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INTRODUCTION
Indo Shell Cast Private Limited manufacturing Ductile Iron, Grey Iron, CG Iron (Vermicular graphite Iron), ADI, Ni Resist & Steel Castings using shell moulding, has a history of continuous improvement. A concept that has given it a past that it can be proud of and a future it can look forward to with confidence.

The vision of Promoter and Managing Director that an illustrious organisation should emerge is realised through his hard work and commitment. Today, Indo Shell Cast Private Limited, an ISO/TS 16949-2002 (E) certified company is having 30 years of casting experience in Shell Moulded S.G.Iron Castings, Shell Moulded Grey Iron Castings, High, Low Pressure and Gravity Die Castings and exports to leading International Industrial giants. As part of the diversifying plans in related areas, Unique Shell Mould India Private Limited Sister Concern, was founded in 1983 in response to the growing demand for quality aluminium castings with a focus on emerging technologies that meet client requirements.

A diverse and well-structured group that strives to produce quality products that conform to the standards, that would satisfy both domestic and international markets while emphasizing on efficiency in every facet of the operation from manufacturing to marketing. The Surface finish and dimensional accuracy of the shell-moulded casting is superior to the conventional green sand mould castings.

We have a strong metallurgical base and experience. Our metallurgical quality of our S.G.Iron is very much acclaimed by our domestic & overseas customers.

INDUSTRY PROFILE
The Indian Metal casting (Foundry Industry) is well established. According to the recent World Census of Castings by Modern Castings, USA India Ranks as 2nd largest casting producer producing estimated 7.44 Million MT of various grades of Castings as per International standards.

The various types of castings which are produced are ferrous,non ferrous,Aluminium Alloy, graded cast iron,ductile iron,Steel etc for application in Automobiles,Railways, Pumps Compressors & Valves, Diesel Engines,Cement/Electrical/Textile Machinery,Aero & Sanitary pipes & Fittings etc & Castings for special applications.However,Grey iron castings is the major share approx 70 % of total castings produced. There are approx 4500 units out of which 80% can be classified as Small Scale units & 10% each as Medium & Large Scale units. Approximately 500 units are having International Quality Accreditation. The large foundries are modern & globally competitive & are working at nearly full capacity. Most foundries use cupolas using LAM Coke. There is growing awareness about environment & many foundries are switching over to induction furnaces & some units in Agra are changing over to coke less cupolas.

EXPORTS:

The Exports are showing Healthy trends approx 25-30% YOY as can be seen from the charts below. The current exports for FY 2005-06 are approx USD 800 Million .

EMPLOYMENT:

The industry directly employs about 5,00,000 people & indirectly about 1,50,000 people & is labor intensive. The small units are mainly dependant on manual labour. However, the medium & Large units are semi/ largely mechanized & some of the large units are world class

Most foundries use cupolas using LAM Coke. There is growing awareness about environment & many foundries are switching over to induction furnaces & some units in Agra are changing over to coke less cupolas. IMPORTANT CLUSTERS: There are several foundry clusters .Some of the major clusters are as below.Each cluster is known for its type of products.

PRODUCTMIX:

Grey iron is the major component of production followed by steel, ductile iron & non ferrous as shown below.

The Indian Foundry Industry is trying to focus on higher value added castings to beat the competition

INVESTMENTS:

India would need approx. $ 3 Billion in investment to meet the demand of growing domestic industry and strong export drive. Following the economic reforms the Govt. of India has reduced tariffs on imported capital goods as a result the annual average amount of FDI is reported to have increased but is still one tenth of the annual FDI in China. The reforms also encourage the privatization of industry enabling foreign companies to invest or enter into joint ventures with Indian Foundries. FDI projects are permitted an automatic approval process. Several International corporate from USA, EU and East Asian Countries have increased overseas foundry operations in India. i.e. VOLVO foundries in Chennai and Suzuki in Haryana. Sundaram Clayton has joined hands with Cummins. Hundai Motors,

Delhi. Ford India, Tata-Cummins, GM and Ford have contracts of foundry products for export with a value of $ 40 Million

RAW MATERIAL ENERGY: Since 2003 the steep increase in cost of raw materials and energy have resulted in the closure of approx. 500 units, Overall India is exporter of Pig Iron but must import Scrap metals and Coke etc. Cost recovery for material and energy is very difficult as most contracts are long term contracts without any clause for price adjustment. India has to import coke & scrap. Moulding sand is locally available & India has an advantage on this account.

