Casting of automotive parts

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 OEM’s
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 PO’s- 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 customer’s 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

7. Axles/
Housings
Capabilities -Machined Castings
Structural
Parts
Braking
System

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

15. Machined from Block/Forgings

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.