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Welcome ToMalnad Alloy Castings Private Limited
Est 1983Alloy Steel Stainless Steel Nickel Base
Castings Manufacturer
MALNAD GROUP COMPANIESMalnad Alloy Castings Pvt Ltd since 1985
ScopeManufacture amp Supply of Raw Machined and Hydro tested Castings in Ferrous Nickel and Cobalt
based alloys
Shimoga Precision Castings Pvt Ltd since 1996Scope
Manufacture and Supply of Alloy Steel Stainless Steel Nickel Alloy Steel Cast Iron and Cobalt Alloy Steel Castings By Investment and Sand Casting Process
Malnad Prime Machining Technologies since 2010Scope
Manufacture of Precision Machined Components
Malnad Alloy Castings Pvt Ltd (Laboratory Division) since 2017
NABL Accredited Mechanical and Chemical Testing Lab
We are located inhellip
Management Contacts
Y V Madhukar Jois Managing Director+91 990 017 7820joismalnadcoin
Prateek M Jois Executive Director +91 966 315 5553pjmalnadcoin
Land Lines - (08182) 46141246142246143
4
Organisation Chart
Photo Name Department Mail ID Cell phone Issues Handled
VynatheyanManager Marketing hrkmktmalnadcoin 9880741704 Enquiry PO OA
Mahesh CNManager
Production cnmprdmalnadcoin 9880741702Delivery dates Planning Dates
Subhanna NManager Quality
Assurance nsqamalnadcoin 9880741703
Test certificates (chemical amp Mechanical)
Swamy MSManager Quality
Control swamyqcmalnadcoin 9880741705 NDT Related
Manjunath M LManager Pattern
Shop manjupatnmalnadcoin 8861002651 Pattern development
SubramanyaHegde
ManagerDispatch and
Logistic sharathmalnadcoin 8861699975dispatch dates Logistics Details
Mahaveer JainProcess Engineer mjainmalnadcoin 8861002642 Customer complaints
The Vision of our company is to
ldquoBecome global leader for the supply of finished cast componentsin wide range of materials with highly committed and sociallyresponsible employeesrdquo
Our Mission is to To meet the casting requirements of the country using latest stateof the art-technology in wide range of materials at competitivecostProvide stable employment and develop highly skilled technicalmanpower and develop wide vendor baseAdopt environmentally sound and safe technology and createawareness on energy conservationServe the community around through welfare schemes
Vision amp Mission
1985 ndash Started with 175 KW furnace amp 30 MTMonth capacity 1991 ndash Addition of 250KW furnace amp Capacity Enhanced to 100 TMonth 1993 ndash Well known foundry status from IBR 1995 ndash Implemented QMS amp Certified for ISO 9001 1996 ndash Implemented integrated ERP system 1998 ndash Certified by AD 2000 MarkBlatt 1999 ndash Enhanced Furnace capacity from 250 to 350 KW amp 150TMonth capacity 2000 ndash Qualified for PED Certificate 2004 ndash Direct Export Business Started 2006 ndashEnhanced Furnace Capacity from 350 to 450 KW increasing production to
275TMonth 2006 ndash Added Machine shop 2007 ndash Started LEAN activities 2009 ndash Approval by BV Marine Division 2012 ndash Added testing facilities like PMI Height Master amp Surface tester 2012 ndash Separated processing of stainless steel and carbon steel in different areas 2013 ndash Added 750KW Furnace increasing production to 625Tmonth
Our Progresshellip
2013 ndash MAGMA Simulation Software installed 2014 ndash Lloyds Foundry Approval 2015 ndash Certified ISO 140012004 amp OHSAS 180012007 2015 ndash Highest sales 2015 ndash DNV Foundry Approval 2015 ndash New building 31360 sq foot for processing of above 500kg castings 2015 ndash CETP of capacity 25000 liters installed 2015 ndash Mould Carousel 8 Station semi automatic system 2016 ndash Fork Lift for Pattern Movement 2016 ndash NORSOK Certification for 4A 5A and 6A Grades 2016 ndash Upgraded ISO 9001-2008 to 2015 Version 2016 ndash Solar Roof Top Cells 100 KW Capacity Installed 2016 ndash 25MT Shake Out Machine With Material Handing EOT Crane 25 10 MT 2016 ndash Mechanized HT Quenching System to facilitate quenching within 50 sec 2016 ndash IBR Well Known Foundry status amp certified for Carbon amp Alloy Steel up to
2400 Kg single piece 2017 ndash Installed 3MT Capacity Table type Shot Blasting Machine 2017 ndash ISO 14001-2004 upgraded to 2015 Version
Our Progresshellip
State of Art Omega Semi Automatic Mold Carousal for consistent moldquality for small amp medium casting production with 120 moldsshiftcapacity
Mechanised Quenching system for Heat treatment Process 10 WPS-PQR Certified Operators for various grades witnessed by TUV
Lloyds amp DNV
10 Qualified Welders for handling the welding activities of various grades More than 15000 Patterns with 6000 patterns live Traceability through
ERP maintained location system and Product code
Exclusive storage arrangement for preservation of patterns
50 to 60 New Products being developed every month
More than 750 fully machined cast components exported month
Our Strength
0
10
20
30
40
50
60
70
80
90
2008 2009 2010 2011 2012 2013 2014 2015 2016
Sales in Cr INR
Sales in Cr INR
Our Saleshellip
Highlights Highest sales for financial year 2015 - 1515 M USD Business with Export 58 M USD
ISO 90012015
ISO 140012015
OHSAS 180012007
Well Known Foundry Status IBR
Since 1983
PED
AD MERKBLATT
Lloyds Bureau Veritas amp DNV
Foundry Approval
NORSOK Process Approval for
4A 5A amp 6A
Export Excellence Award By Govt
Of Karnataka
Export Excellence Award By IIF
Certificates amp Awards
7010
55 5 5
Valve componentsPump componentsHydraulic ComponentsGeneral EngineeringTurbine componentDefence Components
Ball Valve 2rdquo to 30rdquoClass 150
to 1500
Globe Valve 05rdquo to 12rdquoClass 150
to 900
Gate Valve 05rdquo to 12rdquoClass 150
to 900
Check Valve
05rdquo to 12rdquoClass 150
to 900
Control Valve
05rdquo to 16rdquoClass 150
to 2500
Butterfly Valve
2rdquo to 40rdquoClass 150
to 1500
Diaphragm Valve
2rdquo to 12rdquoClass 150
to 300
Piston Valve
2rdquo to 8rdquoClass 150
to 300
Double disc
2rdquo to 24rdquoclass 150
to 300
Check Valve
2 to 12 class 150
to 300
Product Mix
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
q 2006 ndash Upgraded from 350 KW to 450 KW furnace | ||||||||||
q 2006 ndash Added Machine shop | ||||||||||
q 2007 ndash Started LEAN activities | ||||||||||
q 2009 ndash Approval by BV Marine Division | ||||||||||
q 2012 ndash Added testing facilities like PMI Height Master amp Surface tester | ||||||||||
q 2012 ndash separated stainless steel and carbon steel in different areas | ||||||||||
q 2012 ndash Highest Sales Achieved so far | ||||||||||
Ball Valve | 2rdquo to 30rdquo | Class 150 to 1500 | ||||||||
Globe Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Gate Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Check Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Control Valve | 05rdquo to 16rdquo | Class 150 to 2500 | ||||||||
Butterfly Valve | 2rdquo to 40rdquo | Class 150 to 1500 | ||||||||
Diaphragm Valve | 2rdquo to 12rdquo | Class 150 to 300 | ||||||||
Piston Valve | 2rdquo to 8rdquo | Class 150 to 300 | ||||||||
Double disc | 2rdquo to 24rdquo | class 150 to 300 | ||||||||
Check Valve | 2 to 12 | class 150 to 300 |
production | |||
Valve components | 70 | ||
Pump components | 10 | ||
Hydraulic Components | 5 | ||
General Engineering | 5 | ||
Turbine component | 5 | ||
Defence Components | 5 | ||
To resize chart data range drag lower right corner of range |
Valve components | |
Pump components | |
Hydraulic Components | |
General Engineering | |
Turbine component | |
Defence Components |
Sales in Cr INR | Series 2 | Series 3 | |||||||
2008 | 4528 | 452800000 | 9056000 | 9056 | |||||
2009 | 3791 | 379100000 | 7582000 | 7582 | |||||
2010 | 5424 | 542485760 | 108497152 | 108497152 | |||||
2011 | 6539 | 653900000 | 13078000 | 13078 | |||||
2012 | 75 | 750000000 | 15000000 | 15 | |||||
2013 | 7652 | ||||||||
2014 | 6903 | ||||||||
2015 | 90 | ||||||||
2016 | 84 | ||||||||
To resize chart data range drag lower right corner of range |
2008 | |
2009 | |
2010 | |
2011 | |
2012 | |
2013 | |
2014 | |
2015 | |
2016 |
MALNAD GROUP COMPANIESMalnad Alloy Castings Pvt Ltd since 1985
ScopeManufacture amp Supply of Raw Machined and Hydro tested Castings in Ferrous Nickel and Cobalt
based alloys
Shimoga Precision Castings Pvt Ltd since 1996Scope
Manufacture and Supply of Alloy Steel Stainless Steel Nickel Alloy Steel Cast Iron and Cobalt Alloy Steel Castings By Investment and Sand Casting Process
Malnad Prime Machining Technologies since 2010Scope
Manufacture of Precision Machined Components
Malnad Alloy Castings Pvt Ltd (Laboratory Division) since 2017
NABL Accredited Mechanical and Chemical Testing Lab
We are located inhellip
Management Contacts
Y V Madhukar Jois Managing Director+91 990 017 7820joismalnadcoin
Prateek M Jois Executive Director +91 966 315 5553pjmalnadcoin
Land Lines - (08182) 46141246142246143
4
Organisation Chart
Photo Name Department Mail ID Cell phone Issues Handled
VynatheyanManager Marketing hrkmktmalnadcoin 9880741704 Enquiry PO OA
Mahesh CNManager
Production cnmprdmalnadcoin 9880741702Delivery dates Planning Dates
Subhanna NManager Quality
Assurance nsqamalnadcoin 9880741703
Test certificates (chemical amp Mechanical)
Swamy MSManager Quality
Control swamyqcmalnadcoin 9880741705 NDT Related
Manjunath M LManager Pattern
Shop manjupatnmalnadcoin 8861002651 Pattern development
SubramanyaHegde
ManagerDispatch and
Logistic sharathmalnadcoin 8861699975dispatch dates Logistics Details
Mahaveer JainProcess Engineer mjainmalnadcoin 8861002642 Customer complaints
The Vision of our company is to
ldquoBecome global leader for the supply of finished cast componentsin wide range of materials with highly committed and sociallyresponsible employeesrdquo
Our Mission is to To meet the casting requirements of the country using latest stateof the art-technology in wide range of materials at competitivecostProvide stable employment and develop highly skilled technicalmanpower and develop wide vendor baseAdopt environmentally sound and safe technology and createawareness on energy conservationServe the community around through welfare schemes
Vision amp Mission
1985 ndash Started with 175 KW furnace amp 30 MTMonth capacity 1991 ndash Addition of 250KW furnace amp Capacity Enhanced to 100 TMonth 1993 ndash Well known foundry status from IBR 1995 ndash Implemented QMS amp Certified for ISO 9001 1996 ndash Implemented integrated ERP system 1998 ndash Certified by AD 2000 MarkBlatt 1999 ndash Enhanced Furnace capacity from 250 to 350 KW amp 150TMonth capacity 2000 ndash Qualified for PED Certificate 2004 ndash Direct Export Business Started 2006 ndashEnhanced Furnace Capacity from 350 to 450 KW increasing production to
275TMonth 2006 ndash Added Machine shop 2007 ndash Started LEAN activities 2009 ndash Approval by BV Marine Division 2012 ndash Added testing facilities like PMI Height Master amp Surface tester 2012 ndash Separated processing of stainless steel and carbon steel in different areas 2013 ndash Added 750KW Furnace increasing production to 625Tmonth
Our Progresshellip
2013 ndash MAGMA Simulation Software installed 2014 ndash Lloyds Foundry Approval 2015 ndash Certified ISO 140012004 amp OHSAS 180012007 2015 ndash Highest sales 2015 ndash DNV Foundry Approval 2015 ndash New building 31360 sq foot for processing of above 500kg castings 2015 ndash CETP of capacity 25000 liters installed 2015 ndash Mould Carousel 8 Station semi automatic system 2016 ndash Fork Lift for Pattern Movement 2016 ndash NORSOK Certification for 4A 5A and 6A Grades 2016 ndash Upgraded ISO 9001-2008 to 2015 Version 2016 ndash Solar Roof Top Cells 100 KW Capacity Installed 2016 ndash 25MT Shake Out Machine With Material Handing EOT Crane 25 10 MT 2016 ndash Mechanized HT Quenching System to facilitate quenching within 50 sec 2016 ndash IBR Well Known Foundry status amp certified for Carbon amp Alloy Steel up to
2400 Kg single piece 2017 ndash Installed 3MT Capacity Table type Shot Blasting Machine 2017 ndash ISO 14001-2004 upgraded to 2015 Version
Our Progresshellip
State of Art Omega Semi Automatic Mold Carousal for consistent moldquality for small amp medium casting production with 120 moldsshiftcapacity
Mechanised Quenching system for Heat treatment Process 10 WPS-PQR Certified Operators for various grades witnessed by TUV
Lloyds amp DNV
10 Qualified Welders for handling the welding activities of various grades More than 15000 Patterns with 6000 patterns live Traceability through
ERP maintained location system and Product code
Exclusive storage arrangement for preservation of patterns
50 to 60 New Products being developed every month
More than 750 fully machined cast components exported month
Our Strength
0
10
20
30
40
50
60
70
80
90
2008 2009 2010 2011 2012 2013 2014 2015 2016
Sales in Cr INR
Sales in Cr INR
Our Saleshellip
Highlights Highest sales for financial year 2015 - 1515 M USD Business with Export 58 M USD
ISO 90012015
ISO 140012015
OHSAS 180012007
Well Known Foundry Status IBR
Since 1983
PED
AD MERKBLATT
Lloyds Bureau Veritas amp DNV
Foundry Approval
NORSOK Process Approval for