Energy cost typically vary between 12-15% LABOUR:

India has major competitive advantage over the foundry industries in the developed countries. The total labour cost account for 12-15% TECHNOLOGY:

Govt. of India (GOI) has encouraged technology transfer through JV with foreign Companies and GOI has cooperated with UNIDO with many foundry clusters. Indian foundry industry has an edge over China for producing complex machined and precision castings as per international quality standards. The GOI also helps upgrade foundry clusters. The clusters in Belgaum, Coimbatore and Howrah are undergoing modernization under the industrial infrastructure up gradation scheme .More of such clusters are likely to follow The Institute of Indian Foundry men have plans to strengthen and develop various foundry clusters.

INDO SHELL CAST PRIVATE LIMITED

COMPANY PROFILE
Indo Shell Cast Private Limited was started as a small scale unit in the industrial town o f Co imbatore, Sout h India in t he year 1973. In 1994, t hey received t he biggest qualit y award Nat ional Award for Qualit y Products from t he President of India. In1995, it was promoted as a public limited company. The company has obtained ISO 9002 Certification from RWTUV, Germany in 1996. In 1999, they received the Best Vendor Award from TVS- Suzuki. And also t hey have received t he Qualit y Award fro m Yamaha, Honda motors.

MANAGEMENT:

The fir m has been promoted by a t eam of well-experienced technocrats wit h engineering background. Their experience, expert ise, professionalism, dynamism and qualit y conscious approach have been furt her enriched technical guidance fro m t heir overseas customers for past two decades . GROWTH:

Aggressive market ing strat egies, World class qualit y Cast ings, efficiency and technical capability have positioned them on a distinct slot today. A significant rise in the growth charts reflects their consistent, exemplary performance. Indo shell has extended its marketing operations across the globe. Castings are exported to various countries in Europe and USA as per customer specifications.

FERROUS FOUNDRY:

Indo Shell is the Largest Shell Moulded Ferrous Casting manufacturing foundry. Producing crit ical Automot ive, Hydraulic component s wit h Full machining and Subassemblies to fulfill the highest quality requirements .Indo Shell Producing components in Grey Cast Iron, Malleable Iron, Compacted Graphite Iron and Ductile Iron (SG Iron), Austempered Ductile Iron to all national and International specifications. Indo Shell making intricate thin walled (min 3.5 mm) water cooled component for automotive application. Indo Shell producing components with thin, complex internal ports with highest degree of as cast dimensional accuracy for hydraulic application.

ALUMINIUM FOUNDRY:

Indo Shell producing Pressure Die Casting, Low Pressure Die Casting and Gravity Die Casting Aluminium Components for Automotive Applications. Railways compressor components getting tested for pressure tightness. Producing Aluminium castings for National, International specifications based on the requirement. In house Heat Treatment carried out. Indo Shell Producing extruded aluminium tube/rod machined components.

RANGE OF CASTINGS:

High Pressure Die Castings: 60 tons to 600 tons. Low Pressure Die Castings: Well equipped LPDC machines with multi-cavity tools. Gravity Die Castings: GDC sections comprises of many machines for production of cylinder heads, brake housings and other complex parts.

CORPORATE DATA

Company name

Indo Shell Cast

Address

S.F No.349/4, Malumichampati, Coimbatore-641 021. Tel: (0422)3983900,3983906

Year of establishments

2005

Initial workers

150

Status

Private limited

Board of directors

Mr.J.Ganesh kumar Mr.J.Ramprakash Ms.J.Pushpaveni Mrs.P.Vijayalakshmi

Managing director

Mr.S.V.Jegadesan

Vice president

Mr.R.Palanivelu

Head office

A-14,Sidco Industrial Estate, Coimbatore : 641021

Total factory area

8 acres

Bankers

Bank of India Main Branch, Coimbatore

Products

Automobile Components , Engine, Hydraulic parts, breaks appliances.

