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MAHINDRA HINODAY (Foundry Division) PRESENTATION. Mahindra Group Turnover Euro 6 Bn. Farm Equip. Automotive. Systech. Infrastructure. Telecom & IT. Finance. Gear. Steel. Forging. Customer. Stamping. Composites. SSBU. Engg Ser. Tool/Die Design. Casting. Systech Synergies. - PowerPoint PPT Presentation
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Systech SectorMahindra Hinoday
MAHINDRA HINODAYMAHINDRA HINODAY(Foundry Division)(Foundry Division)
PRESENTATIONPRESENTATION
Systech SectorMahindra Hinoday
Farm Equip
Automotive Systech
Telecom & IT Finance Infrastructure
Mahindra Group Turnover Euro 6 Bn
Systech SectorMahindra Hinoday
Gear
Steel Forging
CastingTool/Die Design
Stamping Composites
SSBU Engg Ser
Customer
Systech Synergies
Systech Turnover : Euro 700 Mn
Casting Turnover : Euro 44 Mn
Systech SectorMahindra Hinoday
• Hinoday Overview
• Foundry Overview
• Foundry Customer/Product Profile
• Foundry Design & Development Capabilities
• Foundry Facilities
Systech SectorMahindra Hinoday
Foundry OverviewFoundry Overview
Systech SectorMahindra Hinoday
India’s largest independent SG Iron automotive parts producer
70,000 TPA - 40% Sales is in fully machined condition
Customers’ New Product Partner
Exports 21%
Business HighlightsFoundry Overview
Systech SectorMahindra Hinoday
Established in 1997
Land & Building Total 180,000sq mts Built up 42,000sq mts
Total Investment USD 110 Mn
Man Power Workmen 580 Management staff 208
Total Capacity 70,000 tpa
Sales 11-12 Rs 3,798 Mn (40,667 MT) USD 77 Mn/ Euro 56 Mn
InfrastructureFoundry Overview
Systech SectorMahindra Hinoday
1963
Company started by Dr Morris
Technical Collaboration with Hitachi
Metals
Financial Participation
by Hitachi Metals
Diversified into Foundry
Business
2nd Molding line commissioned
Ownership by M&M
Approval for 3rd Molding
line
1996
Ownership by
Piramals
Exports started
TS16949 certification
1981
1984
1987 2002
2004
2005
2007
2007
2010
In house machine
shop started
3rd Molding line
commissioned
2010
Journey So FarFoundry Overview
2011
4th Molding line
commissioned
Systech SectorMahindra Hinoday
Quality Certifications• ISO/TS : 16949 Certified• ISO/OHSAS : 14001 Certified
Investing in QualityFoundry Overview
d
Systech SectorMahindra Hinoday
First Time in IndiaFoundry Overview
Only Foundry to produce cast Crankshaft
High Pressure line for Ductile Iron by an independent Foundry
Auto pouring System with Automatic inoculation
CAD – CAM process for tool design and manufacturing
Use of Cold box process in mass production
Systech SectorMahindra Hinoday
Capability to produce range of products - Weight range 3kg ~ 83kg single piece
Complex thin wall castings - Nominal wall thickness 4mm
Castings with high strength & high ductility
Various Material Grades - All Grades of SG Iron - High SiMo - Austempered Ductile Iron - SiMo Crome SG Iron
Foundry CapabilitiesFoundry Overview
Systech SectorMahindra Hinoday
Foundry Sales Growth – Rs MillionFoundry Overview
Systech SectorMahindra Hinoday
Foundry Sales Growth Tons/YearFoundry Overview
1812
54506729
9662
12475
16950
20150
23000
26900 27560
23610
28767
35307
40667
-3000
2000
7000
12000
17000
22000
27000
32000
37000
42000
98~99 99~00 00~01 01~02 02~03 03~04 04~05 05~06 06~07 07~08 08~09 09~10 10~11 11~12
Auto pour Casting cooling
Conveyor & TPM
Reached project
Capacity
New line added
10~11 New line added
11~12 New line added
Systech SectorMahindra Hinoday
Foundry Customer/Product ProfileFoundry Customer/Product Profile
Systech SectorMahindra Hinoday
Axles India Ltd.