4A 5A amp 6A
Export Excellence Award By Govt
Of Karnataka
Export Excellence Award By IIF
Certificates amp Awards
7010
55 5 5
Valve componentsPump componentsHydraulic ComponentsGeneral EngineeringTurbine componentDefence Components
Ball Valve 2rdquo to 30rdquoClass 150
to 1500
Globe Valve 05rdquo to 12rdquoClass 150
to 900
Gate Valve 05rdquo to 12rdquoClass 150
to 900
Check Valve
05rdquo to 12rdquoClass 150
to 900
Control Valve
05rdquo to 16rdquoClass 150
to 2500
Butterfly Valve
2rdquo to 40rdquoClass 150
to 1500
Diaphragm Valve
2rdquo to 12rdquoClass 150
to 300
Piston Valve
2rdquo to 8rdquoClass 150
to 300
Double disc
2rdquo to 24rdquoclass 150
to 300
Check Valve
2 to 12 class 150
to 300
Product Mix
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
q 2006 ndash Upgraded from 350 KW to 450 KW furnace | ||||||||||
q 2006 ndash Added Machine shop | ||||||||||
q 2007 ndash Started LEAN activities | ||||||||||
q 2009 ndash Approval by BV Marine Division | ||||||||||
q 2012 ndash Added testing facilities like PMI Height Master amp Surface tester | ||||||||||
q 2012 ndash separated stainless steel and carbon steel in different areas | ||||||||||
q 2012 ndash Highest Sales Achieved so far | ||||||||||
Ball Valve | 2rdquo to 30rdquo | Class 150 to 1500 | ||||||||
Globe Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Gate Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Check Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Control Valve | 05rdquo to 16rdquo | Class 150 to 2500 | ||||||||
Butterfly Valve | 2rdquo to 40rdquo | Class 150 to 1500 | ||||||||
Diaphragm Valve | 2rdquo to 12rdquo | Class 150 to 300 | ||||||||
Piston Valve | 2rdquo to 8rdquo | Class 150 to 300 | ||||||||
Double disc | 2rdquo to 24rdquo | class 150 to 300 | ||||||||
Check Valve | 2 to 12 | class 150 to 300 |
production | |||
Valve components | 70 | ||
Pump components | 10 | ||
Hydraulic Components | 5 | ||
General Engineering | 5 | ||
Turbine component | 5 | ||
Defence Components | 5 | ||
To resize chart data range drag lower right corner of range |
Valve components | |
Pump components | |
Hydraulic Components | |
General Engineering | |
Turbine component | |
Defence Components |
Sales in Cr INR | Series 2 | Series 3 | |||||||
2008 | 4528 | 452800000 | 9056000 | 9056 | |||||
2009 | 3791 | 379100000 | 7582000 | 7582 | |||||
2010 | 5424 | 542485760 | 108497152 | 108497152 | |||||
2011 | 6539 | 653900000 | 13078000 | 13078 | |||||
2012 | 75 | 750000000 | 15000000 | 15 | |||||
2013 | 7652 | ||||||||
2014 | 6903 | ||||||||
2015 | 90 | ||||||||
2016 | 84 | ||||||||
To resize chart data range drag lower right corner of range |
2008 | |
2009 | |
2010 | |
2011 | |
2012 | |
2013 | |
2014 | |
2015 | |
2016 |
We are located inhellip
Management Contacts
Y V Madhukar Jois Managing Director+91 990 017 7820joismalnadcoin
Prateek M Jois Executive Director +91 966 315 5553pjmalnadcoin
Land Lines - (08182) 46141246142246143
4
Organisation Chart
Photo Name Department Mail ID Cell phone Issues Handled
VynatheyanManager Marketing hrkmktmalnadcoin 9880741704 Enquiry PO OA
Mahesh CNManager
Production cnmprdmalnadcoin 9880741702Delivery dates Planning Dates
Subhanna NManager Quality
Assurance nsqamalnadcoin 9880741703
Test certificates (chemical amp Mechanical)
Swamy MSManager Quality
Control swamyqcmalnadcoin 9880741705 NDT Related
Manjunath M LManager Pattern
Shop manjupatnmalnadcoin 8861002651 Pattern development
SubramanyaHegde
ManagerDispatch and
Logistic sharathmalnadcoin 8861699975dispatch dates Logistics Details
Mahaveer JainProcess Engineer mjainmalnadcoin 8861002642 Customer complaints
The Vision of our company is to
ldquoBecome global leader for the supply of finished cast componentsin wide range of materials with highly committed and sociallyresponsible employeesrdquo
Our Mission is to To meet the casting requirements of the country using latest stateof the art-technology in wide range of materials at competitivecostProvide stable employment and develop highly skilled technicalmanpower and develop wide vendor baseAdopt environmentally sound and safe technology and createawareness on energy conservationServe the community around through welfare schemes
Vision amp Mission
1985 ndash Started with 175 KW furnace amp 30 MTMonth capacity 1991 ndash Addition of 250KW furnace amp Capacity Enhanced to 100 TMonth 1993 ndash Well known foundry status from IBR 1995 ndash Implemented QMS amp Certified for ISO 9001 1996 ndash Implemented integrated ERP system 1998 ndash Certified by AD 2000 MarkBlatt 1999 ndash Enhanced Furnace capacity from 250 to 350 KW amp 150TMonth capacity 2000 ndash Qualified for PED Certificate 2004 ndash Direct Export Business Started 2006 ndashEnhanced Furnace Capacity from 350 to 450 KW increasing production to
275TMonth 2006 ndash Added Machine shop 2007 ndash Started LEAN activities 2009 ndash Approval by BV Marine Division 2012 ndash Added testing facilities like PMI Height Master amp Surface tester 2012 ndash Separated processing of stainless steel and carbon steel in different areas 2013 ndash Added 750KW Furnace increasing production to 625Tmonth
Our Progresshellip
2013 ndash MAGMA Simulation Software installed 2014 ndash Lloyds Foundry Approval 2015 ndash Certified ISO 140012004 amp OHSAS 180012007 2015 ndash Highest sales 2015 ndash DNV Foundry Approval 2015 ndash New building 31360 sq foot for processing of above 500kg castings 2015 ndash CETP of capacity 25000 liters installed 2015 ndash Mould Carousel 8 Station semi automatic system 2016 ndash Fork Lift for Pattern Movement 2016 ndash NORSOK Certification for 4A 5A and 6A Grades 2016 ndash Upgraded ISO 9001-2008 to 2015 Version 2016 ndash Solar Roof Top Cells 100 KW Capacity Installed 2016 ndash 25MT Shake Out Machine With Material Handing EOT Crane 25 10 MT 2016 ndash Mechanized HT Quenching System to facilitate quenching within 50 sec 2016 ndash IBR Well Known Foundry status amp certified for Carbon amp Alloy Steel up to
2400 Kg single piece 2017 ndash Installed 3MT Capacity Table type Shot Blasting Machine 2017 ndash ISO 14001-2004 upgraded to 2015 Version
Our Progresshellip
State of Art Omega Semi Automatic Mold Carousal for consistent moldquality for small amp medium casting production with 120 moldsshiftcapacity
Mechanised Quenching system for Heat treatment Process 10 WPS-PQR Certified Operators for various grades witnessed by TUV
Lloyds amp DNV
10 Qualified Welders for handling the welding activities of various grades More than 15000 Patterns with 6000 patterns live Traceability through
ERP maintained location system and Product code
Exclusive storage arrangement for preservation of patterns
50 to 60 New Products being developed every month
More than 750 fully machined cast components exported month
Our Strength
0
10
20
30
40
50
60
70
80
90
2008 2009 2010 2011 2012 2013 2014 2015 2016
Sales in Cr INR
Sales in Cr INR
Our Saleshellip
Highlights Highest sales for financial year 2015 - 1515 M USD Business with Export 58 M USD
ISO 90012015
ISO 140012015
OHSAS 180012007
Well Known Foundry Status IBR
Since 1983
PED
AD MERKBLATT
Lloyds Bureau Veritas amp DNV
Foundry Approval
NORSOK Process Approval for
4A 5A amp 6A
Export Excellence Award By Govt
Of Karnataka
Export Excellence Award By IIF
Certificates amp Awards
7010
55 5 5
Valve componentsPump componentsHydraulic ComponentsGeneral EngineeringTurbine componentDefence Components
Ball Valve 2rdquo to 30rdquoClass 150
to 1500
Globe Valve 05rdquo to 12rdquoClass 150
to 900
Gate Valve 05rdquo to 12rdquoClass 150
to 900
Check Valve
05rdquo to 12rdquoClass 150
to 900
Control Valve
05rdquo to 16rdquoClass 150
to 2500
Butterfly Valve
2rdquo to 40rdquoClass 150
to 1500
Diaphragm Valve
2rdquo to 12rdquoClass 150
to 300
Piston Valve
2rdquo to 8rdquoClass 150
to 300
Double disc
2rdquo to 24rdquoclass 150
to 300
Check Valve
2 to 12 class 150
to 300
Product Mix
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
q 2006 ndash Upgraded from 350 KW to 450 KW furnace | ||||||||||
q 2006 ndash Added Machine shop | ||||||||||
q 2007 ndash Started LEAN activities | ||||||||||
q 2009 ndash Approval by BV Marine Division | ||||||||||
q 2012 ndash Added testing facilities like PMI Height Master amp Surface tester | ||||||||||
q 2012 ndash separated stainless steel and carbon steel in different areas | ||||||||||
q 2012 ndash Highest Sales Achieved so far | ||||||||||
Ball Valve | 2rdquo to 30rdquo | Class 150 to 1500 | ||||||||
Globe Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Gate Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Check Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Control Valve | 05rdquo to 16rdquo | Class 150 to 2500 | ||||||||
Butterfly Valve | 2rdquo to 40rdquo | Class 150 to 1500 | ||||||||
Diaphragm Valve | 2rdquo to 12rdquo | Class 150 to 300 | ||||||||
Piston Valve | 2rdquo to 8rdquo | Class 150 to 300 | ||||||||
Double disc | 2rdquo to 24rdquo | class 150 to 300 | ||||||||
Check Valve | 2 to 12 | class 150 to 300 |
production | |||
Valve components | 70 | ||
Pump components | 10 | ||
Hydraulic Components | 5 | ||
General Engineering | 5 | ||
Turbine component | 5 | ||
Defence Components | 5 | ||
To resize chart data range drag lower right corner of range |
Valve components | |
Pump components | |
Hydraulic Components | |
General Engineering | |
Turbine component | |
Defence Components |
Sales in Cr INR | Series 2 | Series 3 | |||||||
2008 | 4528 | 452800000 | 9056000 | 9056 | |||||
2009 | 3791 | 379100000 | 7582000 | 7582 | |||||
2010 | 5424 | 542485760 | 108497152 | 108497152 | |||||
2011 | 6539 | 653900000 | 13078000 | 13078 | |||||
2012 | 75 | 750000000 | 15000000 | 15 | |||||
2013 | 7652 | ||||||||
2014 | 6903 | ||||||||
2015 | 90 | ||||||||
2016 | 84 | ||||||||
To resize chart data range drag lower right corner of range |
2008 | |
2009 | |
2010 | |
2011 | |
2012 | |
2013 | |
2014 | |
2015 | |
2016 |
Management Contacts
Y V Madhukar Jois Managing Director+91 990 017 7820joismalnadcoin
Prateek M Jois Executive Director +91 966 315 5553pjmalnadcoin
Land Lines - (08182) 46141246142246143
4
Organisation Chart
Photo Name Department Mail ID Cell phone Issues Handled
VynatheyanManager Marketing hrkmktmalnadcoin 9880741704 Enquiry PO OA
Mahesh CNManager
Production cnmprdmalnadcoin 9880741702Delivery dates Planning Dates
Subhanna NManager Quality
Assurance nsqamalnadcoin 9880741703
Test certificates (chemical amp Mechanical)
Swamy MSManager Quality
Control swamyqcmalnadcoin 9880741705 NDT Related
Manjunath M LManager Pattern
Shop manjupatnmalnadcoin 8861002651 Pattern development
SubramanyaHegde
ManagerDispatch and
Logistic sharathmalnadcoin 8861699975dispatch dates Logistics Details
Mahaveer JainProcess Engineer mjainmalnadcoin 8861002642 Customer complaints
The Vision of our company is to
ldquoBecome global leader for the supply of finished cast componentsin wide range of materials with highly committed and sociallyresponsible employeesrdquo
Our Mission is to To meet the casting requirements of the country using latest stateof the art-technology in wide range of materials at competitivecostProvide stable employment and develop highly skilled technicalmanpower and develop wide vendor baseAdopt environmentally sound and safe technology and createawareness on energy conservationServe the community around through welfare schemes
Vision amp Mission
1985 ndash Started with 175 KW furnace amp 30 MTMonth capacity 1991 ndash Addition of 250KW furnace amp Capacity Enhanced to 100 TMonth 1993 ndash Well known foundry status from IBR 1995 ndash Implemented QMS amp Certified for ISO 9001 1996 ndash Implemented integrated ERP system 1998 ndash Certified by AD 2000 MarkBlatt 1999 ndash Enhanced Furnace capacity from 250 to 350 KW amp 150TMonth capacity 2000 ndash Qualified for PED Certificate 2004 ndash Direct Export Business Started 2006 ndashEnhanced Furnace Capacity from 350 to 450 KW increasing production to
275TMonth 2006 ndash Added Machine shop 2007 ndash Started LEAN activities 2009 ndash Approval by BV Marine Division 2012 ndash Added testing facilities like PMI Height Master amp Surface tester 2012 ndash Separated processing of stainless steel and carbon steel in different areas 2013 ndash Added 750KW Furnace increasing production to 625Tmonth
Our Progresshellip
2013 ndash MAGMA Simulation Software installed 2014 ndash Lloyds Foundry Approval 2015 ndash Certified ISO 140012004 amp OHSAS 180012007 2015 ndash Highest sales 2015 ndash DNV Foundry Approval 2015 ndash New building 31360 sq foot for processing of above 500kg castings 2015 ndash CETP of capacity 25000 liters installed 2015 ndash Mould Carousel 8 Station semi automatic system 2016 ndash Fork Lift for Pattern Movement 2016 ndash NORSOK Certification for 4A 5A and 6A Grades 2016 ndash Upgraded ISO 9001-2008 to 2015 Version 2016 ndash Solar Roof Top Cells 100 KW Capacity Installed 2016 ndash 25MT Shake Out Machine With Material Handing EOT Crane 25 10 MT 2016 ndash Mechanized HT Quenching System to facilitate quenching within 50 sec 2016 ndash IBR Well Known Foundry status amp certified for Carbon amp Alloy Steel up to