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AWARDS AND CERTIFICATION

Here are some achievements and milestones for Indo Shell Cast Private Limited. y y y 1992: Productivity Award from Indian Institute of Foundry men Coimbatore Chapter 1996-1997: Best Performance Award From Hindustan Motors Limited for the Year 1999: Self Certification Award from Sundaram Clayton Limited (Demings Award winner), Approval from VOLVO Sweden to Produce Safety Critical Parts, Approval from Trelleborg Automotive U.K. y 2000: Indian National Award for Best Entrepreneur for the Year 2000 2002: Best SSI Unit for the Year 2002 from NIQR (National Institution for Quality and Reliability), Lakshman Kirloskars Foundry of the Year 2002 from Indian Institute of Foundry men, Approved from Cummins USA, Sauer Danfoss- USA, FMC- USA. y 2003: Narashiman Award from Indian Institute of foundry men for Best Modernised foundry the Year 2003, Best supplier award from Rane TRW Steering systems Limited, Approval from Iveco Italy. Certifications from ITF for Best modernized foundry for the year 2003 automotive(UK),FMC(USA),Exton(USA),scania(sweeden),Donfoss(USA),for producing safety critical parts. y 2004: Sidha steel award "Best Foundry Executive" from M/s Sidha steel (P) Ltd. for the year 2004.

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ORGANIZATION CHART

Managing Director

Joint Managing Director

Vice President

System coordinator

Head of the Department Human Resource Department

Head of the Department Moulding

Head of the Department Melting

Head of the Department QC Dimension

Head of the Department Purchase

Head of the Department Accounts

Head of the Department Sales

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PRODUCT
As technology becomes more advanced, we become more reliant on it. The products manufactured from Indo Shell Cast are technologically advanced with exceptional quality. Our range of products provides complete peace of mind at a remarkably affordable cost.

Customized Product Range:

With the most advanced dual zee track medium induction furnace, Indo shell cast is making a head way in the manufacture of S.G.Iron (Ductile Iron) and hydraulic grey iron castings made in shell moulds. It has also specialized in developing Special Grades of S.G.Iron with assured impact property at subzero temperature, (DIN 1693, Grade GGG 40.3) and for pressure valve applications, ASTM - 395, Grade - 60 - 40 - 18. A.D.I., High silicon Molly S.G.Iron, S.G.Iron and Malleable Iron are the other special metals perfected by Indo Shell Cast.

Highlights :  With a weight range of casting from 50 Gms to 15 Kg's, our current annual production is around 7700 tons of Grey Iron and S.G.Iron Castings. Molten metal production is around 19500 tons per annum  The overall size range of the product is 250 x 250 x 150 mm. Since we are having machining capacity (CNC Laths and vertical milling center), we are supplying parts fully machined and ready for use in assembled conditions.

We are familiar with the following quality standards and we are tirelessly updating ourselves with the latest quality requirements.

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Our understanding and application of Quality Standards include:

APQP, FMEA, CONTROL PLANS, STATISTICAL TECHNIQUES, 5S, MISTAKE PROOFING, BENCH MARKING, RE-ENGINEERING & SIX SIGMA STUDIES.

S.G. Iron (Ductile Iron) Castings - Shell Moulded

Two Wheeler

ISC 001

ISC 002

ISC 003

Three Wheeler

ISC 004

ISC 005

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Four Wheeler

ISC 006

ISC 007

ISC 008

ISC 009

ISC 009

ISC 010

ISC 011

ISC 012

ISC 013

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ISC 014

ISC 015

ISC 016

ISC 017

Hydraulics

ISC 018

ISC 019

ISC 020

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ISC 021

ISC 022

ISC 023

ISC 024

ISC 025

ISC 026

ISC 027

ISC 028

ISC 029

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Earth Movers

ISC 030

ISC 031

ISC 032

ISC 033

Other Appliances

ISC 034

ISC 035

ISC 036

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ISC 037

ISC 038

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LIST OF DEPARTMENTS

 HR department  Shell moulding department  Security department  Melting department  Maintenance department  Service sourcing department  Engineering department  Quality control(lab) department  Purchase and stores department  IT department  Sales and marketing department  Finance department  QC dimension department

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MANUFACTURING PROCESS

Indo Shell Cast Private Limited has equipped itself with advanced technological developments which account for its superior process of casting and moulding for bulk production.

