Manufacturing Process

MYCO

INDUSTRIES(M.I.D.C)

CASTING WORLD

Process Flow Chart

Inward Material For Procurement

� Aluminium Alloy

� Aluminium Bronze Alloy

� Brass

� Copper Alloy

� Gun Metal Alloy

� SS 304 (Stainless Steel)

� SS 316

� Zinc Alloy

Different Methods of Die Casting(Process)

1. Centrifugal Die Casting

2. Forging

3. Gravity Die Casting

4. High Pressure Die Casting (HPDC)

5. Low Pressure Die Casting (LPDC)

6. Sand Casting

7. Squeeze Die Casting

Raw Materials Used for Die Casting

Non-Ferrous Materials-

Aluminium

Brass

Gun Metal

Bronze

Lead

Zinc Alloy

Aluminium Bronze

Ferrous Materials-

Stainless Steel

Spring Steel

NH4(Nay Hard Steel)

1. Centrifugal Casting

Description:-

MS Steel or H-13 (Hot dye steel) is used to make a permanent mold which rotates continuously about its own axis at high speeds. The molten metal is poured into the mold and is centrifugally thrown towards the mold wall where it solidifies after cooling.

Raw Material Specifications:-

� Aluminium

1. ALSI 132

2. LM 24

3. LM 4

4. LM 6 (aesthetic look)

� Zinc Alloy

1. Zinc 3

2. Zinc 5

2. Forging

This process is involved in shaping of metals by using compressive forces. This method finds application in the preparation of names plates, rods etc. The force is applied by giving blows through hammering the metal.

3333. Gravity Die Casting

Description:-

Mile Steel (MS) die blocks are made according to the design requirements. The die casting process takes place on a stationary surface with the pouring of molten metal into the die blocks through gravity. Manual control is exercised. It provides good weight control.

Raw Material Specifications:-

� Aluminium

1. ALSI 132

2. LM 24

3. LM 4

4. LM 6 (aesthetic look)

� Zinc Alloy

1. Zinc 3

2. Zinc 5

4. High Pressure Die Casting

(HPDC)

Description:-

This method of die casting is specially used for giving the end product an aesthetic look and for weight control. Here, the molten metal is forced into the mold cavity created by the dies under a high pressure. The thickness of the mold wall components should not be more than 3mm as it leads to shrinkage and creation of pin holes.

Raw Material Specifications:-� Aluminium

1. ALSI 132

2. LM 24

3. LM 4

4. LM 6 (aesthetic look)� Zinc Alloy

1. Zinc 3

2. Zinc 5

5. Low Pressure Die Casting

(LPDC))))

Description:- MS steel is used as the material for making die in this process. It is a comparatively slow method as that compared to HPDC. Here, the molten metal is forced into the mold cavity created by the dies under a low pressure, slowly and steadily. It is similar to HPDC and mainly used for producing spinning materials like rotors in motors and others.

Raw Material Specifications:-

� Aluminium

1. ALSI 132

2. LM 24

3. LM 6 (Aesthetic look)

6. Sand Casting

Description:-Mold consists of a handmade wooden pattern of the drawing to create a negative impression and is then pressed in sand. The mold is then filled with molten metal (one of the procured metals) and is then left to cool and solidify. This method does not provide and aesthetic look and weight control is not possible.

Raw Material Specifications:-

� Aluminium1. ALSI 1322. LM 24 3. LM 4 4. LM 6 (aesthetic look)

� Aluminium Bronze� Phosphorous Bronze� (Copper Alloy)� Gun Metal1. 85 5552. 88 10 2

� Electrolytic Copper

7. Squeeze Die Casting

Description:- In the previous processes, molten metal is poured into the mold cavity and solidified on cooling. But in this process of die casting a dough of the material is prepared and then inserted in the cavity. The pouring process uses a cylinder at the bottom of the material tank to push the material into molds.

Raw Material Specifications:-

� Aluminium

1. ALSI 132

2. LM 24

3. LM 4

4. LM 6 (Aesthetic look)

� Zinc Alloy

1. Zinc 3

2. Zinc 5

� Magnesium Alloy

A Typical Pressure Die Casting Machine

Sales

And

Purchasing

Sales Growth(Turnover) for last 7 years.