2400 Kg single piece 2017 ndash Installed 3MT Capacity Table type Shot Blasting Machine 2017 ndash ISO 14001-2004 upgraded to 2015 Version
Our Progresshellip
State of Art Omega Semi Automatic Mold Carousal for consistent moldquality for small amp medium casting production with 120 moldsshiftcapacity
Mechanised Quenching system for Heat treatment Process 10 WPS-PQR Certified Operators for various grades witnessed by TUV
Lloyds amp DNV
10 Qualified Welders for handling the welding activities of various grades More than 15000 Patterns with 6000 patterns live Traceability through
ERP maintained location system and Product code
Exclusive storage arrangement for preservation of patterns
50 to 60 New Products being developed every month
More than 750 fully machined cast components exported month
Our Strength
0
10
20
30
40
50
60
70
80
90
2008 2009 2010 2011 2012 2013 2014 2015 2016
Sales in Cr INR
Sales in Cr INR
Our Saleshellip
Highlights Highest sales for financial year 2015 - 1515 M USD Business with Export 58 M USD
ISO 90012015
ISO 140012015
OHSAS 180012007
Well Known Foundry Status IBR
Since 1983
PED
AD MERKBLATT
Lloyds Bureau Veritas amp DNV
Foundry Approval
NORSOK Process Approval for
4A 5A amp 6A
Export Excellence Award By Govt
Of Karnataka
Export Excellence Award By IIF
Certificates amp Awards
7010
55 5 5
Valve componentsPump componentsHydraulic ComponentsGeneral EngineeringTurbine componentDefence Components
Ball Valve 2rdquo to 30rdquoClass 150
to 1500
Globe Valve 05rdquo to 12rdquoClass 150
to 900
Gate Valve 05rdquo to 12rdquoClass 150
to 900
Check Valve
05rdquo to 12rdquoClass 150
to 900
Control Valve
05rdquo to 16rdquoClass 150
to 2500
Butterfly Valve
2rdquo to 40rdquoClass 150
to 1500
Diaphragm Valve
2rdquo to 12rdquoClass 150
to 300
Piston Valve
2rdquo to 8rdquoClass 150
to 300
Double disc
2rdquo to 24rdquoclass 150
to 300
Check Valve
2 to 12 class 150
to 300
Product Mix
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
q 2006 ndash Upgraded from 350 KW to 450 KW furnace | ||||||||||
q 2006 ndash Added Machine shop | ||||||||||
q 2007 ndash Started LEAN activities | ||||||||||
q 2009 ndash Approval by BV Marine Division | ||||||||||
q 2012 ndash Added testing facilities like PMI Height Master amp Surface tester | ||||||||||
q 2012 ndash separated stainless steel and carbon steel in different areas | ||||||||||
q 2012 ndash Highest Sales Achieved so far | ||||||||||
Ball Valve | 2rdquo to 30rdquo | Class 150 to 1500 | ||||||||
Globe Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Gate Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Check Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Control Valve | 05rdquo to 16rdquo | Class 150 to 2500 | ||||||||
Butterfly Valve | 2rdquo to 40rdquo | Class 150 to 1500 | ||||||||
Diaphragm Valve | 2rdquo to 12rdquo | Class 150 to 300 | ||||||||
Piston Valve | 2rdquo to 8rdquo | Class 150 to 300 | ||||||||
Double disc | 2rdquo to 24rdquo | class 150 to 300 | ||||||||
Check Valve | 2 to 12 | class 150 to 300 |
production | |||
Valve components | 70 | ||
Pump components | 10 | ||
Hydraulic Components | 5 | ||
General Engineering | 5 | ||
Turbine component | 5 | ||
Defence Components | 5 | ||
To resize chart data range drag lower right corner of range |
Valve components | |
Pump components | |
Hydraulic Components | |
General Engineering | |
Turbine component | |
Defence Components |
Sales in Cr INR | Series 2 | Series 3 | |||||||
2008 | 4528 | 452800000 | 9056000 | 9056 | |||||
2009 | 3791 | 379100000 | 7582000 | 7582 | |||||
2010 | 5424 | 542485760 | 108497152 | 108497152 | |||||
2011 | 6539 | 653900000 | 13078000 | 13078 | |||||
2012 | 75 | 750000000 | 15000000 | 15 | |||||
2013 | 7652 | ||||||||
2014 | 6903 | ||||||||
2015 | 90 | ||||||||
2016 | 84 | ||||||||
To resize chart data range drag lower right corner of range |
2008 | |
2009 | |
2010 | |
2011 | |
2012 | |
2013 | |
2014 | |
2015 | |
2016 |
Organisation Chart
Photo Name Department Mail ID Cell phone Issues Handled
VynatheyanManager Marketing hrkmktmalnadcoin 9880741704 Enquiry PO OA
Mahesh CNManager
Production cnmprdmalnadcoin 9880741702Delivery dates Planning Dates
Subhanna NManager Quality
Assurance nsqamalnadcoin 9880741703
Test certificates (chemical amp Mechanical)
Swamy MSManager Quality
Control swamyqcmalnadcoin 9880741705 NDT Related
Manjunath M LManager Pattern
Shop manjupatnmalnadcoin 8861002651 Pattern development
SubramanyaHegde
ManagerDispatch and
Logistic sharathmalnadcoin 8861699975dispatch dates Logistics Details
Mahaveer JainProcess Engineer mjainmalnadcoin 8861002642 Customer complaints
The Vision of our company is to
ldquoBecome global leader for the supply of finished cast componentsin wide range of materials with highly committed and sociallyresponsible employeesrdquo
Our Mission is to To meet the casting requirements of the country using latest stateof the art-technology in wide range of materials at competitivecostProvide stable employment and develop highly skilled technicalmanpower and develop wide vendor baseAdopt environmentally sound and safe technology and createawareness on energy conservationServe the community around through welfare schemes
Vision amp Mission
1985 ndash Started with 175 KW furnace amp 30 MTMonth capacity 1991 ndash Addition of 250KW furnace amp Capacity Enhanced to 100 TMonth 1993 ndash Well known foundry status from IBR 1995 ndash Implemented QMS amp Certified for ISO 9001 1996 ndash Implemented integrated ERP system 1998 ndash Certified by AD 2000 MarkBlatt 1999 ndash Enhanced Furnace capacity from 250 to 350 KW amp 150TMonth capacity 2000 ndash Qualified for PED Certificate 2004 ndash Direct Export Business Started 2006 ndashEnhanced Furnace Capacity from 350 to 450 KW increasing production to
275TMonth 2006 ndash Added Machine shop 2007 ndash Started LEAN activities 2009 ndash Approval by BV Marine Division 2012 ndash Added testing facilities like PMI Height Master amp Surface tester 2012 ndash Separated processing of stainless steel and carbon steel in different areas 2013 ndash Added 750KW Furnace increasing production to 625Tmonth
Our Progresshellip
2013 ndash MAGMA Simulation Software installed 2014 ndash Lloyds Foundry Approval 2015 ndash Certified ISO 140012004 amp OHSAS 180012007 2015 ndash Highest sales 2015 ndash DNV Foundry Approval 2015 ndash New building 31360 sq foot for processing of above 500kg castings 2015 ndash CETP of capacity 25000 liters installed 2015 ndash Mould Carousel 8 Station semi automatic system 2016 ndash Fork Lift for Pattern Movement 2016 ndash NORSOK Certification for 4A 5A and 6A Grades 2016 ndash Upgraded ISO 9001-2008 to 2015 Version 2016 ndash Solar Roof Top Cells 100 KW Capacity Installed 2016 ndash 25MT Shake Out Machine With Material Handing EOT Crane 25 10 MT 2016 ndash Mechanized HT Quenching System to facilitate quenching within 50 sec 2016 ndash IBR Well Known Foundry status amp certified for Carbon amp Alloy Steel up to
2400 Kg single piece 2017 ndash Installed 3MT Capacity Table type Shot Blasting Machine 2017 ndash ISO 14001-2004 upgraded to 2015 Version
Our Progresshellip
State of Art Omega Semi Automatic Mold Carousal for consistent moldquality for small amp medium casting production with 120 moldsshiftcapacity
Mechanised Quenching system for Heat treatment Process 10 WPS-PQR Certified Operators for various grades witnessed by TUV
Lloyds amp DNV
10 Qualified Welders for handling the welding activities of various grades More than 15000 Patterns with 6000 patterns live Traceability through
ERP maintained location system and Product code
Exclusive storage arrangement for preservation of patterns
50 to 60 New Products being developed every month
More than 750 fully machined cast components exported month
Our Strength
0
10
20
30
40
50
60
70
80
90
2008 2009 2010 2011 2012 2013 2014 2015 2016
Sales in Cr INR
Sales in Cr INR
Our Saleshellip
Highlights Highest sales for financial year 2015 - 1515 M USD Business with Export 58 M USD
ISO 90012015
ISO 140012015
OHSAS 180012007
Well Known Foundry Status IBR
Since 1983
PED
AD MERKBLATT
Lloyds Bureau Veritas amp DNV
Foundry Approval
NORSOK Process Approval for
4A 5A amp 6A
Export Excellence Award By Govt
Of Karnataka
Export Excellence Award By IIF
Certificates amp Awards
7010
55 5 5
Valve componentsPump componentsHydraulic ComponentsGeneral EngineeringTurbine componentDefence Components
Ball Valve 2rdquo to 30rdquoClass 150
to 1500
Globe Valve 05rdquo to 12rdquoClass 150
to 900
Gate Valve 05rdquo to 12rdquoClass 150
to 900
Check Valve
05rdquo to 12rdquoClass 150
to 900
Control Valve
05rdquo to 16rdquoClass 150
to 2500
Butterfly Valve
2rdquo to 40rdquoClass 150
to 1500
Diaphragm Valve
2rdquo to 12rdquoClass 150
to 300
Piston Valve
2rdquo to 8rdquoClass 150
to 300
Double disc
2rdquo to 24rdquoclass 150
to 300
Check Valve
2 to 12 class 150
to 300
Product Mix
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
q 2006 ndash Upgraded from 350 KW to 450 KW furnace | ||||||||||
q 2006 ndash Added Machine shop | ||||||||||
q 2007 ndash Started LEAN activities | ||||||||||
q 2009 ndash Approval by BV Marine Division | ||||||||||
q 2012 ndash Added testing facilities like PMI Height Master amp Surface tester | ||||||||||
q 2012 ndash separated stainless steel and carbon steel in different areas | ||||||||||
q 2012 ndash Highest Sales Achieved so far | ||||||||||
Ball Valve | 2rdquo to 30rdquo | Class 150 to 1500 | ||||||||
Globe Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Gate Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Check Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Control Valve | 05rdquo to 16rdquo | Class 150 to 2500 | ||||||||
Butterfly Valve | 2rdquo to 40rdquo | Class 150 to 1500 | ||||||||
Diaphragm Valve | 2rdquo to 12rdquo | Class 150 to 300 | ||||||||
Piston Valve | 2rdquo to 8rdquo | Class 150 to 300 | ||||||||
Double disc | 2rdquo to 24rdquo | class 150 to 300 | ||||||||
Check Valve | 2 to 12 | class 150 to 300 |
production | |||
Valve components | 70 | ||
Pump components | 10 | ||
Hydraulic Components | 5 | ||
General Engineering | 5 | ||
Turbine component | 5 | ||
Defence Components | 5 | ||
To resize chart data range drag lower right corner of range |
Valve components | |
Pump components | |
Hydraulic Components | |
General Engineering | |
Turbine component | |
Defence Components |
Sales in Cr INR | Series 2 | Series 3 | |||||||
2008 | 4528 | 452800000 | 9056000 | 9056 | |||||
2009 | 3791 | 379100000 | 7582000 | 7582 | |||||
2010 | 5424 | 542485760 | 108497152 | 108497152 | |||||
2011 | 6539 | 653900000 | 13078000 | 13078 | |||||
2012 | 75 | 750000000 | 15000000 | 15 | |||||
2013 | 7652 | ||||||||
2014 | 6903 | ||||||||
2015 | 90 | ||||||||
2016 | 84 | ||||||||
To resize chart data range drag lower right corner of range |
2008 | |
2009 | |
2010 | |
2011 | |
2012 | |
2013 | |
2014 | |
2015 | |
2016 |
Photo Name Department Mail ID Cell phone Issues Handled
VynatheyanManager Marketing hrkmktmalnadcoin 9880741704 Enquiry PO OA
Mahesh CNManager
Production cnmprdmalnadcoin 9880741702Delivery dates Planning Dates
Subhanna NManager Quality
Assurance nsqamalnadcoin 9880741703
Test certificates (chemical amp Mechanical)
Swamy MSManager Quality
Control swamyqcmalnadcoin 9880741705 NDT Related
Manjunath M LManager Pattern
Shop manjupatnmalnadcoin 8861002651 Pattern development
SubramanyaHegde
ManagerDispatch and
Logistic sharathmalnadcoin 8861699975dispatch dates Logistics Details
Mahaveer JainProcess Engineer mjainmalnadcoin 8861002642 Customer complaints
The Vision of our company is to
ldquoBecome global leader for the supply of finished cast componentsin wide range of materials with highly committed and sociallyresponsible employeesrdquo
Our Mission is to To meet the casting requirements of the country using latest stateof the art-technology in wide range of materials at competitivecostProvide stable employment and develop highly skilled technicalmanpower and develop wide vendor baseAdopt environmentally sound and safe technology and createawareness on energy conservationServe the community around through welfare schemes
Vision amp Mission
1985 ndash Started with 175 KW furnace amp 30 MTMonth capacity 1991 ndash Addition of 250KW furnace amp Capacity Enhanced to 100 TMonth 1993 ndash Well known foundry status from IBR 1995 ndash Implemented QMS amp Certified for ISO 9001 1996 ndash Implemented integrated ERP system 1998 ndash Certified by AD 2000 MarkBlatt 1999 ndash Enhanced Furnace capacity from 250 to 350 KW amp 150TMonth capacity 2000 ndash Qualified for PED Certificate 2004 ndash Direct Export Business Started 2006 ndashEnhanced Furnace Capacity from 350 to 450 KW increasing production to