REQUIREMENTS FOR PRODUCTION:

 Raw silica sand  Catalyst - Hexa methylene tetramine  Anti veining agents Iron oxide  Acid Phenol formadihyde resin SAND PROCESS:

In sand process they used to get the pure sand by two process

 

RESINE SAND RECLAMATION SAND

Features of silica sand:

 

Silica sand do not possess the clay content. Suitable binder is added with this sand which make them to usable for foundary work.

RESIN SAND:

   

In sand process silica sand is used. It will be mild yellow in color and usually the sand is in wet condition. In this process the sand is taken into the drier and the sand is dried. From the drier the sand is taken into the hopper.

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From this only 150kg of silica sand is taken to the Muller and the mixture of 1100kg of catalyst powder,6750kg of resin oil in liquid, 150g of iron oxide are mixed. From this mixture we get resin sand. This resin sand is taken to the shell moulding process.

RECLAMATION SAND:       The waste sand from the shell moulding, melting process, and that sand is heated up to 500-550C and it is passed down to cooling filter to reduce its temperature. And that process is repeated as per the resin sand. If the amount of silica sand in the hopper crosses the limit, then we use hot coating. In the hot coating process we get 8 to 9 mixture for an hour. Otherwise we use warm coating which gives 5 mixtures for an hour. For each process they use separate dust remover.

SHELL MOULDING PROCESS:

 Core Making  Core Cleaning and Dressing  Core Coating and Drying  Shell Moulding  Shell Closing  Shell Clamping 10 Semi Automatic 4 station shell moulding (PLC controlled) machines are capable of producing 12000 moulds everyday which finds its application in casting intricate shaped hydraulic and automobile components ranging from 0.05 Kg's to 15.0 Kg's.

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Features:  Dimensional accuracy of +- 0.3mm of these machines when interfaced with the electronic weighing scales for online weight measurement enables to study machine capability.  Inbuilt Poka Yoke system for Pre- Heating and mould curing ensures proper control of the temperature.

CORE MAKING:

     

The resin sand from the sand process is taken in the hopper. The capacity of the hopper is 150kg. The core box should be clean and there should be no air gap. The temperature is set to 260C. And the air pressure is set up to 5kg. When the switch is on, the sand is filled in the core box within 4 sec and the heated up to 40 sec. By that we get the core as per the given shape in the core box, we can also change the core shape as per the requirements.

Form this process we can get,

 Body Brake Valve  NC-6  Saw India  1004etc.

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CORE CLEANING AND DRESSING:

  

First the core is well cleaned by using file. These cores are easily breakable. Dressing should be made by Rheotech-402 for the scratched paces and the small holes are covered by Rheotech. They do 60 pieces per shift.

CORE DRYING AND COATING:

      

In this process the core is made to dry by using a Big oven. For different types of cores difference types are used for drying. The temperature is maintained app.200-220C. The core should be dipped in the Rheotech solution. To get the Rheotech solution in accurate form the solution is filled in a B4 cup and the time is noted up to 16 sec. Then the solution will be perfect otherwise add some water, when the mixture exceeds 16sec more substance is added to get a perfect mixture. The Rheotech -13 is applied on the core to get the shining. Per shift, for small cores 1000 pieces and for big crores 200-500 pieces

SHELL MOULDING:

    

The resine sand is filled in the hopper. And the shell box is cleaned and there should be no air group. It takes 4sec to fill the shell box. The temperature for the top shell box is 400-500c and for the bottom shell box is 300-400c. It should be cleaned by using the file. Per shift, 400 shells are done (including top and bottom shells).

