Detailed Project Report on Forging Unit (MM Forging) Industrial Building

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FORGING UNIT (MM FORGING) INDUSTRIAL BUILDING

[EIRI/EDPR/3678] J.C.: 1764

INTRODUCTION

MM Forgings Limited (MMF), was originally incorporated in 1946 as Madras Motors Ltd carrying out trading and retail of motor cycles from Enfield, UK and manufactured by Royal Enfield, India.

MMF growth has been made possible because of the vision and commitment of its founder Late Sri S. E. Krishnan, FCA and his passion for manufacturing made the Company to diversify into manufacturing from trading activities, commencing its first manufacturing facility of forging in Singampunari (Sivagangai District), Tamilnadu during 1974 with a capacity 780 MT.

Founded on the tradition and philosophy of steadfast commitment to achieving "Total Customer Satisfaction" through excellent quality, on time deliveries and competitive pricing, the Company has grown steadily in strength and stature to attain its present recognition of being one of the largest exporter of Forgings in India in its product range and has created a niche in the International Market.

MMF has been the recipient of EEPC (Engineering Export Promotion Council) award for export excellence for 27 consecutive years, being the largest exporter of steel forgings from South India with 60% of its sales being exported.

The company has continuously expanded by adding state of the art forging facilities and machining capabilities to cater to the requirements of its international customers.

COST ESTIMATION

Plant Capacity 1120 Nos/Day

Land & Building (40,000 sq.mt.) Rs. 46.00 Cr

Plant & Machinery Rs. 116.40 Cr

Working Capital for 2 Months Rs. 32.83 Cr

Total Capital Investment Rs. 197.24 Cr

Rate of Return 15%

Break Even Point 21%

CONTENTS

INTRODUCTION

KEY PERFORMANCE HIGHLIGHTS

MANUFACTURING FACILITIES

GREEN POWER

THE COMPANY ALSO HAS SOLAR FARMS IN TAMILNADU AT THE FOLLOWING SITES:

FACILITIES

THE FACILITIES INCLUDE

CREDIT RATING

THE COMPANY ENJOYS GOOD CREDIT RATING AS BELOW:

SUBSIDIARY COMPANY IN UTTARAKHAND

EXPANSION

COMPANY AND MANAGEMENT

PARTICULARS OF BOARD OF DIRECTORS:

INTRODUCTION ABOUT PRODUCT

FRONT AXLE BEAM AND STUB AXLE

FRONT AXLE BEAM

STUB AXLE

USES AND APPLICATION

B.I.S. SPECIFICATION

PROCESS FLOW CHART

FOR FRONT AXLE BEAM

FOR STUB AXLE

PRODUCTION PROCESS FOR FRONT AXLE BEAM AND STUB AXLE

MACHINING

THERE ARE FOLLOWING MACHINING OPERATION ARE GIVEN BELOW:

(1) MILLING OPERATIONS

THERE ARE FOLLOWING TYPES OF OPERATIONS IN MILLING PROCESS

(A) FACE MILLING

MOUNTING THE WORKPIECE

DEPTH OF CUT

(B) GANG MILLING

(2) DRILLING PROCESS

ESTABLISHING A CENTERING MARK OR FEATURE BEFORE DRILLING, SUCH AS BY

SPOT DRILLING

CENTER DRILLING

DEEP HOLE DRILLING

GUN DRILLING

MICRO DRILLING

DRILLING IN METAL

(3) BOARING OPERATIONS

(4) TURNING OPERATION

TURNING SPECIFIC OPERATIONS INCLUDE:

HARD TURNING

FACING

PARTING

GROOVING

NON-SPECIFIC OPERATIONS INCLUDE:

BORING

KNURLING

(5) DEBURRING OPERATIONS

WHAT IS BURR AND HOW DOES IT OCCUR?

