Press Presentation - Nov 2010 - Metalform Services LLC · (wholly owned subsidiary company) ISGEC...

Corporate Overview

Head Office, Noida Plant at port town of Dahej, Gujarat

Plant at Yamunanagar, Haryana

New Plant at Bawal for Standard PressesHead Office, Noida Plant at port town of Dahej, Gujarat New Plant at Bawal for Standard Presses

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Th S ti I d t i l S di t LtdThe Saraswati Industrial Syndicate Ltd.

ISGEC Group Saraswati Sugar Mills Ltd.

ISGEC John ThompsonISGEC U. P. Steels

(wholly owned subsidiary company)

ISGEC John Thompson

Presses: Mechanical &

ISGEC

Steel CastingsBoilers

U. P. Steels

Pressure Vessels & Heat

Hydraulic

EPC

Sugar Plant & Machinery

Heat Exchangers

Iron Castings

General Fabrication Head Office at Noida

(a suburb of New Delhi), India 2

ISGEC Group Turnover & Exports

483

450

500 USD in Million

303

404

300

350

400

195

267

200

250

300TurnoverExports

53 6390

29 32

81112 122

50

100

150

12 12 15 29 32

0

50

2003 2004 2005 2006 2007 2008 2009 2010

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Financial Year: October - SeptemberConversion @ Rs.45/- to 1USD

ISGEC Machine Building - Experience

• PressesOver 2700 Presses supplied including:

Machine BuildingDivision

pp g

- Including 31 Press Lines

- Most of them supplied in the last 10 years

P i 19 C t i- Presence in 19 Countries

• Contract ManufacturingOver 15000 Tonnes of Mechanical Equipment made to customers design.

• Equipment for Sugar Plants

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Repeat Orders

Customer Country Orders

ThyssenKrupp USA & India 7 (28 Presses)

Valeo France, Mexico & India 4 (9 Presses)


, & ( )

LuK Germany, China, Brazil, 5 (7 Presses) South Africa & India

Brandl Germany, Romania and 2 (3 Presses) y, ( )Czech Republic

Marubeni India 2 (4 Presses)

Bellsonica Corporation India 2 (19 Presses)

Suzuki Maruti India 4 (5 Presses)

Ford Motors India 2 (4 Presses)

T t M t I di 6 (11 P )Tata Motors India 6 (11 Presses)

Mahindra & Mahindra India 4 (9 Presses)

Kalyani Lemmerz India 8 (17 Presses)

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Caparo Group India 10 (31 Presses)

JBML Group India 23 (85 Presses)

CIE Automotive, Egania, Spain


Stamping Center• 2500T Link Drive Press

• Bed Size : 7m x 2.8m

• Press is equipped with: Electronic Transfer SystemElectronic Transfer Systemand Feed Line Equipment

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Brandl, Pfeffenhausen, Germany

2000T Link Drive Transfe


2000T Link Drive TransfePress.

Bolster Size:6100mm x 2800mm

This Press fitted with Robots for transferof components

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Brandl, Pfeffenhausen, Germany


• Interfacing Of COMAU Robots by ISGECby ISGEC

• Press equipped with 5 working stations with a die Cushionstations with a die Cushion capacity of 64T at each station.

O t t f 8 t i t• Output of 8 parts per minute.

R t O d i d f th t ft l f 315T H d li

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• Repeat Order received from the customer after supply of 315T Hydraulic & 400T Mechanical Presses to their Plants in ROMANIA & CZECH REPUBLIC.

Brandl, Czech Republic & Romania


315T Hydraulic Pressfor Sibiu, Romania

400T Mechanical Pressfor Kaplice, Czech Republic

(Photographs taken during inspection at ISGEC Works) 9

Blanking Lines: Neel Metal, India


• Blanking Line with Oscillating Shear for Neel Metal• Integrated with Feedline, Washing Machine and Stacker

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• Working Speed: 60 SPM • Bed Size 4500 x 2500 mm (~180” x 100”)• Similar Blanking Press supplied to Ford Motors

Mahindra & Mahindra India


• 1200T Mechanical Tryout Press.

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Benteler, South Africa


• 630T Hydraulic Press

• Press is fitted with Robots for transfer of componentsof components

• Repeat Order for India received

R t O d f• Repeat Order for China under consideration

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JBM OGIHARA, India


Press Line 8-5-4-4 commissioned in 2010.co ss o ed 0 0

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ThyssenKrupp, India


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1000T & 800T Press Lines (10-6-6-6-4) & (8-6-6-6-4) – Commissioned in 2000

3rd Line (10-6-4-4-4) supplied in 2008

Thyssenkrupp, India

Die Spotting Press:


Die Spotting Press:

• Accuracies as per

JIS 6403 – 1994, special grade

• 25 Presses supplied to valued customers such as:

- Suzuki MotorcyclesM ti S ki- Maruti Suzuki

- ThyssenKrupp- Tata Motors- Sermo Mould- Ashok Leyland

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ThyssenKrupp, Detroit, USA


1200T Hot Forming Press:

• Interfaced with furnace, loader, unloader and cooling circuit for quenchingquenching

• For Hot Forming of Boron Steel Components

• The components produced (Pillars, Front Case etc.) have high strength and low weight and are used inluxury car segment

16(Photograph taken duringinspection at ISGEC Works)

Valeo, San Louis Potosi, Mexico


Tandem Press Line 2 x 1000T and 3 x 600T Presses supplied to Valeo Mexico

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Tandem Press Line 2 x 1000T and 3 x 600T Presses supplied to Valeo, Mexico.ISGEC’s scope includes:Presses ; Die Transfer SystemDie Storage Racks and interfacing with Press to Press transfer system

Valeo, San Louis Potosi, Mexico


1000T Feed Press

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Valeo, India


• 1st Installation in Valeo Group

• 630T Press for Progressive Dies application

• Interfaced with Feedline Equipment

• Satisfactory performance since 1998• Satisfactory performance since 1998

• Working Speed (Variable) : 30 to 90 SPM’s

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Valeo, Amines, France


• 2nd Installation in Valeo Group

• 1000T Press forProgressive Dies application

• Interfaced with Feedline equipment

• Satisfactory performance since 2001

• Working Speed (Variable) : 30 to 100 SPM’s


Valeo, Amines, France


• Repeat order from Valeo,in 2005

• 1000T Mechanical Press

• Installed at Valeo,Amiens, France

• Working Speed (Variable) 30 to 120 SPM’s

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LuK, Sorocaba, Brazil


• 630T Mechanical Press

• 2nd Installation in LuK Group 2 Installation in LuK Group

• Satisfactory performance since 2000

• Working Speed (Variable) : 30 to 100 SPM’s30 to 100 SPM’s

Similar Press supplied toLuK, Port Elizabeth, South Africa in 2007, ,


LuK, Sorocaba, Brazil


• 1500T Hydraulic Presscommissioned at LuK, Brazil in 2008

• High Speed Hydraulic Press with• High Speed Hydraulic Press withdry cycle time of 3.3 seconds

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LuK, Taicang, China


• 630T and 160T Mechanical Presses commissioned at LuK, China in 2006

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LuK, Buehl, Germany


630T630TMechanical Press commissioned atLuK, Germany in 2008

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General Motors, San Louis Potosi, Mexico


• One of the three 1000T Link Drive Mechanical Presses

f t d f GM M imanufactured for GM, Mexico

• These Presses are part of Automated Tandem Press Line supplied by WIApp y

(Photograph takenduring inspection at ISGEC Works)

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Tata Motors, India


• 1200T Hydraulic Press forD D Sh t M t lDeep Drawn Sheet MetalComponents

We have so far supplied11 Presses to this customer

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UTW, Drolshagen, Scheda, Germany


• 1200T Hydraulic Press forcomponent tryout built toJIS 6403 Special Grade

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Wheels, India


• 2000T Hydraulic Pressfor Hot Formingof Earth Mover Wheels

We have so far supplied27 Presses to this customer

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Force Motors, India

• 2000T Hydraulic Pressmanufactured for


Force Motors, Pune,supplied in January 2008

• Repeat order for machineli d i 1999supplied in year 1999

• 4 Point CNC Die Cushion

• Cushion in Slide

• Manufacturing components forMercedes Utility Vehicle

30(Photograph taken duringInspection at ISGEC Works)

Hemming Presses: Ford, Marubeni (Suzuki), Honda


• Repeat Ordersfrom Ford, India

6 Presses Supplied• 6 Presses Supplied to Marubeni (Suzuki India Project)

• Similar Presses supplied to Honda Motors

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ISGEC Machine Building Division


PRODUCTION FACILITIES

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Production FacilitiesMANUFACTURING CAPACITY – 12 LINES PER YEAR

Each Equivalent to A1 Line (1500T Press) Machine BuildingDivision

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• Shop Area: 20,000 sq.m. • Maximum Crane capacity: 200T• 85 Qualified Engineers

• Work Force : 450• Assembly Pits : 4• Maximum pit size : 25m x 10m x 5.5m

Production Facilities

One of the Shops for Assembling and Machining

Production Facilities• Horizontal Boring Mills: - 15 Nos. (including 7 axis CNC)

- Maximum Ram Size (square): 550mm


(square): 550mm- Maximum size:16m x 4.5m x 2.4m (X x Y x Z)

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• Plano Millers - 2 Nos.Table Size: 6000 mm x 3000 mm

Clear Height: 3000mm

Production Facilities

One of the 6 CNC Turning Lathesmaximum turning capacity:- Diameter : 1100 mm- Length : 10000 mm


- Length : 10000 mm

One of 9 Vertical Boring Machines

- Maximum size of job:6.1m Dia. X 3.5m Ht.