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SHELL CLOSING :

  

Between the two shells paste is applied. Both the shell is compressed up to 150c. Filter is used between the shells to remove the dust.

SHELL CAMPING:

    

Bolts and nuts are placed in the shell wherever necessary. After clamping close the hole with paper to avoid the dust. The bots and nuts are used to prevent the flow of iron mixtures into the core. Only one labour is used for this process. Per shift, 400 shells are producing including up and down.

CORE SHOOTING:  14 semi automatic PLC controlled vertical core shooters again with Poka- Yoke System to produce complex shell cores for hydraulic and automobile applications. Features:  Controls process parameters such as Sand Shooting Pressure, Sand Investment time and Sand Curing temperature.

MELTING:  4 medium frequency, one ton capacity induction furnaces with 8 crucibles melt nearly 2000 tons of metal every month.

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Features:    Equipped with spectrometer sand metal lab. Indo-Shell cast produces sumptuous molten metal for various applications. Standards and Normalization (also called Spheroidisation) is carried out through PLC controlled sophisticated used wire magnesium treatment process.

GRINDING:

 

The remaining sand present in the work piece is removed by using the grinding process. For grinding process 2 labours are required per machine.

SHOT BLASTING:

    

In the shot blasting process the work piece becomes more shining and the remaining dust in the core is removed. In this process DUM blast machine is used. Machine runs at 1500rpm. The capacity of the machine is 200-225kg of work piece. The machine runs for 5min per load. Per shift 3 labours required for shot basting.

HEAT NUMBER PUNCHING:

 

In this process they are analyzing the chemistry of the work piece. 8 labours required per shift.

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TOTA OIL MAXING:

In this process to prevent the work piece from rusting oil (Diesel) is applied.

PNEUMATIC AIR GRINDING:

 

To remove the dust from the critical and making the work piece more shining. It is used for accurate finishing. For Pneumatic Air grinding 1 labour is required.

HEAT TREATMENT:

  

Bogie hearth electric ceramic lined furnaces Calibrated as per API standard for annealing and stress relieving. Eclectic Pit type furnaces for Normalizing & Melleablising (Out sourced with facilities to create nurtured atmosphere to avoid decarb and Scaling. In this heat treatment process they follow only three process.

 Stress removing(SR)  Annealing  Normation STRESS RELEAVING:

   

In these process they can get the core has high hardness. Temperature required for this process 550-650C. In this process they required 2 labours. In this process they use bogie furnace for production.

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ANNEALING:

  

In these process they the core has longer life time and perfect finishing. They follow 2 cycle of heating for 1 cycle they heated upto 900C for 2hrs. In 2 cycles they heat up to 700C for 1hr. In this process also they use bogie furnace.

NORMALIZING:

   

In this process they can get the core from low hardness to high hardness. They use pit furnace for these process. In these also they follow 2 cycles for heating. For 1 cycle they heat upto 900C for 2hrs. For 2 cycles they heat up to 700C for 1hr.

HARDNESS TESTING:

     

For hardness testing process they use BRINELL-1 machine. They hang 750kg of weight to the machine for all hardness testing process. To find hardness they insert core into the machine and tap using 5mm ball for 2sec. They measure the tap which they made, by using micron scale. According to the measurement they find the hardness of the material. In this process 2 labours are required.

QUALITY CONTROL DIMENSION: The color codes which are used for indentifying the inspection status of the product  Rejection is indicated by red color code  Rework is indicated by yellow color code  Accepted is indicated by green color code

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MACHINING:

Indo shell Cast has a dedicated Machine shop unit for machining the components produced in the foundry. Machine shop not only focuses on value addition to the product but also helps in maintaining very low rejection PPM at the customer end. More than 80% of our machine shop turnover comes from machining components for export.