275TMonth 2006 ndash Added Machine shop 2007 ndash Started LEAN activities 2009 ndash Approval by BV Marine Division 2012 ndash Added testing facilities like PMI Height Master amp Surface tester 2012 ndash Separated processing of stainless steel and carbon steel in different areas 2013 ndash Added 750KW Furnace increasing production to 625Tmonth
Our Progresshellip
2013 ndash MAGMA Simulation Software installed 2014 ndash Lloyds Foundry Approval 2015 ndash Certified ISO 140012004 amp OHSAS 180012007 2015 ndash Highest sales 2015 ndash DNV Foundry Approval 2015 ndash New building 31360 sq foot for processing of above 500kg castings 2015 ndash CETP of capacity 25000 liters installed 2015 ndash Mould Carousel 8 Station semi automatic system 2016 ndash Fork Lift for Pattern Movement 2016 ndash NORSOK Certification for 4A 5A and 6A Grades 2016 ndash Upgraded ISO 9001-2008 to 2015 Version 2016 ndash Solar Roof Top Cells 100 KW Capacity Installed 2016 ndash 25MT Shake Out Machine With Material Handing EOT Crane 25 10 MT 2016 ndash Mechanized HT Quenching System to facilitate quenching within 50 sec 2016 ndash IBR Well Known Foundry status amp certified for Carbon amp Alloy Steel up to
2400 Kg single piece 2017 ndash Installed 3MT Capacity Table type Shot Blasting Machine 2017 ndash ISO 14001-2004 upgraded to 2015 Version
Our Progresshellip
State of Art Omega Semi Automatic Mold Carousal for consistent moldquality for small amp medium casting production with 120 moldsshiftcapacity
Mechanised Quenching system for Heat treatment Process 10 WPS-PQR Certified Operators for various grades witnessed by TUV
Lloyds amp DNV
10 Qualified Welders for handling the welding activities of various grades More than 15000 Patterns with 6000 patterns live Traceability through
ERP maintained location system and Product code
Exclusive storage arrangement for preservation of patterns
50 to 60 New Products being developed every month
More than 750 fully machined cast components exported month
Our Strength
0
10
20
30
40
50
60
70
80
90
2008 2009 2010 2011 2012 2013 2014 2015 2016
Sales in Cr INR
Sales in Cr INR
Our Saleshellip
Highlights Highest sales for financial year 2015 - 1515 M USD Business with Export 58 M USD
ISO 90012015
ISO 140012015
OHSAS 180012007
Well Known Foundry Status IBR
Since 1983
PED
AD MERKBLATT
Lloyds Bureau Veritas amp DNV
Foundry Approval
NORSOK Process Approval for
4A 5A amp 6A
Export Excellence Award By Govt
Of Karnataka
Export Excellence Award By IIF
Certificates amp Awards
7010
55 5 5
Valve componentsPump componentsHydraulic ComponentsGeneral EngineeringTurbine componentDefence Components
Ball Valve 2rdquo to 30rdquoClass 150
to 1500
Globe Valve 05rdquo to 12rdquoClass 150
to 900
Gate Valve 05rdquo to 12rdquoClass 150
to 900
Check Valve
05rdquo to 12rdquoClass 150
to 900
Control Valve
05rdquo to 16rdquoClass 150
to 2500
Butterfly Valve
2rdquo to 40rdquoClass 150
to 1500
Diaphragm Valve
2rdquo to 12rdquoClass 150
to 300
Piston Valve
2rdquo to 8rdquoClass 150
to 300
Double disc
2rdquo to 24rdquoclass 150
to 300
Check Valve
2 to 12 class 150
to 300
Product Mix
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
q 2006 ndash Upgraded from 350 KW to 450 KW furnace | ||||||||||
q 2006 ndash Added Machine shop | ||||||||||
q 2007 ndash Started LEAN activities | ||||||||||
q 2009 ndash Approval by BV Marine Division | ||||||||||
q 2012 ndash Added testing facilities like PMI Height Master amp Surface tester | ||||||||||
q 2012 ndash separated stainless steel and carbon steel in different areas | ||||||||||
q 2012 ndash Highest Sales Achieved so far | ||||||||||
Ball Valve | 2rdquo to 30rdquo | Class 150 to 1500 | ||||||||
Globe Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Gate Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Check Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Control Valve | 05rdquo to 16rdquo | Class 150 to 2500 | ||||||||
Butterfly Valve | 2rdquo to 40rdquo | Class 150 to 1500 | ||||||||
Diaphragm Valve | 2rdquo to 12rdquo | Class 150 to 300 | ||||||||
Piston Valve | 2rdquo to 8rdquo | Class 150 to 300 | ||||||||
Double disc | 2rdquo to 24rdquo | class 150 to 300 | ||||||||
Check Valve | 2 to 12 | class 150 to 300 |
production | |||
Valve components | 70 | ||
Pump components | 10 | ||
Hydraulic Components | 5 | ||
General Engineering | 5 | ||
Turbine component | 5 | ||
Defence Components | 5 | ||
To resize chart data range drag lower right corner of range |
Valve components | |
Pump components | |
Hydraulic Components | |
General Engineering | |
Turbine component | |
Defence Components |
Sales in Cr INR | Series 2 | Series 3 | |||||||
2008 | 4528 | 452800000 | 9056000 | 9056 | |||||
2009 | 3791 | 379100000 | 7582000 | 7582 | |||||
2010 | 5424 | 542485760 | 108497152 | 108497152 | |||||
2011 | 6539 | 653900000 | 13078000 | 13078 | |||||
2012 | 75 | 750000000 | 15000000 | 15 | |||||
2013 | 7652 | ||||||||
2014 | 6903 | ||||||||
2015 | 90 | ||||||||
2016 | 84 | ||||||||
To resize chart data range drag lower right corner of range |
2008 | |
2009 | |
2010 | |
2011 | |
2012 | |
2013 | |
2014 | |
2015 | |
2016 |
The Vision of our company is to
ldquoBecome global leader for the supply of finished cast componentsin wide range of materials with highly committed and sociallyresponsible employeesrdquo
Our Mission is to To meet the casting requirements of the country using latest stateof the art-technology in wide range of materials at competitivecostProvide stable employment and develop highly skilled technicalmanpower and develop wide vendor baseAdopt environmentally sound and safe technology and createawareness on energy conservationServe the community around through welfare schemes
Vision amp Mission
1985 ndash Started with 175 KW furnace amp 30 MTMonth capacity 1991 ndash Addition of 250KW furnace amp Capacity Enhanced to 100 TMonth 1993 ndash Well known foundry status from IBR 1995 ndash Implemented QMS amp Certified for ISO 9001 1996 ndash Implemented integrated ERP system 1998 ndash Certified by AD 2000 MarkBlatt 1999 ndash Enhanced Furnace capacity from 250 to 350 KW amp 150TMonth capacity 2000 ndash Qualified for PED Certificate 2004 ndash Direct Export Business Started 2006 ndashEnhanced Furnace Capacity from 350 to 450 KW increasing production to
275TMonth 2006 ndash Added Machine shop 2007 ndash Started LEAN activities 2009 ndash Approval by BV Marine Division 2012 ndash Added testing facilities like PMI Height Master amp Surface tester 2012 ndash Separated processing of stainless steel and carbon steel in different areas 2013 ndash Added 750KW Furnace increasing production to 625Tmonth
Our Progresshellip
2013 ndash MAGMA Simulation Software installed 2014 ndash Lloyds Foundry Approval 2015 ndash Certified ISO 140012004 amp OHSAS 180012007 2015 ndash Highest sales 2015 ndash DNV Foundry Approval 2015 ndash New building 31360 sq foot for processing of above 500kg castings 2015 ndash CETP of capacity 25000 liters installed 2015 ndash Mould Carousel 8 Station semi automatic system 2016 ndash Fork Lift for Pattern Movement 2016 ndash NORSOK Certification for 4A 5A and 6A Grades 2016 ndash Upgraded ISO 9001-2008 to 2015 Version 2016 ndash Solar Roof Top Cells 100 KW Capacity Installed 2016 ndash 25MT Shake Out Machine With Material Handing EOT Crane 25 10 MT 2016 ndash Mechanized HT Quenching System to facilitate quenching within 50 sec 2016 ndash IBR Well Known Foundry status amp certified for Carbon amp Alloy Steel up to
2400 Kg single piece 2017 ndash Installed 3MT Capacity Table type Shot Blasting Machine 2017 ndash ISO 14001-2004 upgraded to 2015 Version
Our Progresshellip
State of Art Omega Semi Automatic Mold Carousal for consistent moldquality for small amp medium casting production with 120 moldsshiftcapacity
Mechanised Quenching system for Heat treatment Process 10 WPS-PQR Certified Operators for various grades witnessed by TUV
Lloyds amp DNV
10 Qualified Welders for handling the welding activities of various grades More than 15000 Patterns with 6000 patterns live Traceability through
ERP maintained location system and Product code
Exclusive storage arrangement for preservation of patterns
50 to 60 New Products being developed every month
More than 750 fully machined cast components exported month
Our Strength
0
10
20
30
40
50
60
70
80
90
2008 2009 2010 2011 2012 2013 2014 2015 2016
Sales in Cr INR
Sales in Cr INR
Our Saleshellip
Highlights Highest sales for financial year 2015 - 1515 M USD Business with Export 58 M USD
ISO 90012015
ISO 140012015
OHSAS 180012007
Well Known Foundry Status IBR
Since 1983
PED
AD MERKBLATT
Lloyds Bureau Veritas amp DNV
Foundry Approval
NORSOK Process Approval for
4A 5A amp 6A
Export Excellence Award By Govt
Of Karnataka
Export Excellence Award By IIF
Certificates amp Awards
7010
55 5 5
Valve componentsPump componentsHydraulic ComponentsGeneral EngineeringTurbine componentDefence Components
Ball Valve 2rdquo to 30rdquoClass 150
to 1500
Globe Valve 05rdquo to 12rdquoClass 150
to 900
Gate Valve 05rdquo to 12rdquoClass 150
to 900
Check Valve
05rdquo to 12rdquoClass 150
to 900
Control Valve
05rdquo to 16rdquoClass 150
to 2500
Butterfly Valve
2rdquo to 40rdquoClass 150
to 1500
Diaphragm Valve
2rdquo to 12rdquoClass 150
to 300
Piston Valve
2rdquo to 8rdquoClass 150
to 300
Double disc
2rdquo to 24rdquoclass 150
to 300
Check Valve
2 to 12 class 150
to 300
Product Mix
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
q 2006 ndash Upgraded from 350 KW to 450 KW furnace | ||||||||||
q 2006 ndash Added Machine shop | ||||||||||
q 2007 ndash Started LEAN activities | ||||||||||
q 2009 ndash Approval by BV Marine Division | ||||||||||
q 2012 ndash Added testing facilities like PMI Height Master amp Surface tester | ||||||||||
q 2012 ndash separated stainless steel and carbon steel in different areas | ||||||||||
q 2012 ndash Highest Sales Achieved so far | ||||||||||
Ball Valve | 2rdquo to 30rdquo | Class 150 to 1500 | ||||||||
Globe Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Gate Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Check Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Control Valve | 05rdquo to 16rdquo | Class 150 to 2500 | ||||||||
Butterfly Valve | 2rdquo to 40rdquo | Class 150 to 1500 | ||||||||
Diaphragm Valve | 2rdquo to 12rdquo | Class 150 to 300 | ||||||||
Piston Valve | 2rdquo to 8rdquo | Class 150 to 300 | ||||||||
Double disc | 2rdquo to 24rdquo | class 150 to 300 | ||||||||
Check Valve | 2 to 12 | class 150 to 300 |
production | |||
Valve components | 70 | ||
Pump components | 10 | ||
Hydraulic Components | 5 | ||
General Engineering | 5 | ||
Turbine component | 5 | ||
Defence Components | 5 | ||
To resize chart data range drag lower right corner of range |
Valve components | |
Pump components | |
Hydraulic Components | |
General Engineering | |
Turbine component | |
Defence Components |
Sales in Cr INR | Series 2 | Series 3 | |||||||
2008 | 4528 | 452800000 | 9056000 | 9056 | |||||
2009 | 3791 | 379100000 | 7582000 | 7582 | |||||
2010 | 5424 | 542485760 | 108497152 | 108497152 | |||||
2011 | 6539 | 653900000 | 13078000 | 13078 | |||||
2012 | 75 | 750000000 | 15000000 | 15 | |||||
2013 | 7652 | ||||||||
2014 | 6903 | ||||||||
2015 | 90 | ||||||||
2016 | 84 | ||||||||
To resize chart data range drag lower right corner of range |
2008 | |
2009 | |
2010 | |
2011 | |
2012 | |
2013 | |
2014 | |
2015 | |
2016 |
1985 ndash Started with 175 KW furnace amp 30 MTMonth capacity 1991 ndash Addition of 250KW furnace amp Capacity Enhanced to 100 TMonth 1993 ndash Well known foundry status from IBR 1995 ndash Implemented QMS amp Certified for ISO 9001 1996 ndash Implemented integrated ERP system 1998 ndash Certified by AD 2000 MarkBlatt 1999 ndash Enhanced Furnace capacity from 250 to 350 KW amp 150TMonth capacity 2000 ndash Qualified for PED Certificate 2004 ndash Direct Export Business Started 2006 ndashEnhanced Furnace Capacity from 350 to 450 KW increasing production to
275TMonth 2006 ndash Added Machine shop 2007 ndash Started LEAN activities 2009 ndash Approval by BV Marine Division 2012 ndash Added testing facilities like PMI Height Master amp Surface tester 2012 ndash Separated processing of stainless steel and carbon steel in different areas 2013 ndash Added 750KW Furnace increasing production to 625Tmonth
Our Progresshellip
2013 ndash MAGMA Simulation Software installed 2014 ndash Lloyds Foundry Approval 2015 ndash Certified ISO 140012004 amp OHSAS 180012007 2015 ndash Highest sales 2015 ndash DNV Foundry Approval 2015 ndash New building 31360 sq foot for processing of above 500kg castings 2015 ndash CETP of capacity 25000 liters installed 2015 ndash Mould Carousel 8 Station semi automatic system 2016 ndash Fork Lift for Pattern Movement 2016 ndash NORSOK Certification for 4A 5A and 6A Grades 2016 ndash Upgraded ISO 9001-2008 to 2015 Version 2016 ndash Solar Roof Top Cells 100 KW Capacity Installed 2016 ndash 25MT Shake Out Machine With Material Handing EOT Crane 25 10 MT 2016 ndash Mechanized HT Quenching System to facilitate quenching within 50 sec 2016 ndash IBR Well Known Foundry status amp certified for Carbon amp Alloy Steel up to