Figures in Euro

2.64

3.91

3.8

5.84.94

3.33

6.18

Amount(in lakhs)

2008-09

2009-10

2010-11

2011-12

2012-13

2013-14

2014-15

Purchasing

Internal requirements and incoming orders are recognized. A purchase manager attends to the request. He makes a purchase indent and raises a quotation as well as asks for the lead time permissible from the customer. Low priced and fast delivery suppliers are selected to meet the needs. Grading is done according to the inspections conducted. The grading system is as follows-

A- No inspection.B- Little improvement needed.C- Lot of improvement needed.Raising a purchase order:- Specifications of the material,

the terms and conditions and the material quantity, amount and its taxes are drafted. This draft is called a Purchase Order (PO)

Statutory

� 5% (as cast) on semi-finished product.� 12.5% VAT on finished goods material where full rate of

duty without any exemption or any form.� 2% CST charge on materials sales outside of Maharashtra

against C-form.� Excise duty charged at 12.5%.� OCTROI/LBT is charged on full invoice value for

materials purchased outside Mumbai. For plastic granules and aluminium ingots this is 5.5%

� 14% Service Tax.� A TDS of 2% is charged if the total invoice value of labour

charges exceeds 75,000/-. Also, if the company fails to provide a pan card, this charge goes up to 20%.

Supply Chain Management Model

1. Through telephonic enquiry (new customer) or timely scheduling (regular customer) orders are received.

2. After confirmation, 2D or 3D drawings on AutoCAD are prepared by the supplier as per the desired dimensions or the customer himself sends these drawings.

3. If the quantity required is 100-200 pieces, a wooden pattern is made and sandcastingis used in the production.

4. Inspection of the raw material used in die casting is done by spectroscopy post which a chemical analysis report of the same is produced. Thus, a material test certificate is made. This testing is outsourced.

5. After the detailed analysis and inspection of the raw material a die of the product is prepared according to the given specifications.

6. The following actions then take place in the given order-

1. Casting of the product

2. Drilling

3. Filing

In case of an aesthetic look as desired by the customer, powder coating, electroplating or anodizing is done. These processes are outsourced as well.

7. The product which is ready to be dispatched undergoes inspection for the required specifications and thereby a report is prepared which is emailed to the customer. This inspection is carried out by instruments such as VernierCaliper and Micrometer.

8. After careful inspection the product is packed and labeled and ready to be dispatched.

9. This dispatch takes place via local transport services assigned by the customer company. A quotation of the transportation charges are fixed beforehand where the prices are assigned per kilogram.

10. A Lorry Receipt (LR) or consignment booking document is generated by the transport and emailed.

11. A copy of this, original and two more copies are sent physically to the customer as well as e-mailed along with the invoice prepared. Invoice preparation is done by Tally software.

12. A dispatch notification is also emailed to the company.

13. A Goods Receipt Note (GRN) is sent by the customer company after receiving the goods. If damage or lack of goods is observed, another report is prepared and emailed.

14. A customer company has a certain document called Vendor Form which is an evaluation report of its suppliers. Thus from time to time, this form is sent to the supplier grading them on certain fundamental aspects.

In order to reduce the taxation on out of state transport, the government issues another document called the C form. This form is issued to any company on a quarter yearly basis for concession on the taxes levied.

In order to reduce the taxation on out of state transport, the government issues another document called the C form. This form is issued to any company on a quarter yearly basis for concession on the taxes levied.

H-form is used for exemption on taxation of export materialH-form is used for exemption on taxation of export material

Crucial Documents

A.R.E-1 documents are prepared against bond and CT1 for export. A.R.E-1 documents are prepared against bond and CT1 for export.

ER-1 document is prepared on a monthly basis for the goods sold to the customer for excise duty.

ER-1 document is prepared on a monthly basis for the goods sold to the customer for excise duty.

1.Filing1.Filing 2. Drilling2. Drilling

Departments

3. Linishing3. Linishing 4. Vibro Finishing4. Vibro Finishing

5. Shot Blasting5. Shot Blasting 6. Moulding6. Moulding