Our machine shop is equipped with New generation turning centers, vertical milling centers with 4th axis and horizontal milling centers machining facilities. We are also equipped with other ancillary machines like honing, lapping and cleaning machines. Our primary focus is machining complicated hydraulic castings. This requires a very low contamination levels in the complicated core areas. We have installed an ultra-sonic cleaning machine which can achieve cleanliness to the level of about 2 milligrams. Necessary softwares are installed in all the key areas of manufacturing and measurements to ensure productivity, accuracy, repeatability and reliability. Machine shop is equipped with state of the art of metrology lab with the latest measuring equipments for linear, angular dimension and surface finish measurements to compete and satisfy stringent quality measurement requirements of the customer. Since we understand our castings better, we design tools suitable for machining to achieve the required dimensional accuracy. .

Indo Shell Cast Private Limited having full fledged machining and sub assembly setup for Automotive, Hydraulic components machining. Indo Shell Producing extruded aluminium tube/rod machined components

 Horizontal machining centers  Vertical machining centers

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 Turning centers  Turn mill centers  Honing machine  Precidor honing machine  Surface grinding machines  High speed SPM drilling machines  Tig welding PACKAGING:

At Indo Shell Cast Private Limited, Superior Products, Sound Quality Control Process matches with Excellent Delivery Systems.

Packaging is custom designed to suit the specific requirements of the domestic and international supplies.

Many crucial factors like Seaworthiness, Shelf life, Rust Prevention, Pest Control, Termite Control, Size of the package, Handling systems at customer end are considered to ensure proper delivery.

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PURCHASE AND STORES DEPARTMENT

The main role is to keep track of the supply and demand. Their main function is to, y Before they give the order, they check the details of,     Quality Quantity Reliability Transportation facility

The raw materials (especially sand and phenol formaldehyde) are send to the quality control lab for verifying the quality.

y y

Based on the indend, purchase order is given. They give the payment for suppliers, payment follow up, purchase order details, stock information.

They store and maintain the raw materials.

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QUALITY MANAGEMENT

At Indo- Shell Cast Private Limited, quality starts right from the selection of the resources. Aided by stringent quality checks and controls in every stage of the process, the Process drastically reduces the risk of final inspection, enabling mitigation of the quality costs. QUALITY OBJECTIVES:

y y

To improve the customer and supplier delivery adherence. To spearhead the productivity improvement through,    Improving the overall equipment effectiveness (OEE) of key equipments. Optimizing inventory turnover ratio. Reducing the wastage and non-value added activities.

y y y y

Minimizing the utilization of resources. Improving people productivity. To reduce the cost of poor quality by controlling the internal and external rejections. Promoting the concept of Defect prevention and process control by adopting various statistical techniques.

Carrying out socio-environmental human resources up gradation activities continuously.

QUALITY POLICY:

We, at indo shell cast private limited are strongly committed, to retain the supremacy in our segment of business by achieving total customer delight. This will be achieved through,

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Supplying castings as per customer requirements , at right cost, on time and every time. Continual improvements in our system, practices, and process technology. Effective team work. Providing a clean and safe work environment.

INSTRUMENT LIST: For product inspection, the following instruments are used.  Micrometer  Bore dial  Plug guage  Thread plug guage  Air gauge  Vernier caliper  Profiling projector  Surface roughness tester  Tool pre setter  Trimas height gauge  Digital height guage

PRODUCT TESTING EQUIPMENT: A separate well-equipped laboratory with complete testing facilities has been established for ultimate quality checks. Experienced professionals constitute the lab technicians team.

The lab is fortified with the following advanced instruments:  PROFILE PROJECTOR

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 TESA MICROHITE Height gauge for Linear and Geometrical Dimensional checking  MICROSCOPE with image analyzing software for quantitative metalographic study  ENDOSCOPE For checking internal core passages with CCD camera & monitor  ROUGHNESS TESTER  HARDNESS TESTER  UNIVERSAL TESTING MACHINE

HIGHLIGHTS:  We are extensively using CAD and CAM to make pattern and tools. This gives consistency in dimensional and Geometrical parameters from cavity to cavity when multi cavity patterns are made  The development CAD CAM Route of tool making and pattern making shorten the prototype development period and first time acceptance is assured Some interesting highlights of our Quality Control Process:  Spectrometers( 26 element analyzer), melt lab, image analyzer , ultrasonic velocity meter- Ensure metallurgical superiority of the castings  VTMs and various hardness testers ensure conformity of mechanical properties of the casting.  Emm, Height master, Profile Projector and other conventional measuring instruments ensure dimensional accuracy of the castings.   Similarly Millipore checks enable cleanliness of the casting. Soundness of the castings is measured by Ultrasonic Flow detectors, Gamma ray, Xray and magnetic particle testing.

