ABI Group Organization Chartabishowatech.co.in/wp-content/uploads/2017/06/20170619...2017/06/19  ·...

ABI Group – Organization Chart

2

R. Srikanth

MD

K. Sundar

ED

K. Kannan

VP - Foundry

R. Balaji

VP -Machining

V. SenthilvelDGM –

Marketing

ABI Group - Footprint

3

1991 – Incorporation of ABI Showatech India Limited [ABI]

ABI traces its lineage to the TVS Group – A Leading player in Indian AutomotiveComponent Industry.

1995 – Incorporation of Light Alloy Products Limited [LAP] [100% subsidiary of ABI]

ABI & LAP supply brake-parts and turbocharger parts.

2005 - LAP JV with Ross Casting and Innovation [RCI] to form LAP-Ross EngineeringLimited [LRE].

2011 - LAP and Hitchiner Inc. – Technical collaboration agreement for Turbine Wheels

2013 - ABI acquired RCI

2013 – Merger of LAP and LRE with ABI

ABI Group sales in 2016-2017 was greater than INR 500 Crores (~ USD +90 Million)

ABI Group – Business Chart

4

ABI SHOWATECH INDIA LTD

Super Alloys Division

Aluminum DivisionFerrous Division

Turbine Housing Bearing Housing

Compressor Wheel

Compressor Housing

USA India China

safety critical parts [Brakes Parts]

Turbine WheelStainless Steel Turbine Housing

ABI Group – Process Capability

5

ABI

Casting

Gravity Die Casting

Investment Casting

Hind Hivac -High Vacuum

Hitchiner

Plaster Mould – Counter

Gravity

Machining

CNC Machining 5-Axis Milling Assembly

Process Highlights

6

Process Key Highlights

Investment Casting –Hitchiner – CLI-C3

Technical collaboration with Hitchiner for Manufacturing of Investment parts

Capability to cast different Alloy’s [Inco 713C / MAR M246 / GMR]

Ability to Cast parts with excellent Microstructure

Investment Casting – Hind Hivac

Melting and Casting under Vacuum Capability to cast various high temperature alloy’s

Plaster Mould Process –Counter Gravity Ability to cast thin parts up to 0.3 mm

Capability to produce any intricate shape aluminium Alloy casting

In-house HIP facility

Gravity Die Casting Internal Tool / Mould manufacturing Capability to melt 60 Tons of aluminium / day Carousel based gravity pouring

Process Highlights

7

Process Key Highlights

Stainless Steel Foundry Resin bonded Sand process Capability to cast any Air melted material Robotic coating 700 X 700 horizontal core shooting machine

Machining Proven Expertise and capability to Machine high precision and safety critical components

Facility and Capability to do 5-Axis Milling

Others Certified to TS 16949, ISO 14001, OSHAS 18001 and TPM. Government recognized R&D center Complete metallurgical, chemical, and testing laboratories at

ABI

Products portfolio

8

Our Product Portfolio consists of Safety Critical & Precision parts (Brake parts) |Turbo charger parts | Aluminum Parts | Stainless steel parts | Housings, Etc.

We are equipped with both Casting and Machining Facility .

The Brake parts includes Master Cylinder , Wheel Cylinder, Clutch Boosters, calipers, Pistons .

Turbo Charger parts includes Compressor Wheel , Turbine Wheel , Bearing housings, Compressor Housings and Turbine housings.

Housings include in Line Pump Housing , Steering Housing , Radiator Tanks , Gear Housings, etc.

