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ACNielsen ORG-MARG
Situation Analysis for SME
Sector
Submitted to TERI
By
Rajkot Cluster
ACNielsen ORG-MARG
SUMMARY OF FINDINGS
• There are approximately 500 plus units in this cluster who are engaged in
foundry and forging activities.
➢ ANNUAL TURNOVER
Annual Turnover (In crores)
73
101
110
2530
42
17 15 16
49 10
72
41
22
0
10
20
30
40
50
60
70
80
90
100
110
2005-06 2006-07 2007-08
Upto 0.5 crore 0.5 crore to 1 crore 1 to 3 crores
3 to 5 crores Above 5 crores
ACNielsen ORG-MARG
➢ PRODUCTION
Annual Production (In Tonnes)
86
99
88
19
27
44
22
29 29
7 7 912 12
82 2
6
44
21
16
0
10
20
30
40
50
60
70
80
90
100
2005-06 2006-07 2007-08
Upto 100 Tonnes 100 to 200 Tonnes 200 to 300 Tonnes
300 to 500 Tonnes 500 to 1000 Tonnes 1000 to 2000 Tonnes
Above 2000 Tonnes
ACNielsen ORG-MARG
➢ ENERGY REQUIREMENTS
• CUMULATIVE FUEL USAGE
Qty consumer per annum
Number of Units using the fuel
Electricity 36871932 Units 58
Coal / Hard Coke 126384 Tonnes 151
• USAGE OF ELECTRICITY (IN UNITS CONSUMED PER ANNUM)
Usage of Electricity (In Units consumed per annum)
35%
3%5%
7%
19%
8%
5%
12%
3%
3%
Upto 20000 Units
20000 to 50000 Units
50000 to 100000 Units
100000 to 200000 Units
200000 to 300000 Units
300000 to 500000 Units
500000 to 1000000 Units
1000000 to 2000000 Units
Above 2000000 Units
Above 2000000 Units
• USAGE OF COAL / HARD COKE (IN TONNES PER ANNUM)
Usage of Coal / Hard Coke (In Liters consumed per annum)
5%
15%
27%
37%
8%2%
6%
Upto 300 Tonnes
300 to 600 Tonnes
600to 900 Tonnes
900 to 1200 Tonnes
1200 to 1500 Tonnes
1500 to 2500 Tonnes
Above 2500 Tonnes
ACNielsen ORG-MARG
➢ RAW MATERIAL REQUIREMENT
• CUMULATIVE RAW MATERIAL USAGE
Qty consumed per annum
Number of Units using the raw material
Iron Scrap 34384 Tonnes 165
Pig Iron 26773 Tonnes 165
Sand 5262 Tonnes 158
Clay 2659 Tonnes 141
Steel 29970 Tonnes 33
Manganese 37 Tonnes 22
Silicon 36 Tonnes 22
• USAGE OF IRON SCRAP (IN TONNES PER ANNUM)
Usage of Iron Scrap (In Tonnes per annum)
2%
13%
6%
22%
32%
15%3% 7%
Upto 50 Tonnes
50 to 100 Tonnes
100 to 150 Tonnes
150 to 200 Tonnes
200 to 300 Tonnes
300 to 500 Tonnes
500 to 1000 Tonnes
Above 1000 Tonnes
• USAGE OF PIG IRON (IN TONNES PER ANNUM)
ACNielsen ORG-MARG
Usage of Pig Iron (In Tonnes per annum)
4%
24%
42%
25%
1%
1%
3%
Upto 50 Tonnes
50 to 100 Tonnes
100 to 200 Tonnes
200 to 500 Tonnes
500 to 1000 Tonnes
1000 to 1500 Tonnes
Above 1500 Tonnes
• USAGE OF SAND (IN TONNES PER ANNUM)
Usage of Sand (In Tonnes per annum)
1%
40%
44%
11%
3%
1%
Upto 20 Tonnes
20 to 40 Tonnes
40 to 60 Tonnes
60 to 120 Tonnes