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QUALITY PROCESS:

The products moulded out from Indo Shell Cast private Limited are exceptional in quality. Indo Shell Cast Private Limited is committed to quality - first time, on time, and every time. All the processes are streamlined and strict adherence to international standards of quality is ensured, to offer only the best quality to our customers. Our objective is to deliver the highest quality results to our clients, thus providing good value through competitive systems and processes.

We have been accredited with ISO/TS 16949-2002 (E) certificates.

ACCREDITATIONS FOR OUR QUALITY PROCESS:

       

ISO 9001- 2000 Certification by RWTUV, Germany 2002. We have been accredited with ISO 9001:2000 certificate. We have installed ISO/TS 16949-2002-certification. We are Familiar with and implementing: APQP Advanced Product Quality Planning FMEA Failure Mode Effect and Analysis MSA Measurement System Analysis Statistical Process and Quality Control Sampling Technique Cp & Cpk Study Parato analysis for defect analysis.

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HUMAN RESOURCE DEPARTMENT

The HR department plays a vital role in recruiting the persons to the company. It is very important that a company to have HR department to make industrial relation with public. Functions of HRD: The main functions of HR manager in the company,  Recruitment  Organizing training program  Preparing payroll  Involvement in the strategic panning process  Forecasting the labour requirements  Motivation  Performance appraisal  Managing employee grievances. EMPLOYEE MOTIVATION PROGRAM: Indo shell Cast Private Limited believes in constantly upgrading skills of its employees, driving perfection at work. There are many programs for employees to develop both curricular and non-curricular activities.

We believe that employees are the core asset. We constantly identify individuals /teams with exceptional performance get them to share ideas with the rest. The company ensures through frequent meetings a fair exchange of ideas of development in each of the fields.

Employees are constant updated on technology, market, and the latest developments in the field. All these make the employees get involved in work thereby giving better productivity. Dedication of the Indo Shell Cast Private Limited team and its unity create a synergic work environment.

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Indo Shell Cast Private Limited is running various schemes and adopting various beneficial measures to motivate its workforce. Some are given below:

In addition to the statuary welfare measures like, ESI, Provident fund etc, we are doing the following measures: 1. Meeting the first month educational expenses of the children of employees every year and liberal assistance for higher education. 2. Meeting the specialized medical treatment for deserving employees. 3. Free medical insurance scheme for the employees who are not covered under ESI 4. Helping the employees to overcome any emergency personal problem. 5. Eye test for all employees and provision of corrective treatment and spectacles. 6. Arrangement of blood donation for employees and their relatives in case of any emergency. 7. Arranging for soft loans through co-operative bank to the employees. 8. Provision of uniforms, shoes etc.

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FINANCE DEPARTMENT
Role purpose: To establish and maintain financial and management procedures for Community Technology Project. Ensure compliance with all regulatory requirements as relating to company and charity law, and in conjunction with the operations manager and board of trustees ensure adequate resource acquisition for the development of services in the support of our Charitable aims. MACHINE SHOP DETAILS: MONTH T.O(in RS) CUMM T.O (in RS) Jan 09 Feb 09 Mar 09 Apr 09 May 09 Jun 09 Jul 09 Aug 09 Sep 09 Oct 09 Nov 09 Dec 09 Jan 10 Feb 10 Average 1,1616,672 16.16 lakhs 701,175 1,027,181 1,509,602 1,796,153 1,831,012 1,467,864 1,715,384 1,787,070 1,656,533 1,749,400 1,896,140 2,169,480 1,709,750 701,175 1,728,355 3,237,957 5,034,110 6,865,122 8,332,986 10,048,370 11,835,440 13,491,973 15,241,373 17,137,513 19,306,992 21,016,742 43.9 56.8 55.2 57.3 53.3 51.2 59.8 60.0 52.5 64.0 60.4 62.9 52.9 66.8 56.9 1.9% 19998 36007 20967 35494 16991 16696 24463 15045 11426 16802 17892 14924 16895 16068 OEE PPM

