sector Skill Councils for sector specific skill upgradation Introduction of Vocational programmes at CBSE level
  • 31. The Institute of Indian Foundrymen..New/Recent Plans for Investments inRs Crores Maruti Suzuki: 18000 ( in 3 phases in Gujrat incl their vendors) Ashok Leyland: 1000 Nissan Jt Venturewith AL: 2300 Asia Motor Works: 500 Hyundai: 400 Daimler Trucks: 4400 Eicher Volvo: 500 Force Motors: 800 Mahindra: 1350 Tata Motors: 12000 Volvo Buses: 500
  • 32. The Institute of Indian Foundrymen..Upcoming/New Projects-Auto Industry Fiat at Ranjangaon with investment of INR 4000 Cr GM India Expansion plans investment of INR 1000 Cr Volkswagen plans new investment of INR 3800 Cr Mercedes Benz investments INR 250 Cr Bajaj Auto for two wheelers & cars INR 1500 Cr
  • 33. The Institute of Indian Foundrymen..New/Recent Foundry Projects /Expansions DCM Engg  Steel Cast Sharp Chucks  Indian Smelting RPS Vikas  Kastrel Bhagwati Foundries  PSG Coimbatore Flowmetalic  Bagree Alloys Nelcast  Tata Motors Brakes India  Hinduja L&T  Amtek Ace Designers  DGP Hinoday(M&M)  Srinivas engg
  • 34. The Institute of Indian Foundrymen..New Foundries Green Tech Industries of Taiwan new foundry near Chennai ( Meita Group) 100% EOU supplying turbochargers 1100 MT/Annuam
  • 35. The Institute of Indian Foundrymen..Major Constraints Availability of skilled manpower Reliable power supply Raw Materials shortage forecast by some High cost of capital High cost of Energy
  • 36. The Institute of Indian Foundrymen..Recent IIF Initiatives Proposal submitted for setting up of Sector Skill Council-Foundry which is being pursued Initiated Committee on Environment to Focus on this vital aspect Initiated various programmes on Energy conservation MoU with JFS under consideration for synergy between industry bodies to promote exchange of information & support each other for benefit of members Promote cause of Industry with various stakeholders
  • 37. The Institute of Indian Foundrymen.. Thank You