2400 Kg single piece 2017 ndash Installed 3MT Capacity Table type Shot Blasting Machine 2017 ndash ISO 14001-2004 upgraded to 2015 Version
Our Progresshellip
State of Art Omega Semi Automatic Mold Carousal for consistent moldquality for small amp medium casting production with 120 moldsshiftcapacity
Mechanised Quenching system for Heat treatment Process 10 WPS-PQR Certified Operators for various grades witnessed by TUV
Lloyds amp DNV
10 Qualified Welders for handling the welding activities of various grades More than 15000 Patterns with 6000 patterns live Traceability through
ERP maintained location system and Product code
Exclusive storage arrangement for preservation of patterns
50 to 60 New Products being developed every month
More than 750 fully machined cast components exported month
Our Strength
0
10
20
30
40
50
60
70
80
90
2008 2009 2010 2011 2012 2013 2014 2015 2016
Sales in Cr INR
Sales in Cr INR
Our Saleshellip
Highlights Highest sales for financial year 2015 - 1515 M USD Business with Export 58 M USD
ISO 90012015
ISO 140012015
OHSAS 180012007
Well Known Foundry Status IBR
Since 1983
PED
AD MERKBLATT
Lloyds Bureau Veritas amp DNV
Foundry Approval
NORSOK Process Approval for
4A 5A amp 6A
Export Excellence Award By Govt
Of Karnataka
Export Excellence Award By IIF
Certificates amp Awards
7010
55 5 5
Valve componentsPump componentsHydraulic ComponentsGeneral EngineeringTurbine componentDefence Components
Ball Valve 2rdquo to 30rdquoClass 150
to 1500
Globe Valve 05rdquo to 12rdquoClass 150
to 900
Gate Valve 05rdquo to 12rdquoClass 150
to 900
Check Valve
05rdquo to 12rdquoClass 150
to 900
Control Valve
05rdquo to 16rdquoClass 150
to 2500
Butterfly Valve
2rdquo to 40rdquoClass 150
to 1500
Diaphragm Valve
2rdquo to 12rdquoClass 150
to 300
Piston Valve
2rdquo to 8rdquoClass 150
to 300
Double disc
2rdquo to 24rdquoclass 150
to 300
Check Valve
2 to 12 class 150
to 300
Product Mix
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
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36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
q 2006 ndash Upgraded from 350 KW to 450 KW furnace | ||||||||||
q 2006 ndash Added Machine shop | ||||||||||
q 2007 ndash Started LEAN activities | ||||||||||
q 2009 ndash Approval by BV Marine Division | ||||||||||
q 2012 ndash Added testing facilities like PMI Height Master amp Surface tester | ||||||||||
q 2012 ndash separated stainless steel and carbon steel in different areas | ||||||||||
q 2012 ndash Highest Sales Achieved so far | ||||||||||
Ball Valve | 2rdquo to 30rdquo | Class 150 to 1500 | ||||||||
Globe Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Gate Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Check Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Control Valve | 05rdquo to 16rdquo | Class 150 to 2500 | ||||||||
Butterfly Valve | 2rdquo to 40rdquo | Class 150 to 1500 | ||||||||
Diaphragm Valve | 2rdquo to 12rdquo | Class 150 to 300 | ||||||||
Piston Valve | 2rdquo to 8rdquo | Class 150 to 300 | ||||||||
Double disc | 2rdquo to 24rdquo | class 150 to 300 | ||||||||
Check Valve | 2 to 12 | class 150 to 300 |
production | |||
Valve components | 70 | ||
Pump components | 10 | ||
Hydraulic Components | 5 | ||
General Engineering | 5 | ||
Turbine component | 5 | ||
Defence Components | 5 | ||
To resize chart data range drag lower right corner of range |
Valve components | |
Pump components | |
Hydraulic Components | |
General Engineering | |
Turbine component | |
Defence Components |
Sales in Cr INR | Series 2 | Series 3 | |||||||
2008 | 4528 | 452800000 | 9056000 | 9056 | |||||
2009 | 3791 | 379100000 | 7582000 | 7582 | |||||
2010 | 5424 | 542485760 | 108497152 | 108497152 | |||||
2011 | 6539 | 653900000 | 13078000 | 13078 | |||||
2012 | 75 | 750000000 | 15000000 | 15 | |||||
2013 | 7652 | ||||||||
2014 | 6903 | ||||||||
2015 | 90 | ||||||||
2016 | 84 | ||||||||
To resize chart data range drag lower right corner of range |
2008 | |
2009 | |
2010 | |
2011 | |
2012 | |
2013 | |
2014 | |
2015 | |
2016 |
2013 ndash MAGMA Simulation Software installed 2014 ndash Lloyds Foundry Approval 2015 ndash Certified ISO 140012004 amp OHSAS 180012007 2015 ndash Highest sales 2015 ndash DNV Foundry Approval 2015 ndash New building 31360 sq foot for processing of above 500kg castings 2015 ndash CETP of capacity 25000 liters installed 2015 ndash Mould Carousel 8 Station semi automatic system 2016 ndash Fork Lift for Pattern Movement 2016 ndash NORSOK Certification for 4A 5A and 6A Grades 2016 ndash Upgraded ISO 9001-2008 to 2015 Version 2016 ndash Solar Roof Top Cells 100 KW Capacity Installed 2016 ndash 25MT Shake Out Machine With Material Handing EOT Crane 25 10 MT 2016 ndash Mechanized HT Quenching System to facilitate quenching within 50 sec 2016 ndash IBR Well Known Foundry status amp certified for Carbon amp Alloy Steel up to
2400 Kg single piece 2017 ndash Installed 3MT Capacity Table type Shot Blasting Machine 2017 ndash ISO 14001-2004 upgraded to 2015 Version
Our Progresshellip
State of Art Omega Semi Automatic Mold Carousal for consistent moldquality for small amp medium casting production with 120 moldsshiftcapacity
Mechanised Quenching system for Heat treatment Process 10 WPS-PQR Certified Operators for various grades witnessed by TUV
Lloyds amp DNV
10 Qualified Welders for handling the welding activities of various grades More than 15000 Patterns with 6000 patterns live Traceability through
ERP maintained location system and Product code
Exclusive storage arrangement for preservation of patterns
50 to 60 New Products being developed every month
More than 750 fully machined cast components exported month
Our Strength
0
10
20
30
40
50
60
70
80
90
2008 2009 2010 2011 2012 2013 2014 2015 2016
Sales in Cr INR
Sales in Cr INR
Our Saleshellip
Highlights Highest sales for financial year 2015 - 1515 M USD Business with Export 58 M USD
ISO 90012015
ISO 140012015
OHSAS 180012007
Well Known Foundry Status IBR
Since 1983
PED
AD MERKBLATT
Lloyds Bureau Veritas amp DNV
Foundry Approval
NORSOK Process Approval for
4A 5A amp 6A
Export Excellence Award By Govt
Of Karnataka
Export Excellence Award By IIF
Certificates amp Awards
7010
55 5 5
Valve componentsPump componentsHydraulic ComponentsGeneral EngineeringTurbine componentDefence Components
Ball Valve 2rdquo to 30rdquoClass 150
to 1500
Globe Valve 05rdquo to 12rdquoClass 150
to 900
Gate Valve 05rdquo to 12rdquoClass 150
to 900
Check Valve
05rdquo to 12rdquoClass 150
to 900
Control Valve
05rdquo to 16rdquoClass 150
to 2500
Butterfly Valve
2rdquo to 40rdquoClass 150
to 1500
Diaphragm Valve
2rdquo to 12rdquoClass 150
to 300
Piston Valve
2rdquo to 8rdquoClass 150
to 300
Double disc
2rdquo to 24rdquoclass 150
to 300
Check Valve
2 to 12 class 150
to 300
Product Mix
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
q 2006 ndash Upgraded from 350 KW to 450 KW furnace | ||||||||||
q 2006 ndash Added Machine shop | ||||||||||
q 2007 ndash Started LEAN activities | ||||||||||
q 2009 ndash Approval by BV Marine Division | ||||||||||
q 2012 ndash Added testing facilities like PMI Height Master amp Surface tester | ||||||||||
q 2012 ndash separated stainless steel and carbon steel in different areas | ||||||||||
q 2012 ndash Highest Sales Achieved so far | ||||||||||
Ball Valve | 2rdquo to 30rdquo | Class 150 to 1500 | ||||||||
Globe Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Gate Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Check Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Control Valve | 05rdquo to 16rdquo | Class 150 to 2500 | ||||||||
Butterfly Valve | 2rdquo to 40rdquo | Class 150 to 1500 | ||||||||
Diaphragm Valve | 2rdquo to 12rdquo | Class 150 to 300 | ||||||||
Piston Valve | 2rdquo to 8rdquo | Class 150 to 300 | ||||||||
Double disc | 2rdquo to 24rdquo | class 150 to 300 | ||||||||
Check Valve | 2 to 12 | class 150 to 300 |
production | |||
Valve components | 70 | ||
Pump components | 10 | ||
Hydraulic Components | 5 | ||
General Engineering | 5 | ||
Turbine component | 5 | ||
Defence Components | 5 | ||
To resize chart data range drag lower right corner of range |
Valve components | |
Pump components | |
Hydraulic Components | |
General Engineering | |
Turbine component | |
Defence Components |
Sales in Cr INR | Series 2 | Series 3 | |||||||
2008 | 4528 | 452800000 | 9056000 | 9056 | |||||
2009 | 3791 | 379100000 | 7582000 | 7582 | |||||
2010 | 5424 | 542485760 | 108497152 | 108497152 | |||||
2011 | 6539 | 653900000 | 13078000 | 13078 | |||||
2012 | 75 | 750000000 | 15000000 | 15 | |||||
2013 | 7652 | ||||||||
2014 | 6903 | ||||||||
2015 | 90 | ||||||||
2016 | 84 | ||||||||
To resize chart data range drag lower right corner of range |
2008 | |
2009 | |
2010 | |
2011 | |
2012 | |
2013 | |
2014 | |
2015 | |
2016 |
State of Art Omega Semi Automatic Mold Carousal for consistent moldquality for small amp medium casting production with 120 moldsshiftcapacity
Mechanised Quenching system for Heat treatment Process 10 WPS-PQR Certified Operators for various grades witnessed by TUV
Lloyds amp DNV
10 Qualified Welders for handling the welding activities of various grades More than 15000 Patterns with 6000 patterns live Traceability through
ERP maintained location system and Product code
Exclusive storage arrangement for preservation of patterns
50 to 60 New Products being developed every month
More than 750 fully machined cast components exported month
Our Strength
0
10
20
30
40
50
60
70
80
90
2008 2009 2010 2011 2012 2013 2014 2015 2016
Sales in Cr INR
Sales in Cr INR
Our Saleshellip
Highlights Highest sales for financial year 2015 - 1515 M USD Business with Export 58 M USD
ISO 90012015
ISO 140012015
OHSAS 180012007
Well Known Foundry Status IBR
Since 1983
PED
AD MERKBLATT
Lloyds Bureau Veritas amp DNV
Foundry Approval
NORSOK Process Approval for
4A 5A amp 6A
Export Excellence Award By Govt
Of Karnataka
Export Excellence Award By IIF
Certificates amp Awards
7010
55 5 5
Valve componentsPump componentsHydraulic ComponentsGeneral EngineeringTurbine componentDefence Components
Ball Valve 2rdquo to 30rdquoClass 150
to 1500
Globe Valve 05rdquo to 12rdquoClass 150
to 900
Gate Valve 05rdquo to 12rdquoClass 150
to 900
Check Valve
05rdquo to 12rdquoClass 150
to 900
Control Valve
05rdquo to 16rdquoClass 150
to 2500
Butterfly Valve
2rdquo to 40rdquoClass 150
to 1500
Diaphragm Valve
2rdquo to 12rdquoClass 150
to 300
Piston Valve
2rdquo to 8rdquoClass 150
to 300
Double disc
2rdquo to 24rdquoclass 150
to 300
Check Valve
2 to 12 class 150
to 300
Product Mix
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
q 2006 ndash Upgraded from 350 KW to 450 KW furnace | ||||||||||
q 2006 ndash Added Machine shop | ||||||||||
q 2007 ndash Started LEAN activities | ||||||||||
q 2009 ndash Approval by BV Marine Division | ||||||||||
q 2012 ndash Added testing facilities like PMI Height Master amp Surface tester | ||||||||||
q 2012 ndash separated stainless steel and carbon steel in different areas | ||||||||||
q 2012 ndash Highest Sales Achieved so far | ||||||||||
Ball Valve | 2rdquo to 30rdquo | Class 150 to 1500 | ||||||||
Globe Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Gate Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Check Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Control Valve | 05rdquo to 16rdquo | Class 150 to 2500 | ||||||||
Butterfly Valve | 2rdquo to 40rdquo | Class 150 to 1500 | ||||||||
Diaphragm Valve | 2rdquo to 12rdquo | Class 150 to 300 | ||||||||
Piston Valve | 2rdquo to 8rdquo | Class 150 to 300 | ||||||||
Double disc | 2rdquo to 24rdquo | class 150 to 300 | ||||||||
Check Valve | 2 to 12 | class 150 to 300 |
production | |||
Valve components | 70 | ||
Pump components | 10 | ||
Hydraulic Components | 5 | ||
General Engineering | 5 | ||
Turbine component | 5 | ||
Defence Components | 5 | ||
To resize chart data range drag lower right corner of range |
Valve components | |
Pump components | |
Hydraulic Components | |
General Engineering | |
Turbine component | |
Defence Components |
Sales in Cr INR | Series 2 | Series 3 | |||||||
2008 | 4528 | 452800000 | 9056000 | 9056 | |||||
2009 | 3791 | 379100000 | 7582000 | 7582 | |||||
2010 | 5424 | 542485760 | 108497152 | 108497152 | |||||
2011 | 6539 | 653900000 | 13078000 | 13078 | |||||
2012 | 75 | 750000000 | 15000000 | 15 | |||||
2013 | 7652 | ||||||||
2014 | 6903 | ||||||||
2015 | 90 | ||||||||
2016 | 84 | ||||||||
To resize chart data range drag lower right corner of range |
2008 | |
2009 | |
2010 | |
2011 | |
2012 | |
2013 | |
2014 | |
2015 | |
2016 |
0
10
20
30
40
50
60
70
80
90
2008 2009 2010 2011 2012 2013 2014 2015 2016
Sales in Cr INR
Sales in Cr INR
Our Saleshellip
Highlights Highest sales for financial year 2015 - 1515 M USD Business with Export 58 M USD
ISO 90012015
ISO 140012015
OHSAS 180012007
Well Known Foundry Status IBR
Since 1983
PED
AD MERKBLATT