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Where, y y y T.O - Turn Over PPM Parts Per Million OEE Overall Equipment Efficiency OEE ratio is calculated as, OEE = Availability*performance Rate*Quality Rate OEE is a way to monitor and improve the efficiency of our manufacturing REJECTION DETAILS: Month Plate Selector ( In %) Jan 09 Feb 09 Mar 09 Apr 09 May 09 Jun 09 Jul 09 Aug 09 Sep 09 Oct 09 Nov 09 Dec 09 Average (%) 37 20 11 5 18 9 5 12 7 2 12 2 63 14 3 7 28 28 5 1 7 10 8 5 15 12 9 3 6 4 7 8 6 5 4 Valve housing (In %) Brake valve (In %) 3 1 5 2 2 2 1 1 1 1 1 2 2 Plate support (In %) process.

In Indo Shell cast the production is maximum by upgrading the quality and efficiency of the product and earning the good profit.

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MARKETING DEPARTMENT

Marketing managers develop the firms marketing strategy in detail. With the help of subordinates, including product development managers and market research managers, they estimate the demand for products and services offered by the firm and its competitors. In addition, they identify potential marketsfor example, business firms, wholesalers, retailers, government, or the general public. Marketing managers develop pricing strategy to help firms maximize profits and market share while ensuring that the firms customers are satisfied. In collaboration with sales, product development, and other managers, they monitor trends that indicate the need for new products and services, and they oversee product development. Marketing managers work with advertising and promotion managers to promote the firms products and services and to attract potential users."

CLIENTS:

Our services ensure a long-term customer relationship; our list of satisfied clientele proves our quality service. Our domestic customers:  Bajaj Auto Limited  Volvo  Maruti  Ashok Leyland  Hindustan Transmissions  Godrej  Tempo

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 Rexorth Bosch Group  Vickers  Autotech  Sai Hydraulic motors  Tafe  TVS Our international customers:

 Italy Steprava  Gnuttti Carlo Italy  Minigears  FMC Energy Systems  Drell Borg Automating-Italy, UK.  Jack up vehicle system, USA  Catterpilor  Poclaine hydraulics  Parker Hannifin Hydraulics  Bosch Raxroth  Indo Autoshell America

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FINDINGS

Every employee in the organization got their respective roles & responsibilities from their HR manager. It is also agreed by majority of the employees.

Motivation and support are regularly provided to the employees by the HR manager and the top authority.

Due to the training program provided by the organization, the organizations productivity has also increased. It is also provided at a free of cost.

The biggest achievement of the HR manager is wages and bonus settlement to the Employees and providing sufficient manpower to the production.

The training programs conducted by the HR department are: 5S awareness, Kaizen method, Model machine concept, Why-Why analysis, presentation skills and TS 16949 awareness.

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SUGGESTIONS y Employees should be educated about the safety policy and training programs must be conducted to make the employees aware of the importance of safety. y y y y Team spirit and total involvement of the organization should be improved. Proper communication can be inducted among the design and production department. Employees will be satisfied if proper counseling is provided to them. The organization should provide a separate cabin for each employee to excel their talents so that the employee also feels independence in their work.

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CONCLUSION The organization culture is good. Most of the employees are satisfied with salary and working environment. Team work is prevailing in the organization. If more attention is given in the training and development, it will fetch more benefit to the organization that leads to winwin strategy.

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BIBILIOGRAPHY Books:
1. M.Y.Khan and P. K. Jain, (2001), Third edition, Financial Management, Tata McGraw Hill Publishing Company Limited, New Delhi. 2. VSP Rao, (2009) Second edition Human Resource Management, Excel Books

Websites:
3. http://www.indoshellcast.com/ 4. www.foundryinfo-india.org/