MAHINDRA HINODAY (Foundry Division) PRESENTATION

Systech SectorMahindra Hinoday

MAHINDRA HINODAYMAHINDRA HINODAY(Foundry Division)(Foundry Division)

PRESENTATIONPRESENTATION


Farm Equip

Automotive Systech

Telecom & IT Finance Infrastructure

Mahindra Group Turnover Euro 6 Bn


Gear

Steel Forging

CastingTool/Die Design

Stamping Composites

SSBU Engg Ser

Customer

Systech Synergies

Systech Turnover : Euro 700 Mn

Casting Turnover : Euro 44 Mn


• Hinoday Overview

• Foundry Overview

• Foundry Customer/Product Profile

• Foundry Design & Development Capabilities

• Foundry Facilities


Foundry OverviewFoundry Overview


India’s largest independent SG Iron automotive parts producer

70,000 TPA - 40% Sales is in fully machined condition

Customers’ New Product Partner

Exports 21%

Business HighlightsFoundry Overview


Established in 1997

Land & Building Total 180,000sq mts Built up 42,000sq mts

Total Investment USD 110 Mn

Man Power Workmen 580 Management staff 208

Total Capacity 70,000 tpa

Sales 11-12 Rs 3,798 Mn (40,667 MT) USD 77 Mn/ Euro 56 Mn

InfrastructureFoundry Overview


1963

Company started by Dr Morris

Technical Collaboration with Hitachi

Metals

Financial Participation

by Hitachi Metals

Diversified into Foundry

Business

2nd Molding line commissioned

Ownership by M&M

Approval for 3rd Molding

line

1996

Ownership by

Piramals

Exports started

TS16949 certification

1981

1984

1987 2002

2004

2005

2007

2007

2010

In house machine

shop started

3rd Molding line

commissioned

2010

Journey So FarFoundry Overview

2011

4th Molding line

commissioned


Quality Certifications• ISO/TS : 16949 Certified• ISO/OHSAS : 14001 Certified

Investing in QualityFoundry Overview

d


First Time in IndiaFoundry Overview

Only Foundry to produce cast Crankshaft

High Pressure line for Ductile Iron by an independent Foundry

Auto pouring System with Automatic inoculation

CAD – CAM process for tool design and manufacturing

Use of Cold box process in mass production


Capability to produce range of products - Weight range 3kg ~ 83kg single piece

Complex thin wall castings - Nominal wall thickness 4mm

Castings with high strength & high ductility

Various Material Grades - All Grades of SG Iron - High SiMo - Austempered Ductile Iron - SiMo Crome SG Iron

Foundry CapabilitiesFoundry Overview


Foundry Sales Growth – Rs MillionFoundry Overview


Foundry Sales Growth Tons/YearFoundry Overview

1812

54506729

9662

12475

16950

20150

23000

26900 27560

23610

28767

35307

40667

-3000

2000

7000

12000

17000

22000

27000

32000

37000

42000

98~99 99~00 00~01 01~02 02~03 03~04 04~05 05~06 06~07 07~08 08~09 09~10 10~11 11~12

Auto pour Casting cooling

Conveyor & TPM

Reached project

Capacity

New line added

10~11 New line added

11~12 New line added


Foundry Customer/Product ProfileFoundry Customer/Product Profile


Axles India Ltd.

TRANSMISSIONSTRANSMISSIONSTRANSMISSIONSTRANSMISSIONS

TRANSMISSIONSTRANSMISSIONSTRANSMISSIONSTRANSMISSIONS

Export

Domestic

Customer BaseCustomer & Products


Axle & Transmission parts Turbine housing

Medium & Heavy Commercial Vehicle (MHCV), Utility Vehicle (UV)

Passenger car

Crankshafts

CV & UV, Pass car

Focused Product VerticalsCustomer & Products


• Largest Ductile Iron Foundry

• Capacity 70 KT/year

• F12 Revenues Rs 3797 Mn • Export 29%

Customer Segment

Product Portfolio

Customers

• Top 4 Customer 66% - M&M, AAL, JCB, JD

• TC customers - CTT & HTT

Product ApplicationCustomer & Products


Design CapabilityDesign Capability


CAD-CAM process for Tool Manufacturing - Versatility in use of different soft wares – Catia and Pro-E - Design Engineers trained at Hitachi Metals - Lead time reduction – Design Automation and Standardization

Flow and Thermal analysis for Product development - Right first time - Castings with high Integrity

Design CapabilitiesDesign & Development


Design Process – Flow & Thermal AnalysisDesign & Development


30 50 15 55 30 55 15 20 40 40140 100 5030

80 95150

180235 250 270

310350

490

590640

0

100

200

300

400

500

600

700

98~99 99~00 00~01 01~02 02~03 03~04 04~05 05~06 06~07 07~08 08~09 09~10 10~11

Year Cummulative nos

Product DevelopmentDesign & Development


FacilitiesFacilities


Molding Line : GF Horizontal Parting 96moulds/hr 900*700*300/300

Flask less Horizontal 120 moulds/hr 610*509*200/200

Flask less Horizontal - 2 lines 100 moulds/hr 700*600*300/300

Sand Plant : GF Automated Sand Plant High Speed Intensive Mixer Sand Cooling System On Line Compactibility

measurement

Melting MF Furnaces 6T/3.5MW - 1no Dual track 4T/2.5MW – 1no Dual track 2T/1000KW – 1no Mono Track 3T/2.5MW – 1no Dual track Vibratory Chargers : 8 nos

Pouring 2T Unheated Tundish with Vision

Control - Autopour Pouring car – 1 no

Facilities


Core ShopCold Box Machines Horizontal Parted – 5L/20L/30L Vertical Parted – 5L/10L/20L

Shell Core Machines Size 600*300

Shot Blasting Spinner Hanger GF : 2no Tumblast GF 2.7t/hr : 3no Casting Cooling Conveyor

Quality Assurance Vacuum Emission

Spectrometer – 2 nos Hardness Testing Tensile Testing Image Analyzer CMM Ultrasonic Testing

Designs 3D Modeling – Pro E Simulation – Pro Cast Auto Cad 14

Facilities


• Established in April 2006• Land & Building 1540sq mts • Total Investment USD 4.5 Mn• Man Power - Operators 200 - Management staff 15• Total Capacity 650,000 nos/year• Sales 11-12 - Value added Rs 206Mn (448,085 nos)

Machining FacilitiesMachining Business Overview


46 nosLeak Testing, Washing, Nuber Punching & Welding

4 nosElectronic Guages

Contour Tracer, Roundness Tester 1 each

CMM Accurate (3 nos)

Mori Seiki (1 nos)HMC

Fanuc (14 nos)VMC

Lokesh (23 nos)CNC

Mori Seiki (4 nos)VMC

Machining (In-house)

Machine Shop caters to the global demand of Turbocharger OEMs

Machining Facilities


Familiar with • EDI (Electronic Data Exchange) and VMI (Vendor Managed Inventory)

• Full container shipments

• Global RFQ /RFI /Global bidding process

• European OEM’s quality requirements

• Bar coding

Familiarity with Export business


THANK YOU

THANK YOU

MAHINDRA HINODAY (Foundry Division) PRESENTATION

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