Products | Location | Volume

9

Product Plant Location Average Volume Per annum

Master Cylinder India 2.70 Million

Wheel Cylinder India 2.90 Million

Caliper India 0.04 Million

Compressor Wheel India, USA and China 7.00 Million

Turbine Wheel India 1.40 Million

Bearing Housing India and Oman 3.50 Million

Turbine Housing India 0.60 Million

Compressor Housing India 1.30 Million

Bearing Cap India 1.30 Million

Casting

10

Gravity Die Casting

11

Gravity Die casting Process

Modeling and Simulation Manufacture of tools Melting Furnace

Casting facility – Horizontal and Vertical Parting line cell

12

Gravity Die casting Process

Conveyor based – Core and Casting Handling

Heat Treatment

13

100% Visual inspection, Packing and Dispatch

Investment casting - Hitchiner CLI-C3

process

Hitchiner Process Flow

Modeling and Simulation Manufacture of toolsManufacture of Wax Stem

and Patterns

Assembly of Wax Pattern Shell Making and Drying Rotary de-waxing of shells

Pre Firing of Shells Washing of shells Firing of Shells

15

Hitchiner Process Flow - Continued

Pouring and Casting Knockout / De-Moulding Shot Blasting

100% FPI 100% Visual inspection Packing and Dispatch

16

Counter-Gravity Plaster Mould Process

17

Compressor Wheel - Process

Mould Making

APF Knockout Riser Cutting

Shot blasting Initial Inspection HIP

18

Compressor Wheel – Process - Continued

100% FPI100% Ultrasonic Testing

Packing and Dispatch100% Visual inspection

Heat Treatment

19

Stainless Steel Foundry

20

Raw Material

ReceiptMelting

Raw Material Inspecti

on

DP Testing

Core

Painting

Core

Assembly

Core

Manufacturing

Core

HeatingPouring

Initial Shot

Blasting

R&R Cutting

& FettlingShot Blasting

Knock Out

Final Inspecti

onDispatch

PROCESS FLOW

Product Footprint

Chemical Composition

1.4826 1.4848 1.4849 1.4837

Any other Air melted material

Weight Range

2.5 – 7 Kg

Volumes

100 K – 300 K per part number / Annum

Capability to produce Single Scroll / Twin Scroll / Integrated Manifold

Capability to supply as assembled Turbine Housing

Proposed Plan for New Foundry

Capacity – Scalable to One Million Parts Per Year [Approximate 3000 Metric

Tonnes]

Process – Resin bonded Sand

Casting – Automatic Pouring - Counter Gravity

Flexibility to accommodate other casting process based on requirements

Integrated machining shop would be setup to support the casting volume

Machining

24

Machining

25

ABI is specialized in turned parts, milled parts with secondary operations like turning, drilling, milling , honing , grinding ,heat treatment etc.

State of the art resources comprising of CNC turning centre's, turn mill centre's, Assembly machines, honing machines, Testing Machines and a number of conventional production machinery to manufacture a finished part

Facility and Capability to do 5-Axis Milling

Proven Expertise and capability to Machine high precision and safety critical components

Total Number of Machines at ABI is 350+

Machining

Machining

Ferrous

Turbine Housing

Bearing Housing

Caliper

Non-Ferrous

Turbine Wheel

Master Cylinder

Wheel cylinder

Compressor Wheels

26

Machining Facilities at site

27

Machining Facilities at site

28

Machining Facilities at site

29

Machining Facilities at site

30

31

Milled Wheel Or

Fully machined Wheel from Bar / Forged blanks

OP 10 – Cutting and Rough Machining

OP 20 - Back face & Bore Machining

OP 30 – Blade Profile & Height

Machining

OP 40 – 5 Axis Milling

OP 50 –Balancing & Correction

OP 60 –Washing

OP 70 –Inspection and

Packing

OP 80 -Despatch

Process Flow

Raw Material Rough / Forged Blank

Despatch5 Axis- Blade Machining

Blade Profile Machining

Back face Machining

Balancing

Material Flow

Design - Tool Room Facilities

34

TOOL DESIGN WITH PRO-E

Capability to design tools / jig / fixture. We are equipped with the required hardware and software.

In-House Tool Design Facilities

35

5 AXES TOOL MAKING MACHINE

We are equipped with 6 & 5 axis CNCtool and cutter grinder formanufacture of cutting tools.