Lloyds Bureau Veritas amp DNV
Foundry Approval
NORSOK Process Approval for
4A 5A amp 6A
Export Excellence Award By Govt
Of Karnataka
Export Excellence Award By IIF
Certificates amp Awards
7010
55 5 5
Valve componentsPump componentsHydraulic ComponentsGeneral EngineeringTurbine componentDefence Components
Ball Valve 2rdquo to 30rdquoClass 150
to 1500
Globe Valve 05rdquo to 12rdquoClass 150
to 900
Gate Valve 05rdquo to 12rdquoClass 150
to 900
Check Valve
05rdquo to 12rdquoClass 150
to 900
Control Valve
05rdquo to 16rdquoClass 150
to 2500
Butterfly Valve
2rdquo to 40rdquoClass 150
to 1500
Diaphragm Valve
2rdquo to 12rdquoClass 150
to 300
Piston Valve
2rdquo to 8rdquoClass 150
to 300
Double disc
2rdquo to 24rdquoclass 150
to 300
Check Valve
2 to 12 class 150
to 300
Product Mix
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
q 2006 ndash Upgraded from 350 KW to 450 KW furnace | ||||||||||
q 2006 ndash Added Machine shop | ||||||||||
q 2007 ndash Started LEAN activities | ||||||||||
q 2009 ndash Approval by BV Marine Division | ||||||||||
q 2012 ndash Added testing facilities like PMI Height Master amp Surface tester | ||||||||||
q 2012 ndash separated stainless steel and carbon steel in different areas | ||||||||||
q 2012 ndash Highest Sales Achieved so far | ||||||||||
Ball Valve | 2rdquo to 30rdquo | Class 150 to 1500 | ||||||||
Globe Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Gate Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Check Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Control Valve | 05rdquo to 16rdquo | Class 150 to 2500 | ||||||||
Butterfly Valve | 2rdquo to 40rdquo | Class 150 to 1500 | ||||||||
Diaphragm Valve | 2rdquo to 12rdquo | Class 150 to 300 | ||||||||
Piston Valve | 2rdquo to 8rdquo | Class 150 to 300 | ||||||||
Double disc | 2rdquo to 24rdquo | class 150 to 300 | ||||||||
Check Valve | 2 to 12 | class 150 to 300 |
production | |||
Valve components | 70 | ||
Pump components | 10 | ||
Hydraulic Components | 5 | ||
General Engineering | 5 | ||
Turbine component | 5 | ||
Defence Components | 5 | ||
To resize chart data range drag lower right corner of range |
Valve components | |
Pump components | |
Hydraulic Components | |
General Engineering | |
Turbine component | |
Defence Components |
Sales in Cr INR | Series 2 | Series 3 | |||||||
2008 | 4528 | 452800000 | 9056000 | 9056 | |||||
2009 | 3791 | 379100000 | 7582000 | 7582 | |||||
2010 | 5424 | 542485760 | 108497152 | 108497152 | |||||
2011 | 6539 | 653900000 | 13078000 | 13078 | |||||
2012 | 75 | 750000000 | 15000000 | 15 | |||||
2013 | 7652 | ||||||||
2014 | 6903 | ||||||||
2015 | 90 | ||||||||
2016 | 84 | ||||||||
To resize chart data range drag lower right corner of range |
2008 | |
2009 | |
2010 | |
2011 | |
2012 | |
2013 | |
2014 | |
2015 | |
2016 |
ISO 90012015
ISO 140012015
OHSAS 180012007
Well Known Foundry Status IBR
Since 1983
PED
AD MERKBLATT
Lloyds Bureau Veritas amp DNV
Foundry Approval
NORSOK Process Approval for
4A 5A amp 6A
Export Excellence Award By Govt
Of Karnataka
Export Excellence Award By IIF
Certificates amp Awards
7010
55 5 5
Valve componentsPump componentsHydraulic ComponentsGeneral EngineeringTurbine componentDefence Components
Ball Valve 2rdquo to 30rdquoClass 150
to 1500
Globe Valve 05rdquo to 12rdquoClass 150
to 900
Gate Valve 05rdquo to 12rdquoClass 150
to 900
Check Valve
05rdquo to 12rdquoClass 150
to 900
Control Valve
05rdquo to 16rdquoClass 150
to 2500
Butterfly Valve
2rdquo to 40rdquoClass 150
to 1500
Diaphragm Valve
2rdquo to 12rdquoClass 150
to 300
Piston Valve
2rdquo to 8rdquoClass 150
to 300
Double disc
2rdquo to 24rdquoclass 150
to 300
Check Valve
2 to 12 class 150
to 300
Product Mix
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
q 2006 ndash Upgraded from 350 KW to 450 KW furnace | ||||||||||
q 2006 ndash Added Machine shop | ||||||||||
q 2007 ndash Started LEAN activities | ||||||||||
q 2009 ndash Approval by BV Marine Division | ||||||||||
q 2012 ndash Added testing facilities like PMI Height Master amp Surface tester | ||||||||||
q 2012 ndash separated stainless steel and carbon steel in different areas | ||||||||||
q 2012 ndash Highest Sales Achieved so far | ||||||||||
Ball Valve | 2rdquo to 30rdquo | Class 150 to 1500 | ||||||||
Globe Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Gate Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Check Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Control Valve | 05rdquo to 16rdquo | Class 150 to 2500 | ||||||||
Butterfly Valve | 2rdquo to 40rdquo | Class 150 to 1500 | ||||||||
Diaphragm Valve | 2rdquo to 12rdquo | Class 150 to 300 | ||||||||
Piston Valve | 2rdquo to 8rdquo | Class 150 to 300 | ||||||||
Double disc | 2rdquo to 24rdquo | class 150 to 300 | ||||||||
Check Valve | 2 to 12 | class 150 to 300 |
production | |||
Valve components | 70 | ||
Pump components | 10 | ||
Hydraulic Components | 5 | ||
General Engineering | 5 | ||
Turbine component | 5 | ||
Defence Components | 5 | ||
To resize chart data range drag lower right corner of range |
Valve components | |
Pump components | |
Hydraulic Components | |
General Engineering | |
Turbine component | |
Defence Components |
Sales in Cr INR | Series 2 | Series 3 | |||||||
2008 | 4528 | 452800000 | 9056000 | 9056 | |||||
2009 | 3791 | 379100000 | 7582000 | 7582 | |||||
2010 | 5424 | 542485760 | 108497152 | 108497152 | |||||
2011 | 6539 | 653900000 | 13078000 | 13078 | |||||
2012 | 75 | 750000000 | 15000000 | 15 | |||||
2013 | 7652 | ||||||||
2014 | 6903 | ||||||||
2015 | 90 | ||||||||
2016 | 84 | ||||||||
To resize chart data range drag lower right corner of range |
2008 | |
2009 | |
2010 | |
2011 | |
2012 | |
2013 | |
2014 | |
2015 | |
2016 |
ISO 90012015
ISO 140012015
OHSAS 180012007
Well Known Foundry Status IBR
Since 1983
PED
AD MERKBLATT
Lloyds Bureau Veritas amp DNV
Foundry Approval
NORSOK Process Approval for
4A 5A amp 6A
Export Excellence Award By Govt
Of Karnataka
Export Excellence Award By IIF
Certificates amp Awards
7010
55 5 5
Valve componentsPump componentsHydraulic ComponentsGeneral EngineeringTurbine componentDefence Components
Ball Valve 2rdquo to 30rdquoClass 150
to 1500
Globe Valve 05rdquo to 12rdquoClass 150
to 900
Gate Valve 05rdquo to 12rdquoClass 150
to 900
Check Valve
05rdquo to 12rdquoClass 150
to 900
Control Valve
05rdquo to 16rdquoClass 150
to 2500
Butterfly Valve
2rdquo to 40rdquoClass 150
to 1500
Diaphragm Valve
2rdquo to 12rdquoClass 150
to 300
Piston Valve
2rdquo to 8rdquoClass 150
to 300
Double disc
2rdquo to 24rdquoclass 150
to 300
Check Valve
2 to 12 class 150
to 300
Product Mix
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
q 2006 ndash Upgraded from 350 KW to 450 KW furnace | ||||||||||
q 2006 ndash Added Machine shop | ||||||||||
q 2007 ndash Started LEAN activities | ||||||||||
q 2009 ndash Approval by BV Marine Division | ||||||||||
q 2012 ndash Added testing facilities like PMI Height Master amp Surface tester | ||||||||||
q 2012 ndash separated stainless steel and carbon steel in different areas | ||||||||||
q 2012 ndash Highest Sales Achieved so far | ||||||||||
Ball Valve | 2rdquo to 30rdquo | Class 150 to 1500 | ||||||||
Globe Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Gate Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Check Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Control Valve | 05rdquo to 16rdquo | Class 150 to 2500 | ||||||||
Butterfly Valve | 2rdquo to 40rdquo | Class 150 to 1500 | ||||||||
Diaphragm Valve | 2rdquo to 12rdquo | Class 150 to 300 | ||||||||
Piston Valve | 2rdquo to 8rdquo | Class 150 to 300 | ||||||||
Double disc | 2rdquo to 24rdquo | class 150 to 300 | ||||||||
Check Valve | 2 to 12 | class 150 to 300 |
production | |||
Valve components | 70 | ||
Pump components | 10 | ||
Hydraulic Components | 5 | ||
General Engineering | 5 | ||
Turbine component | 5 | ||
Defence Components | 5 | ||
To resize chart data range drag lower right corner of range |
Valve components | |
Pump components | |
Hydraulic Components | |
General Engineering | |
Turbine component | |
Defence Components |
Sales in Cr INR | Series 2 | Series 3 | |||||||
2008 | 4528 | 452800000 | 9056000 | 9056 | |||||
2009 | 3791 | 379100000 | 7582000 | 7582 | |||||
2010 | 5424 | 542485760 | 108497152 | 108497152 | |||||
2011 | 6539 | 653900000 | 13078000 | 13078 | |||||
2012 | 75 | 750000000 | 15000000 | 15 | |||||
2013 | 7652 | ||||||||
2014 | 6903 | ||||||||
2015 | 90 | ||||||||
2016 | 84 | ||||||||
To resize chart data range drag lower right corner of range |
ISO 90012015
ISO 140012015
OHSAS 180012007
Well Known Foundry Status IBR
Since 1983
PED
AD MERKBLATT
Lloyds Bureau Veritas amp DNV
Foundry Approval
NORSOK Process Approval for
4A 5A amp 6A
Export Excellence Award By Govt
Of Karnataka
Export Excellence Award By IIF
Certificates amp Awards
7010
55 5 5
Valve componentsPump componentsHydraulic ComponentsGeneral EngineeringTurbine componentDefence Components
Ball Valve 2rdquo to 30rdquoClass 150
to 1500
Globe Valve 05rdquo to 12rdquoClass 150
to 900
Gate Valve 05rdquo to 12rdquoClass 150
to 900
Check Valve
05rdquo to 12rdquoClass 150
to 900
Control Valve
05rdquo to 16rdquoClass 150
to 2500
Butterfly Valve
2rdquo to 40rdquoClass 150
to 1500
Diaphragm Valve
2rdquo to 12rdquoClass 150
to 300
Piston Valve
2rdquo to 8rdquoClass 150
to 300
Double disc
2rdquo to 24rdquoclass 150
to 300
Check Valve
2 to 12 class 150
to 300
Product Mix
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
q 2006 ndash Upgraded from 350 KW to 450 KW furnace | ||||||||||
q 2006 ndash Added Machine shop | ||||||||||
q 2007 ndash Started LEAN activities | ||||||||||
q 2009 ndash Approval by BV Marine Division | ||||||||||
q 2012 ndash Added testing facilities like PMI Height Master amp Surface tester | ||||||||||
q 2012 ndash separated stainless steel and carbon steel in different areas | ||||||||||
q 2012 ndash Highest Sales Achieved so far | ||||||||||
Ball Valve | 2rdquo to 30rdquo | Class 150 to 1500 | ||||||||
Globe Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Gate Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Check Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Control Valve | 05rdquo to 16rdquo | Class 150 to 2500 | ||||||||
Butterfly Valve | 2rdquo to 40rdquo | Class 150 to 1500 | ||||||||
Diaphragm Valve | 2rdquo to 12rdquo | Class 150 to 300 | ||||||||
Piston Valve | 2rdquo to 8rdquo | Class 150 to 300 | ||||||||
Double disc | 2rdquo to 24rdquo | class 150 to 300 | ||||||||
Check Valve | 2 to 12 | class 150 to 300 |
production | |||
Valve components | 70 | ||
Pump components | 10 | ||
Hydraulic Components | 5 | ||
General Engineering | 5 | ||
Turbine component | 5 | ||
Defence Components | 5 | ||
To resize chart data range drag lower right corner of range |
Valve components | |
Pump components | |
Hydraulic Components | |
General Engineering | |
Turbine component | |
Defence Components |
7010
55 5 5
Valve componentsPump componentsHydraulic ComponentsGeneral EngineeringTurbine componentDefence Components
Ball Valve 2rdquo to 30rdquoClass 150
to 1500
Globe Valve 05rdquo to 12rdquoClass 150
to 900
Gate Valve 05rdquo to 12rdquoClass 150
to 900
Check Valve
05rdquo to 12rdquoClass 150
to 900
Control Valve
05rdquo to 16rdquoClass 150
to 2500
Butterfly Valve
2rdquo to 40rdquoClass 150
to 1500
Diaphragm Valve
2rdquo to 12rdquoClass 150
to 300
Piston Valve
2rdquo to 8rdquoClass 150
to 300
Double disc
2rdquo to 24rdquoclass 150
to 300
Check Valve
2 to 12 class 150
to 300
Product Mix
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
q 2006 ndash Upgraded from 350 KW to 450 KW furnace | ||||||||||
q 2006 ndash Added Machine shop | ||||||||||
q 2007 ndash Started LEAN activities | ||||||||||
q 2009 ndash Approval by BV Marine Division | ||||||||||
q 2012 ndash Added testing facilities like PMI Height Master amp Surface tester | ||||||||||
q 2012 ndash separated stainless steel and carbon steel in different areas | ||||||||||
q 2012 ndash Highest Sales Achieved so far | ||||||||||
Ball Valve | 2rdquo to 30rdquo | Class 150 to 1500 | ||||||||
Globe Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Gate Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Check Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Control Valve | 05rdquo to 16rdquo | Class 150 to 2500 | ||||||||
Butterfly Valve | 2rdquo to 40rdquo | Class 150 to 1500 | ||||||||
Diaphragm Valve | 2rdquo to 12rdquo | Class 150 to 300 | ||||||||
Piston Valve | 2rdquo to 8rdquo | Class 150 to 300 | ||||||||
Double disc | 2rdquo to 24rdquo | class 150 to 300 | ||||||||
Check Valve | 2 to 12 | class 150 to 300 |
production | |||
Valve components | 70 | ||
Pump components | 10 | ||
Hydraulic Components | 5 | ||
General Engineering | 5 | ||
Turbine component | 5 | ||
Defence Components | 5 | ||
To resize chart data range drag lower right corner of range |
Valve components | |
Pump components | |
Hydraulic Components | |
General Engineering | |
Turbine component | |
Defence Components |