120 to 500 Tonnes
Above 500 Tonnes
• USAGE OF CLAY (IN TONNES PER ANNUM)
Usage of Clay (In Tonnes per annum)
1%
23%
57%
16%1%
2%
Upto 10 Tonnes
10 to 20 Tonnes
20 to 50 Tonnes
50 to 100 Tonnes
100 to 150 Tonnes
Above 150 Tonnes
ACNielsen ORG-MARG
• USAGE OF STEEL (IN TONNES PER ANNUM)
Usage of Steel (In Tonnes per annum)
9%
15%
27%
34%
3%12%
Upto 50 Tonnes
50 to 100 Tonnes
100 to 250 Tonnes
250 to 500 Tonnes
500 to 1500 Tonnes
Above 1500 Tonnes
• USAGE OF MANGANESE(IN METRES PER ANNUM)
Usage of Manganese (In Meters per annum)
5%
72%
14%
9%
Upto 1 Tonne
1 to 5 Tonnes
5 to 10 Tonnes
Above 10 Tonnes
• USAGE OF SILICON (IN TONNES PER ANNUM)
ACNielsen ORG-MARG
Usage of Silicon (In Tonnes per annum)
11%
68%
21%
Upto 0.5 Tonnes
0.5 to 75 Tonnes
Above 0.75 Tonnes
ACNielsen ORG-MARG
FIELD OBSERVATIONS
➢ Rajkot is an important foundry cluster in Gujarat. The main industrial area’s are
GIDC(Metoda), Udyog Nagar (Bhakti nagar), GIDC, Atika Industrial area,
Dhebar road & Gondal road, Khanderi.
➢ The forging units are located across Jamnagar road, Sapar, Metoda
➢ Majority of the foundry units at Rajkot produce G.I. casting, and catering to
domestic as well as export market.
➢ Segment catering (Automotive 40%, Textile 10%, Machine tools 10% Oil
Engines30%, & others 10%)
➢ Maximum units are operating since 15 to 20years and are working in general
shift of 10 to 12 hours
➢ There are certain locations wherein induction furnace is only used in areas like
Sapar due to high cost of coal /coke & secondly the units are of much larger
size.
➢ The forging units are running for maximum 1 to 2 weeks in a month as the raw
material cost is very high and lot of variation is happening on day to day basis.
➢ Except for large units which have direct customers of automotive parts -
Maruti, Escorts, TAFE, M&M i.e. 5 to8%, all other units which are having cupola
run for maximum 12 to 14 days in a month, as rest of the time goes in for
preparing the sand, mixing, preparing the required pattern, mold making.
➢ Power situation is very stable, there are hardly any power cuts and the units are
having LT/HT connection, the avg. unit rate @4.80/-.
➢ The energy cost is hardly 8 to 10% of the total production cost as compared to
the raw material cost which is as high as 70%.
➢ The process is an combination of manual and mechanized & the major
equipment is either Cupola /induction furnace, oil furnace, power press.
➢ It was observed during the discussion majority of the units which were engaged
in making products for Delhi based clients were using scrap and not pig iron.