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Production FacilitiesThi FThis Furnace[size 4m (13’) x 4.5m (15’) x 14.5m (47.5’)]is one of the 5 Heat Treatment Furnaces usedfor Normalizing, Annealing, Hardening,Tempering and Stress Relieving of Fabrications


p g gand Castings

We also have facility for Water and Polymer Quenching

We can hot rollSteel Plates up to

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p200 mm (8”) thickness

and cold roll up to100 mm (4”) thickness

Production FacilitiesR di h f ilit tRadiography facility up to200 mm (8”) thickness using aCobalt 60 source.We have 7 radiography halls andtake more than 100,000 radiographs


, g pannually. We also have facility for X-Ray andIridium Radiography.

Steel is melted in an 8.5Tonne Arc Furnace and Dual Track Induction

Furnace having 2 crucibles of 9 Tonnes each. Besides, there is also a

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Tonnes each. Besides, there is also a AOD Furnace of 16 Tonnes capacity

and a LR Furnace of 22T capacity for secondary refining of steel.

ISGEC Machine Building Division


QUALITY, SAFETY AND ENVIRONMENT

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Quality, Safety and Environment - Standards

• Accuracy


Hydraulic Presses : JIS 6403 – 1994, Grade I

Die Spotting & Tryout Presses : JIS 6403 – 1994, Special Grade

Mechanical Presses : JIS 6402 – 1985, Grade I

• RigidityDeflection of Bed / Slide : 0.17 mm/mDeflection of Bed / Slide : 0.17 mm/munder full load) or better as per customer requirement

• Safety : EN (CE Safeties) / OSHA

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Quality, Safety and Environment


ISO 9001 : 2000 ISO 14001 2004OSHAS 18001 : 1999

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ISO 9001 : 2000 ISO 14001 : 2004(Environmental Management System)

OSHAS 18001 : 1999(Occupational Health & Safety Management System)

Global Sourcing

Component Make*

Hydraulic Components : Bosch Rexroth, Parker, Vickers

PLC Controls : Siemens, Telemechanique, Allan Bradley, Mitsubishi,


Safety Relays : PILZ

Electrical Motors : Siemens, ABB, Reliance

Clutch and brake unit : Ortlinghaus, Goizper, Ompi

Cam limit Switch : Balluf, KAMCO, Showa Seiki

Electrical Drives : Siemens, Allan Bradley, Mitsubishi

Pneumatic Components : SMC, Festo-Norgenp g

Dual Solenoid Safety Valve : ROSS, Herion

Die Clamps : Pascal, Hilma

Slide Locking arrangement : Pascal, Hilma, Ortlinghausg g , , g

Tonnage Monitor : IMCO, Toledo

Brake Monitor : Wintress, Helm

* Other makes can be provided on request

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Other makes can be provided on request

Design Capabilities

Software

• Drafting : Auto Cad

3 D M d lli MDT (M h i l D kt )


• 3-D Modelling : MDT (Mechanical Desktop)INVENTORSolid EdgeSolid Works

• Analysis : NISA (Stress, Strain, Deflection)DDM-Pro (Mechanism of Link Drive and Knuckle Joint Presses)

• Electric Circuits : E Plan• Electric Circuits : E Plan

• Software Available for Ladder Diagrams of most of the PLC manufacturers including Siemens, Allen Bradley, Telemechanique, Mitsubishi

Manpower

• Total Manpower : 30, including 7 for Electrical & Electronics design

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• Dedicated team for Technology Upgradation

Finite Element Analysis

• To ensure safe stress and strain in critical members of the Press Machine BuildingDivision

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Servo Presses: Under Development

High torque servo motors


motors

Main drive shaft

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New Plant - Bawal


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New Plant being set up at Bawal (near Delhi)for manufacturing standard Gap Frame and ‘H’ Frame Presses

ISGEC Group

OTHER PRODUCTS

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Other Group Products - Pressure Vessels

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Lavalin, Canada for PDO, Omanjob weighing 210T with a length of 12.5 M

Other Group Products - Heat Exchangers

49Galaxy Projects, UAE for Burrup Fertiliser, Australia

- EPC, Power Plants, BoilersOther Group Products

Dhampur Sugar Mills Asmoli, India30.4MW Power Plant

Zambia Sugar Plc, Zambia(IJT capability – up to 100MW)( p y p )

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Other Group Products - Complete Sugar Plants

• Consolidated Farming Ltd., Zambia

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Other Group Products - Castings

G.E. Hydro, Canada VA Tech Hydro, India

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THANK YOU

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Press Presentation - Nov 2010 - Metalform Services LLC · (wholly owned subsidiary company) ISGEC...

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Transcript of Press Presentation - Nov 2010 - Metalform Services LLC · (wholly owned subsidiary company) ISGEC...