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
q 2006 ndash Upgraded from 350 KW to 450 KW furnace | ||||||||||
q 2006 ndash Added Machine shop | ||||||||||
q 2007 ndash Started LEAN activities | ||||||||||
q 2009 ndash Approval by BV Marine Division | ||||||||||
q 2012 ndash Added testing facilities like PMI Height Master amp Surface tester | ||||||||||
q 2012 ndash separated stainless steel and carbon steel in different areas | ||||||||||
q 2012 ndash Highest Sales Achieved so far | ||||||||||
Ball Valve | 2rdquo to 30rdquo | Class 150 to 1500 | ||||||||
Globe Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Gate Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Check Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Control Valve | 05rdquo to 16rdquo | Class 150 to 2500 | ||||||||
Butterfly Valve | 2rdquo to 40rdquo | Class 150 to 1500 | ||||||||
Diaphragm Valve | 2rdquo to 12rdquo | Class 150 to 300 | ||||||||
Piston Valve | 2rdquo to 8rdquo | Class 150 to 300 | ||||||||
Double disc | 2rdquo to 24rdquo | class 150 to 300 | ||||||||
Check Valve | 2 to 12 | class 150 to 300 |
production | |||
Valve components | 70 | ||
Pump components | 10 | ||
Hydraulic Components | 5 | ||
General Engineering | 5 | ||
Turbine component | 5 | ||
Defence Components | 5 | ||
To resize chart data range drag lower right corner of range |
Valve components | |
Pump components | |
Hydraulic Components | |
General Engineering | |
Turbine component | |
Defence Components |
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
q 2006 ndash Upgraded from 350 KW to 450 KW furnace | ||||||||||
q 2006 ndash Added Machine shop | ||||||||||
q 2007 ndash Started LEAN activities | ||||||||||
q 2009 ndash Approval by BV Marine Division | ||||||||||
q 2012 ndash Added testing facilities like PMI Height Master amp Surface tester | ||||||||||
q 2012 ndash separated stainless steel and carbon steel in different areas | ||||||||||
q 2012 ndash Highest Sales Achieved so far | ||||||||||
Ball Valve | 2rdquo to 30rdquo | Class 150 to 1500 | ||||||||
Globe Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Gate Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Check Valve | 05rdquo to 12rdquo | Class 150 to 900 | ||||||||
Control Valve | 05rdquo to 16rdquo | Class 150 to 2500 | ||||||||
Butterfly Valve | 2rdquo to 40rdquo | Class 150 to 1500 | ||||||||
Diaphragm Valve | 2rdquo to 12rdquo | Class 150 to 300 | ||||||||
Piston Valve | 2rdquo to 8rdquo | Class 150 to 300 | ||||||||
Double disc | 2rdquo to 24rdquo | class 150 to 300 | ||||||||
Check Valve | 2 to 12 | class 150 to 300 |
production | |||
Valve components | 70 | ||
Pump components | 10 | ||
Hydraulic Components | 5 | ||
General Engineering | 5 | ||
Turbine component | 5 | ||
Defence Components | 5 | ||
To resize chart data range drag lower right corner of range |
Total Capacity - 625 MTMonth Utilized Capacity - 350 MTMonth(in view of recession in market)
Maximum Single Piece Weight We Can Produce is 2400 Kgs
Foundry Capacity
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
10112017
15
2700 Kg Casting Exported from Malnad
2400 Kg Butterfly Valve
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
SECTION TIME REQUIREDPattern Development 3 weeks
Sample Castings (Including Radiography Test)
45 Working Days (From the date of receipt Pattern ready for molding)
Sample Machining 3-4 Weeks (From Receipt Of Castings)
Production Castings 45 Working Days
Production Machining 75 Working Days
Typical Lead Time
All the above lead time depends on the size amp complexity of the castings
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
Material Of Construction Carbon Steel
ASTM Grades WCBWCCWC6LCBLCCWC9
Alloy SteelC5C12C12A
Stainless SteelCF8 CF-8C CF8MCA-15CD4MCUCD4MCUN Grade 4A 5A amp 6ACN7MCF-3CF-3M CG8mCA6NM SS420 CA40 SS410 SS430174PH
Nickel Base AlloysCW12MW CW2MCW6MCW6MCCU5MCuCN7MN-12MV
All the above grades corresponding to DIN and Indian Standards
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
Pattern Methoding And Mounting
Magma Simulation Pattern Mounting
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
2 Numbers
NO BAKE SystemContinuous Mixer 12 MTHour 1 NumberContinuous Mixer 6 MTHour 2 NumbersContinuous Mixer 15MTHourBatch Mixer 150 Kgs 2 NumbersSand Reclamation Plant 4 MTHour 1 Number
Manufacturing - Molding
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
Manufacturing - MoldingCore Making Mold Coating
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
Manufacturing - Melting
Medium Frequency Induction Furnaces
750 KW 3000 Kg amp 2000 Kg Crucible
450 KW 1500 Kg amp 1000 Kg Crucible
175 KW 300 Kg amp 150 Kg Crucible
One Crucible is standby in all the above cases
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
Manufacturing ndash Post Pouring Shot Blasting Machine
1MT hook type - 1 No5MT hook type - 1 No
Shot blasting machineTable type 1 MT - 2 NosTable type 3 MT - 1 No
Aluminum grit blastingMachine 750 Kg - 2 NosRoom Blast - 2 Nos
Pedestal grindingMachine 3HP - 1 No
Swing frameGrinding Hp - 4 Nos
Flexible shaft with variableSpeed 25 HP - 25 Nos
Subcontracting Facilities3 Groups within the campus withcapacity 20 amp 80 MTMonth6 Subcontractors outside withtotal capacity 350 MTMonth
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
Manufacturing ndash Heat Treatment3 amp 5 Ton Furnaces Mechanised Quenching
System
One each of Electric PLC Controlled 075 15 20 amp 30 MT Furnaces amp one eachof 3 and 5 MT furnace with Mechanized quenching system to facilitate waterquenching within 50 Sec
Quenching Water tanks of 60000 amp 75000 Liter Capacity with Cooling System
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
QualityTesting FacilitiesSpectro Analyzer with Three Base Metal - Iron Nickel and Cobalt with 25
elements including Nitrogen And Oxygen
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
QualityTesting Facilities
PMI20 MT Capacity UTM with BHN attachment
BHN Testing Machine
Vickers Hardness
Impact testing Machine up to -196deg C
PMI
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
QualityTesting Facilities
Magnetic Particle Inspection Ultrasonic TestDie Penetrate Test RT With Iridium 192 And Cobalt 60 Source (Upto200 mm Thickness) Available Within 300 Meters5 Qualified NDT Level II Personnel Including 1 NDT Level II As Per EN Standard
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
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10112017
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Manufacturing Experience10112017
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Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
QualityTesting Facilities LIST OF NDT QUALIFIED INSPECTORS AND OPERATORS - MACPL
SR NAME CERTIFICATE No LEVEL II LEVEL I NDT METHODS DATE OF EXPIRY
1 MrMSSIDDALIGESWARA SWAMY
EN-3197CERTNDT-0564-16 radic RT 23-Sep-2021P2MG03905 radic LPT
5-May-2019M2MG03905 radic MPTR2MG01905 radic RT
BNDT134UTII10 radic UT 22-Oct-2019
2 MrCUKESHAVAMURTHY
BNDT114PTII10 radic LPT
22-Oct-2019BNDT115MTII10 radic MPTBNDT116RTII10 radic RTBNDT117UTII10 radic UT
3 MrAVIGHNESHWARA MANJA
BNDT124PTII08 radic LPT
20-May-2019BNDT125MTII08 radic MPTBNDT129RTI10 radic RTBNDT130UTI10 radic UT
4 MrNSURESH RAOHYDB266 radic LPT
20-Apr-2019HYDB266 radic MPT
5 MrDOULATH PASHAHYDB263 radic LPT
20-Apr-2019HYDB263 radic MPT
6 MrGAJENDRABNDT123PTI08 radic LPT
20-Apr-2019BNDT122MTI08 radic MPT
7 MrKMANJUNATHABNDT117PTI08 radic LPT
20-Apr-2019BNDT116MTI08 radic MPT
8 MrKRISHNABNDT118PTI08 radic LPT
20-Apr-2019BNDT119MTI08 radic MPT
9 MrNANJAPPANHYDB268 radic LPT
20-Apr-2019HYDB268 radic MPT
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
QualityTesting Facilities
050rdquo Flow Bore Casting
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
QualityTesting Facilities
Ultrasonic Thickness Gauge
Digital Poldie Hardness Tester
Ferrito Scope
Radio Active Contamination Detector
Digital pH Meter
Digital Lux meter Sound meter Tachometer
Casting Comparator From Steel International France
Infrared Temperature measuring instruments 500 degC amp 1600 degC
Other Testing Instruments -
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
Manufacturing ndash Machine Shop
Vertical Machining Centre
CNC Turning Centre
Conventional Lathes
Radial Drilling Machine
Conventional Milling
Hydro Testing Machine for 150300600
amp 90015002500 CLASS
Malnad hydro procedure in line with
ASNT and EN standards
In House Machine Shop equipments amp Facilities
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
Customer Base
China
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
Major Customers
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
Web Access To Customers
Website address wwwmalnadcoin
Customers will be given with unique login id amp Password
Data Available Order Status Test Certificates (3months) Dimension Ins Report NDT Reports amp Pattern List
33
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
On Going Projects-2017 Thermal Reclamation plant- 15 MT per hour to improve
Sand quality amp to reduce environmental issues NABL Accreditation for chemical amp mechanical lab
Planned Projects
Energy Management System Rain water harvesting
34
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
EMS Measures Bio Diesel as a Replacement for Petroleum Diesel Transparent sheets in order to avoid electric lights in day time Roof Top Solar Cell with 100KW capacity Solar Lights to reduce usage of Hydro Electricity during day time RO plant having capacity of 1500ltshour capacity has been installed
50+ Plants planted Across The Company
Compound
100 KW Roof top static solar cell installed in
hall number 7
RO plant 1500ltshour capacity
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
36
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
Our Progress
1996 ndash Start up of Production 2001 - Started ERP 2002 ndash ISO 9001 Certification 2008 ndash Added new building for shell activity 2009 ndash Started Wax formulation in house 2010 ndash Started Manufacturing of Ceramic cores 2013-14 ndash 78 Crore sales(INR) 2014-15 ndash 15 Crore sales (INR) 2016 ndash ISO 9001 upgraded to Latest version 2015 2016 ndash EMS amp OHSAS Certifications under progress
10112017
37SHIMOGA PRECISION CASTINGS PVT LTD
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
Facility Details10112017
38
Total Installed Capacity - 40MT per Month Utilized Capacity ndash 25 MT per Month Single piece we can pour up to 40 Kgs Experts in-Steam Trap Control Valve components Special grades Stellite-6Stellite-21NNRD2Monel-
M35 Ultimate Alloy Duplex steel apart from standard Austenitic Martensitic Steels
SHIMOGA PRECISION CASTINGS PVT LTD
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
Various Stages Of Investment Casting10112017
39SHIMOGA PRECISION CASTINGS PVT LTD
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
Customer Base
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
10112017
41
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
10112017
42
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
Manufacturing Experience10112017
43
Ball Valve 15MM TO 25 MM Class 150 to 300
Globe Valve 05rdquo to 2 rdquo Class 150 to 900
Gate Valve 05rdquo to 2rdquo Class 150 to 900
Check Valve 05rdquo to 2rdquo Class 150 to 900
Control Valve 05rdquo to 3rdquo Class 150 to 2500
Butterfly Valve 2rdquo to 4rdquo Class 150 to 1500
Diaphragm Valve Upto 2rdquo Class 150 to 300
Piston Valve Upto 2rdquo Class 150 to 300
Double discCheck Valve
2rdquo to 4rdquo Class 150 to 2500
SHIMOGA PRECISION CASTINGS PVT LTD
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
10112017
44
MALNAD PRIME MACHINING TECHNOLOGY
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
MACHINING
FACILITY
Malnad Prime Machining Technology Private Limited a Sister concern of Malnad Alloy Castingis well equipped to machine up 10rdquo size Valves
We have following CNC machines with the table size details We can supply the castings incompletely machined amp Hydro tested condition
X Y ZHAAS VF2 762 406 508VCS 430A 560 430 510
550 MAX TURNING DIA 650 - MAX TURNING LENGTH 700650 MAX TURNING DIA 800 - MAX TURNING LENGTH 750
HMC HORIZONTAL CENTER NEXUS 5000-2 730 730 740CNC - Turning MAZAK E160C 165 - 330
9C Lathes9C Lathes
Radial Drilling Machine
VMC
VTL
Conventional Lathes
SizeMachines Specification
MALNAD PRIME MACHINING TECHNOLOGY
MachinesSize
VMC450 mm
VTL650 mm
HMC650 mm
CNC - Turning250 mm
Conventional Lathes9C Lathes
Radial Drilling Machine
10112017
46
Thank You
Induction Furnace | ||||||||||||
3000 Kg | 750 kw with 3000 Kg and 2000 Kg Crucible | |||||||||||
1500 Kg | 450 Kw with 1500 Kg and 1000 Kg Crucible | |||||||||||
300 Kg | 150 kw with 300 Kg and 150 Kg Crucible | |||||||||||
NO BAKE System | ||||||||||||
Continuous mixer | 12 MT perHour | 1 Numbers | ||||||||||
Continuous mixer | 6 MT perHour | 2 Numbers | ||||||||||
Continuous mixer | 15MT perHour | 1 Number | ||||||||||
Batch mixer | 150 kgrsquos | 2 Numbers | ||||||||||