Facilities – Tool room for tools manufacture / regrinding

6 AXES TOOL MAKING MACHINE

36

Our Tool Room setup isequipped with CNC millingmachines / grinding machines/ heat treatment and fittingfacilities .

Facilities – Tool room for Jigs / Fixtures manufacture

37

Products - Snapshot

38

Gravity Die Casting products

39

Master Cylinder PistonClutch Booster

Pressure Block Radiator Tank

Brake Caliper

Gravity Die Casting products

40

4 Cylinder Housing 3 Cylinder Housing Master Cylinder

Master Cylinder Steering Housing Wheel Cylinder

Gravity Die Casting products

41

Steering Gear Housing Compressor Housing Hub Strut

Compressor Housings

Investment casting [Hitchiner and Hind Hi-Vacuum] Products

42

Turbine Wheels

Guide Vanes Bushes

Counter Gravity Plaster Mould Process – Compressor Wheels

43

Counter Gravity Plaster Mould Process - Water Impellers , Super Charger and Inter-Cooler .

44

Turbine Housing for Turbo chargers

45

Bearing Housing for Turbo chargers

46

Master Cylinders

47

Wheel Cylinders

48

Caliper’s

49

Fully Machined From Bar - Compressor Wheels

50

Stainless Steel Products – Turbine Housing

51

LAB and Quality Testing Facilities

52

Lab and Quality Testing Facilities at ABI

Hardware

Scanning Electron Microscope (SEM) including EDX capability

Geometric Optical Measurement – GOM CMM Thermal analysis equipment Creep testing equipment Vacuum testing and analysis equipment Multiple elevated temperature fatigue

testing equipment

Natural frequency tester Complete metallographic and

microscopy laboratories Elevated temperature tensile

testing equipment Profile Projector Moisture analyzer

Software

Pro-E-Design AutoCad Magma Soft

Weibull reliability Grain structure analysis Procast

Incoming Material Testing

ICP OES to check trace elements such asTe, Ag, PB, Bi, Se, etc at 1 ppm level

Spectrometer for analysis of majorelements of the alloy

54

Incoming Material Testing

Leco O2 & N2 analyzer to analyzeOxygen and Nitrogen presence at 2PPM level.

Leco C, S, analyzer to analyze carbonand Sulphur

55

Quality Testing Facilities in the site

Creep Testing at elevated temperatureMachine

Tensile Testing At ElevatedTemperature

56

Quality Testing Facilities in the site

UTM Vickers Hardness Test

57

58

Millipore Apparatus

Magnetic Particle Crack Detection Machine

Universal Testing Machine

Quality Testing Facilities in the site

59

Customised Boroscope

2D Height Master

3D Height Master Tool Presetting Machine

Opto Electric Measuring Machine

Spring load Testing Machine

Quality Testing Facilities in the site

60

Surface Roughness Testing Machine

Roundness Testing Machine

Cylindricity Testing Machine CNC CMM

Quality Testing Facilities in the site

61

Rockwell Hardness Tester Micro Hardness Tester

Contour Tracer Profile Projector with

Auto Edge sensor

Quality Testing Facilities in the site

Laboratory Measurement Facilities

CMM

GOM

62

Laboratory Investigative Facilities

SEM With EDS

63

CERTIFICATES

Quality - ISO TS 16949 : 2009EMS - ISO 14001 : 2004 Safety – BS OHSAS 18001 : 2007TPM - Excellence

64

Snaps of Certificates

65

CSR

66

We as a group are obligated to our society and we show our gratitude in many ways. Some of them are :

“Vidhya Peetam School” established to provide quality education to the children

in Sholinghur area

“Matrix Technical Training Institute” was established to impart excellent

technical training and education

“Siksha Kendra” a training school established to impart knowledge on

Turbochargers

Support to SMF (Sundaram Medical Foundation) – Community hospital

CSR

67

ABI Group – Customers

68

THANK YOU

Contact:

+91- 4172-308441 | abimarketing@abishowatech.co.in