ACNielsen ORG-MARG
Process Forging
Raw material
mixing
Melting in cupola –
1100 -1450 deg
induction furnace
Knock out /short
blasting – 1 to 15-
20hp motors
Pouring
Mixing with other
minerals – silicon
/manganese
Machining – hand
grinders
Billets – cut as per
size
Heating hard coke
+ FO
Cooling / punching Cutting / pUnching
Power Press
Use of hand tools
ACNielsen ORG-MARG
Raw materials
Press machine
ACNielsen ORG-MARG
Oil furnace
Cutting machine
ACNielsen ORG-MARG
Press machine
ACNielsen ORG-MARG
Punching machine
ACNielsen ORG-MARG
Press machine
Lathe machine
ACNielsen ORG-MARG
Cupola
Blower for cupola
ACNielsen ORG-MARG
Sand Muller
Sand mixing machine
ACNielsen ORG-MARG
Short blasting
After knock out product
ACNielsen ORG-MARG
Finished products
ACNielsen ORG-MARG
Equipments used
❖ Induction Furnace (1100oC to 1400oC), 75/200/250kw ❖ Cupola – 1100 to 1450 deg ❖ Sand Mixer – 100to 250 kg ❖ Sand muller – 150to 250 kg capacity ❖ Molding Machine ❖ Short blasting - 0.5 hp to 5 hp motors ❖ Power press/Screw press ❖ Grinding machine
Main raw materials
❖ Pig iron ❖ Iron scrap ❖ Coke/Coal ❖ Lime stone ❖ Magnesia
ACNielsen ORG-MARG
Service Provider
Equipment Shah Brothers 3/10, Bhaktinagar station plot, Opp. Post office, Rajkot-360002 0281-2462376 Indutotherm (India) Pvt. Ltd Bopal, Ahmedabd-380058 Pithuva Engg. Mauri Plot, Rajkot 0281-2388984 New Pithuwa Engg Atika Rajkot Mr. Bharat Bhai 09824217299 Shailesh Machine Tools Station Plot – I Bhaktinagar Rajkot Raw Material Mahendra Bhai Ring road highway, Rajkot 09426249715 D.N.Enterprises Jilka Garden, Bapunagar, Rajkot 0281-2234031 Natraj Sales Rajkot 09824477330 Ambika Sales Corportation, Limra Chowk, Rajkot, 0281-2465308 Premier Sales Udyog nagar, Rajkot, Mr. Nalin Bhai (9374102478) Kalyani Steel
ACNielsen ORG-MARG
Mesco Steel Oswal Minerals, Bangalore SK Steels, Bhavnagar FO Essar Oil, Jamnagar Reliance Petroleum, Jmnagar IOC, Rajkot
Association Rajkot Engineering Association Bhakti Nagar industrial estate, Rajkot-360002 0281-2362235/36/37 (Mr. Kirti Dave) Sapar Veraval Industrial Association 8-a, National Highways, Rajkot-360024 02827-253364 (Mr. Ramesh bhai Patel, President) Bamanbore Industries Association 29, J.P. Tower, Tagore road, Rajkot-360002 Ph- 0281-2466522 (Mr. Vasantbhai Manvar) Machine tools manufactuers Association 44, Shivanand Complex, Dhebar Road, Rajkot Ph- 0281-2238708 The Institute of Indian Foundrymen Aji Vasaht, Street no-10, Rajkot Ph- 0281-2387276.
ACNielsen ORG-MARG
Bankers
o Majority of the units are associated with some or the other banks for CC limits but have not taken any loans
Uco Bank Merchant Building, Satta Bazar, Rajkot, 360001 Ph-- 0281 2222869 ICICI Bank 204,Planery Arcade,Near Bombay Petrol Pump, Gondal Road, Rajkot, 360002 Ph - 0281 2443972 Bank of India Station plot, Rajkot Ph-2461834 Corporation Bank Nijanand,P B No 556, Dhebar Road, Rajkot, 360002 Ph- - 0281 2232435 Bank of Baroda Bhakti Nagar, Rajkot Ph-2264342 The Federal Bank ltd 7,Panchnath Plot,Opposite Shastri Maidan, Subhash Chowk, Rajkot, 360001 Ph - 0281 2231239 State bank of Saurastra Gondal road, Rajkot Central bank of India Bhakti Nagar, Rajkot Ph-22462195 Andhra bank Bhakti Nagar, Rajkot Ph-23819994/2363312 Bank of India Shakha,Lidhavad Chowk, Malaviya Road, Rajkot, 360005 Ph- 0281 2231751 Rajkot Nagriak Co. Op. Bank Ltd DENA BANK Oman Bhuvan,Dr. Ygnik Road,,Rajkot - 360 001
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