Sand Reclamation plant | 4 MT perHour | 1 Number | ||||||||||
Machines | Size | |||||||||||
VMC | 450 mm | |||||||||||
VTL | 650 mm | |||||||||||
HMC | 650 mm | |||||||||||
CNC - Turning | 250 mm | |||||||||||
Conventional Lathes | 9C Lathes | |||||||||||
Radial Drilling Machine |
pouring | Desp | IR | CR | ||||||||||
tonnage | 75019 MT | 65615 MT | 23911 | 27236 | |||||||||
Qty | 12766 | 12183 | 430 | 938 | |||||||||
Value | 173043543 | 1572000 | 1183883 | ||||||||||
HT Cycle | members | ||||||||||||
Hegde | |||||||||||||
Swamy | |||||||||||||
Adarsh Bhosle | |||||||||||||
Sathyanarayan | |||||||||||||
Subbanna |
Certification | Team Members | Start Date | Close Date | ||||||||
Norsok | SubbannaSwamyCNMPrateek JoisAdash Bhosle | ||||||||||
ISO-140001 | SubbannaSwamyCNMPrateek JoisAdash BhosleSatishSathya Prakash | ||||||||||
OSHAs | SubbannaSwamyCNMHegdePrateek JoisAdash BhosleHarishMahveer Jain AnandYashoda |
Team no | Team Memebrs | Department | Project | Start Date | Close Date | Cost Saved | Tangible Benefits | Intangible Benefits | ||||||||||||||
1 | HRKumar Adarsh BhosleKiran S | Marketing | ||||||||||||||||||||
2 | Krithika JoisMahesh Kumar BTRagavendraMadhu Kumar | Purchase | ||||||||||||||||||||
3 | Manjunath ML Sathish GSCN MaheshSwamyAdarsh BhosleAvinash Senthil | Development | ||||||||||||||||||||
4 | CN Mahesh Moulding amp Melting Supervisors | Production | ||||||||||||||||||||
5 | Mahveer Jain and Team | Process Control | ||||||||||||||||||||
6 | NSubbannaRagvendra Bhatt | Q A | ||||||||||||||||||||
7 | Hegde Adarsh BhosleSubbannaSwamy | Fellting amp Heat Treatment | ||||||||||||||||||||
8 | VynathianGuruswamyChandrappDavid RT Kiran | Dispatch | ||||||||||||||||||||
9 | Swamy CU KeshavAdarh BhosleVignesh ManjalSubbanna | QC | ||||||||||||||||||||
10 | Harish Yagnarayn NeelakantaMahadeva | Machineshop | ||||||||||||||||||||
11 | SathishSathyaprakashNaveen | Maintainance | ||||||||||||||||||||
12 | RekaKamathGirish | Finance |
Continuous mixer | 12 MT perHr | 1 Numbers | ||||||||
Continuous mixer | 6 MT perHr | 2 numbers | ||||||||
Continuous mixer | 15MT perHr | 1 number | ||||||||
Batch mixer | 150 kgrsquos | 2 numbers | ||||||||
Sand Reclamation plant | 4 MT perHr | 1 number |
JAN | FEB | MAR | APR | |||||||||
Production | 94 | 70722 | 9781 | 9139 | ||||||||
Dispacth | 5973 | 6702 | 9426 | 6698 | ||||||||
Value | 247 Cr | 255 Cr | 327 Cr | 217 Cr |
Parameter | 2011-12 | |||||
Gas | 52036 | |||||
sand drop | 17737 | |||||
crack | 13845 | |||||
shrinkage | 13648 | |||||
slag inclussion | 6195 | |||||
cold metal | 4785 | |||||
mould leak | 4465 | |||||
excess Material | 4 | |||||
excess pouring | 4 | |||||
mis match | 3246 | |||||
open | 3211 | |||||
Stock Difference | 3026 | |||||
sand inclussion | 2899 | |||||
short pour | 2164 | |||||
sand fusion | 0888 | |||||
blow hole | 0773 | |||||
machining Rejection | 0737 | |||||
wrong order booking | 0248 | |||||
core reverse | 0003 |
Parameter | 2012-13 | 2011-12 | Comparision in MT | Comparision in | ||||||||||||||||||||
Gas | 145 | 1006 | 01441351889 | 144135188867 | 52036 | 14545 | 035775868 | 357758679959 | 212758679959 | 213623491092 | 2516 | |||||||||||||
shrinkage | 1241 | 1006 | 0123359841 | 123359840954 | 13648 | 14545 | 00938329323 | 93832932279 | -30267067721 | 26 | 030 | |||||||||||||
crack | 729 | 1006 | 00724652087 | 72465208748 | 13845 | 14545 | 00951873496 | 95187349605 | 22287349605 | 22722140857 | 418 | |||||||||||||
core reverse | 5612 | 1006 | 00557852883 | 5578528827 | 0003 | 14545 | 00000206256 | 00020625645 | -56099374355 | 557 | 558 | |||||||||||||
slag inclussion | 535 | 1006 | 00531809145 | 53180914513 | 6195 | 14545 | 0042591956 | 42591955999 | -10908044001 | -10588958514 | 034 | |||||||||||||
wrong order booking | 532 | 1006 | 00528827038 | 52882703777 | 0248 | 14545 | 00017050533 | 01705053283 | -51494946717 | -51177650494 | 512 | |||||||||||||
sand fusion | 467 | 1006 | 00464214712 | 46421471173 | 0888 | 14545 | 00061051908 | 06105190787 | -40594809213 | -40316280386 | 403 | |||||||||||||
sand drop | 427 | 1006 | 0042445328 | 42445328032 | 17737 | 14545 | 01219456858 | 121945685803 | 79245685803 | 79500357771 | 900 | |||||||||||||
machining Rejection | 31 | 1006 | 00308151093 | 30815109344 | 0737 | 14545 | 00050670333 | 05067033345 | -25932966655 | -25748075999 | 257 | |||||||||||||
sand inclussion | 298 | 1006 | 00296222664 | 29622266402 | 2899 | 14545 | 00199312479 | 19931247851 | -09868752149 | -0969101855 | 097 | |||||||||||||
open | 276 | 1006 | 00274353877 | 27435387674 | 3211 | 14545 | 00220763149 | 22076314885 | -05523685115 | -05359072789 | 018 | |||||||||||||
mis match | 271 | 1006 | 00269383698 | 26938369781 | 3246 | 14545 | 00223169474 | 22316947405 | -04783052595 | -04621422377 | 025 | |||||||||||||
blow hole | 253 | 1006 | 00251491054 | 25149105368 | 0773 | 14545 | 00053145411 | 05314541079 | -19985458921 | -19834564288 | 198 | |||||||||||||
cold metal | 245 | 1006 | 00243538767 | 2435387674 | 4785 | 14545 | 00328979031 | 32897903059 | 08397903059 | 0854402632 | 149 | |||||||||||||
mould leak | 202 | 1006 | 00200795229 | 20079522863 | 4465 | 14545 | 00306978343 | 30697834307 | 10497834307 | 10618311444 | 159 | |||||||||||||
excess pouring | 185 | 1006 | 0018389662 | 18389662028 | 4 | 14545 | 00275008594 | 27500859402 | 09000859402 | 09111197374 | 140 | |||||||||||||
short pour | 17 | 1006 | 00168986083 | 1689860835 | 2164 | 14545 | 00148779649 | 14877964936 | -02122035064 | -02020643413 | 024 |
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | ||||||
Order Recevied | 359642 | 269283 | 90359 | |||||||
Pouring Weight | 35129 | 298755 | 52535 | |||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | ||||||
I R in | 414 | 458 | 044 | 257 | ||||||
Dispatch Weight | 320135 | 288797 | 31338 | |||||||
C R Weight | 6736 | 6279 | 457 | |||||||
C R in | 210 | 217 | 007 | |||||||
Poured Qty | 168601 | 122015 | 46586 | |||||||
I R Qty | 5279 | 6238 | 959 | |||||||
Dispatch Qty | 161566 | 132163 | 29403 | |||||||
C R Qty | 5927 | 7525 | 1598 | |||||||
I R value | 15059767 | 13379419 | 1680348 | |||||||
Sales Value | 686287306 | 702702994 | 16415688 | |||||||
C R Value | 6023410 | 4702170 | 1321240 |
2012 - 13 | ||||||||||||
Customer Rejection | total | SPCPL | Malnad | |||||||||
Weight | 6279 | 1756 | 4523 | |||||||||
Qty | 7525 | 5366 | 2159 | |||||||||
Value | 4702170 | 2591136 | 2111034 |
product code | Poured Qty | Yield in | IR | CR | Rej | Rej | |||||||||||
640120 | 30 | 448 | 3 | 12 | 15 | 05 | 5000 | ||||||||||
640126 | 49 | 5448 | 10 | 4 | 14 | 02857142857 | 2857 | ||||||||||
640123 | 92 | 4538 | 8 | 11 | 19 | 02065217391 | 2065 | ||||||||||
640131 | 12 | 4793 | 2 | 0 | 2 | 01666666667 | 1667 | ||||||||||
640119 | 71 | 5024 | 3 | 5 | 8 | 01126760563 | 1127 | ||||||||||
640128 | 12 | 5541 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640129 | 12 | 5567 | 1 | 0 | 1 | 00833333333 | 833 | ||||||||||
640137 | 16 | 5537 | 1 | 0 | 1 | 00625 | 625 | ||||||||||
640125 | 18 | 5613 | 1 | 0 | 1 | 00555555556 | 556 | ||||||||||
640134 | 215 | 5925 | 4 | 4 | 8 | 00372093023 | 372 | ||||||||||
640115 | 143 | 5127 | 1 | 4 | 5 | 0034965035 | 350 | ||||||||||
640127 | 14 | 59 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640336 | 8 | 6284 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640342 | 3 | 4288 | 0 | 0 | 0 | 0 | 000 | ||||||||||
640381 | 12 | 554 | 0 | 0 | 0 | 0 | 000 | ||||||||||
Parameter | 2012-13 | PRD | 2011-12 | PRD | Comparision in MT | Comparision in | |||||||||||||||||||||||||||||||||||||||
Stock Difference | 3538 | 2987 | 11844660194 | 10067 | 03514453164 | 35144531638 | 3026 | 3512 | 00861617312 | 14545 | 00208044001 | 1164 | 20804400138 | 32354 | 3306 | ||||||||||||||||||||||||||||||
Gas | 145 | 2987 | 04854368932 | 10067 | 01440349657 | 14403496573 | 52036 | 3512 | 14816628702 | 14545 | 035775868 | 0128 | 357758679959 | 375 | 2516 | ||||||||||||||||||||||||||||||
shrinkage | 1241 | 2987 | 04154670238 | 10067 | 01232740638 | 123274063773 | 13648 | 3512 | 03886104784 | 14545 | 00938329323 | 0322 | 93832932279 | 1238 | 030 | ||||||||||||||||||||||||||||||
excess Material | 1011 | 2987 | 0338466689 | 10067 | 01004271382 | 100427138174 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0311 | 27500859402 | 611 | 729 | ||||||||||||||||||||||||||||||
crack | 729 | 2987 | 02440575829 | 10067 | 00724148207 | 72414820701 | 13845 | 3512 | 03942198178 | 14545 | 00951873496 | 0149 | 95187349605 | 655 | 418 | ||||||||||||||||||||||||||||||
core reverse | 5612 | 2987 | 01878808169 | 10067 | 00557464985 | 5574649846 | 0003 | 3512 | 00000854214 | 14545 | 00000206256 | 0188 | 00020625645 | 5609 | 557 | ||||||||||||||||||||||||||||||
slag inclussion | 535 | 2987 | 01791094744 | 10067 | 00531439356 | 53143935631 | 6195 | 3512 | 01763952164 | 14545 | 0042591956 | 0137 | 42591955999 | 0845 | 034 | ||||||||||||||||||||||||||||||
wrong order booking | 532 | 2987 | 01781051222 | 10067 | 00528459323 | 52845932254 | 0248 | 3512 | 00070615034 | 14545 | 00017050533 | 0176 | 01705053283 | 5072 | 511 | ||||||||||||||||||||||||||||||
sand fusion | 467 | 2987 | 0156344158 | 10067 | 00463891924 | 46389192411 | 0888 | 3512 | 0025284738 | 14545 | 00061051908 | 0150 | 06105190787 | 3782 | 403 | ||||||||||||||||||||||||||||||
sand drop | 427 | 2987 | 01429527954 | 10067 | 0042415814 | 42415814046 | 17737 | 3512 | 05050398633 | 14545 | 01219456858 | 0021 | 121945685803 | 13467 | 900 | ||||||||||||||||||||||||||||||
machining Rejection | 31 | 2987 | 01037830599 | 10067 | 00307936823 | 30793682328 | 0737 | 3512 | 00209851936 | 14545 | 00050670333 | 0099 | 05067033345 | 2363 | 257 | ||||||||||||||||||||||||||||||
sand inclussion | 298 | 2987 | 00997656512 | 10067 | 00296016688 | 29601668819 | 2899 | 3512 | 00825455581 | 14545 | 00199312479 | 0080 | 19931247851 | 0081 | 097 | ||||||||||||||||||||||||||||||
open | 276 | 2987 | 00924004017 | 10067 | 00274163107 | 27416310718 | 3211 | 3512 | 0091429385 | 14545 | 00220763149 | 0070 | 22076314885 | 0451 | 018 | 13715 | 5933 | 7782 | |||||||||||||||||||||||||||
mis match | 271 | 2987 | 00907264814 | 10067 | 00269196384 | 26919638423 | 3246 | 3512 | 00924259681 | 14545 | 00223169474 | 0068 | 22316947405 | 0536 | 025 | ||||||||||||||||||||||||||||||
blow hole | 253 | 2987 | 00847003683 | 10067 | 00251316182 | 25131618158 | 0773 | 3512 | 00220102506 | 14545 | 00053145411 | 0079 | 05314541079 | 1757 | 198 | ||||||||||||||||||||||||||||||
cold metal | 245 | 2987 | 00820220957 | 10067 | 00243369425 | 24336942485 | 4785 | 3512 | 01362471526 | 14545 | 00328979031 | 0049 | 32897903059 | 233 | 149 | ||||||||||||||||||||||||||||||
mould leak | 202 | 2987 | 0067626381 | 10067 | 00200655607 | 20065560743 | 4465 | 3512 | 01271355353 | 14545 | 00306978343 | 0037 | 30697834307 | 244 | 159 | ||||||||||||||||||||||||||||||
excess pouring | 185 | 2987 | 00619350519 | 10067 | 00183768749 | 18376874938 | 4 | 3512 | 01138952164 | 14545 | 00275008594 | 0034 | 27500859402 | 215 | 140 | ||||||||||||||||||||||||||||||
short pour | 17 | 2987 | 00569132909 | 10067 | 00168868581 | 16886858051 | 2164 | 3512 | 00616173121 | 14545 | 00148779649 | 0042 | 14877964936 | 0464 | 024 | ||||||||||||||||||||||||||||||
3538 | |||||||||||||||||||||||||||||||||||||||||||||
1011 | |||||||||||||||||||||||||||||||||||||||||||||
5612 | |||||||||||||||||||||||||||||||||||||||||||||
532 | |||||||||||||||||||||||||||||||||||||||||||||
1857 | |||||||||||||||||||||||||||||||||||||||||||||
1043 | |||||||||||||||||||||||||||||||||||||||||||||
Parameter | 2011-12 | 2012-13 | Comparision | Remarks | |||||||||||||||||
Order Recevied | 359642 | 269283 | 90359 | 3596 | |||||||||||||||||
Pouring Weight | 35129 | 298755 | 52535 | 903 | 2692 | 03354383358 | 33543833581 | ||||||||||||||
I R Weight | 14534 | 13667 | 867 | 59 MT | |||||||||||||||||
I R in | 414 | 458 | 044 | 257 | 59 | ||||||||||||||||
Dispatch Weight | 320135 | 288797 | 31338 | 1366 | |||||||||||||||||
C R Weight | 6736 | 6279 | 457 | 0 | |||||||||||||||||
C R in | 210 | 217 | 007 | 2987 | |||||||||||||||||
Poured Qty | 168601 | 122015 | 46586 | ||||||||||||||||||
I R Qty | 5279 | 6238 | 959 | ||||||||||||||||||
Dispatch Qty | 161566 | 132163 | 29403 | ||||||||||||||||||
C R Qty | 5927 | 7525 | 1598 | ||||||||||||||||||
I R value | 15059767 | 13379419 | 1680348 | ||||||||||||||||||
Sales Value | 686287306 | 702702994 | 16415688 | ||||||||||||||||||
C R Value | 6023410 | 4702170 | 1321240 |
Machines | Specification | Size | |||||||
X | Y | Z | |||||||
VMC | HAAS VF2 | 762 | 406 | 508 | |||||
VCS 430A | 560 | 430 | 510 | ||||||
VTL | 550 | MAX TURNING DIA 650 | - | MAX TURNING LENGTH 700 | |||||
650 | MAX TURNING DIA 800 | - | MAX TURNING LENGTH 750 | ||||||
HMC | HORIZONTAL CENTER NEXUS 5000-2 | 730 | 730 | 740 | |||||
CNC - Turning MAZAK | E160C | 165 | - | 330 | |||||
Conventional Lathes | 9C Lathes | ||||||||
9C Lathes | |||||||||
Radial Drilling Machine |
10112017
46
Thank You