TRANSMISSIONSTRANSMISSIONSTRANSMISSIONSTRANSMISSIONS
TRANSMISSIONSTRANSMISSIONSTRANSMISSIONSTRANSMISSIONS
Export
Domestic
Customer BaseCustomer & Products
Systech SectorMahindra Hinoday
Axle & Transmission parts Turbine housing
Medium & Heavy Commercial Vehicle (MHCV), Utility Vehicle (UV)
Passenger car
Crankshafts
CV & UV, Pass car
Focused Product VerticalsCustomer & Products
Systech SectorMahindra Hinoday
• Largest Ductile Iron Foundry
• Capacity 70 KT/year
• F12 Revenues Rs 3797 Mn • Export 29%
Customer Segment
Product Portfolio
Customers
• Top 4 Customer 66% - M&M, AAL, JCB, JD
• TC customers - CTT & HTT
Product ApplicationCustomer & Products
Systech SectorMahindra Hinoday
Design CapabilityDesign Capability
Systech SectorMahindra Hinoday
CAD-CAM process for Tool Manufacturing - Versatility in use of different soft wares – Catia and Pro-E - Design Engineers trained at Hitachi Metals - Lead time reduction – Design Automation and Standardization
Flow and Thermal analysis for Product development - Right first time - Castings with high Integrity
Design CapabilitiesDesign & Development
Systech SectorMahindra Hinoday
Design Process – Flow & Thermal AnalysisDesign & Development
Systech SectorMahindra Hinoday
30 50 15 55 30 55 15 20 40 40140 100 5030
80 95150
180235 250 270
310350
490
590640
0
100
200
300
400
500
600
700
98~99 99~00 00~01 01~02 02~03 03~04 04~05 05~06 06~07 07~08 08~09 09~10 10~11
Year Cummulative nos
Product DevelopmentDesign & Development
Systech SectorMahindra Hinoday
FacilitiesFacilities
Systech SectorMahindra Hinoday
Molding Line : GF Horizontal Parting 96moulds/hr 900*700*300/300
Flask less Horizontal 120 moulds/hr 610*509*200/200
Flask less Horizontal - 2 lines 100 moulds/hr 700*600*300/300
Sand Plant : GF Automated Sand Plant High Speed Intensive Mixer Sand Cooling System On Line Compactibility
measurement
Melting MF Furnaces 6T/3.5MW - 1no Dual track 4T/2.5MW – 1no Dual track 2T/1000KW – 1no Mono Track 3T/2.5MW – 1no Dual track Vibratory Chargers : 8 nos
Pouring 2T Unheated Tundish with Vision
Control - Autopour Pouring car – 1 no
Facilities
Systech SectorMahindra Hinoday
Core ShopCold Box Machines Horizontal Parted – 5L/20L/30L Vertical Parted – 5L/10L/20L
Shell Core Machines Size 600*300
Shot Blasting Spinner Hanger GF : 2no Tumblast GF 2.7t/hr : 3no Casting Cooling Conveyor
Quality Assurance Vacuum Emission
Spectrometer – 2 nos Hardness Testing Tensile Testing Image Analyzer CMM Ultrasonic Testing
Designs 3D Modeling – Pro E Simulation – Pro Cast Auto Cad 14
Facilities
Systech SectorMahindra Hinoday
• Established in April 2006• Land & Building 1540sq mts • Total Investment USD 4.5 Mn• Man Power - Operators 200 - Management staff 15• Total Capacity 650,000 nos/year• Sales 11-12 - Value added Rs 206Mn (448,085 nos)
Machining FacilitiesMachining Business Overview
Systech SectorMahindra Hinoday
46 nosLeak Testing, Washing, Nuber Punching & Welding
4 nosElectronic Guages
Contour Tracer, Roundness Tester 1 each
CMM Accurate (3 nos)
Mori Seiki (1 nos)HMC
Fanuc (14 nos)VMC
Lokesh (23 nos)CNC
Mori Seiki (4 nos)VMC
Machining (In-house)
Machine Shop caters to the global demand of Turbocharger OEMs
Machining Facilities
Systech SectorMahindra Hinoday
Familiar with • EDI (Electronic Data Exchange) and VMI (Vendor Managed Inventory)
• Full container shipments
• Global RFQ /RFI /Global bidding process
• European OEM’s quality requirements
• Bar coding
Familiarity with Export business
Systech SectorMahindra Hinoday
THANK YOU
THANK YOU