(6) CLEANING PROCESS

(7) MAGNETIC PARTICLE INSPECTION

PROCEDURE

1.0 MAGNETIC PARTICLE INSPECTION - SCOPE

2.0 MAGNETIC PARTICLE INSPECTION -DESCRIPTION OF METHOD

3.0 MAGNETIC PARTICLE INSPECTION - EAUIPMENT AND MATERIALS

4.0 MAGNETIC PARTICLE INSPECTION - PARTS TO BE EXAMINED

5.0 MAGNETIC PARTICLE INSPECTION - SURFACE PREPARATION

6.0 MAGNETIC PARTICLE INSPECTION - EQUIPMENT AND CONSUMABLE CONTROL

7.0 MAGNETIC PARTICLE INSPECTION - LIGHTING CONDITIONS

8.0 MAGNETIC PARTICLE INSPECTION - DIRECTION OF MAGNETISING FIELD

9.0 MAGNETIC PARTICLE INSPECTION - SEQUENCE OF OPERATIONS

10.0 MAGNETIC PARTICLE INSPECTION - EVALUATION OF INDICATIONS

11.0 MAGNETIC PARTICLE INSPECTION - ACCEPTANCE CRITERIA

12.0 MAGNETIC PARTICLE INSPECTION - PERSONNEL QUALIFICATION

16.0 MAGNETIC PARTICLE INSPECTION - REFERENCED DOCUMENTS

(8) INSPECTION PROCESS

FUNDAMENTALS OF INSPECTION

TYPES OF INSPECTION

INSPECTION PROCEDURE

EXAMINATION

DECISION

ACTION

INSPECTION ACCURACY

INSPECTION VS. TESTING

AUTOMATED INSPECTION

FEEDBACK PROCESS CONTROL

TIMING OF INSPECTION

OFF-LINE INSPECTION METHODS

ON-LINE/IN-PROCESS AND ON-LINE/POST-PROCESS INSPECTION METHODS

(9) ANTI RUST OILING PROCESS

UNDERSTANDING THE RUSTING PROCEDURE

INCONSISTENT ATOMS

CORROSION ON A BUSINESS SCALE

OILING PREVENT RUSTING: RUST REMOVER OILS

AUTOMOTIVE RUST REMOVAL TREATMENT

RUST REMOVING CHEMICALS

DEBURRING MACHINE

LINEAR DEBURRING MACHINES

DOUBLE-SIDED DEBURRING MACHINES

DISC BRUSHES

MOST USED MATERIALS:

MARKET OVERVIEW

MARKET SIZE

INVESTMENTS

GOVERNMENT INITIATIVES

ACHIEVEMENTS

ROAD AHEAD

INTRODUCTION

MARKET SIZE

INVESTMENTS

ACHIEVEMENTS

GOVERNMENT INITIATIVES

ROAD AHEAD

AUTOMOTIVE AXLE & PROPELLER SHAFT MARKET DYNAMICS

DRIVERS

RESTRAINTS

OPPORTUNITIES

CHALLENGES

OBJECTIVES OF THE AUTOMOTIVE AXLE & PROPELLER SHAFT MARKET STUDY

RESEARCH METHODOLOGY OF AUTOMOTIVE AXLE & PROPELLER SHAFT MARKET

TO KNOW ABOUT THE ASSUMPTIONS CONSIDERED FOR THE STUDY

PASSENGER CARS

LIGHT COMMERCIAL VEHICLES

HEAVY COMMERCIAL VEHICLES

FRONT AXLE

REAR AXLE

DEAD AXLE

LIVE AXLE

TANDEM AXLE

FRONT PROPELLER SHAFT

REAR PROPELLER SHAFT

INTER-AXLE PROPELLER SHAFT

DETAILED EXPORT DATA OF FRONT AXLE BEAM

EXPORT DATA OF RIGHT STUB AXLE

IMPORT DATA OF FRONT AXLE BEAM

IMPORT DATA OF RIGHT STUB AXLE

PLANT LAYOUT

SUPPLIERS OF FRONT AXLE BEAM

SUPPLIERS OF STUB AXLE

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF STEEL FORGING

SUPPLIERS OF CUTTING FLUID

SUPPLIERS OF PACKING MATERIALS

SUPPLIERS OF DEGREASING CHEMICAL

SUPPLIERS OF PICKLING CHEMICALS

SUPPLIERS OF OIL AND GREASE

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF MILLING MACHINE

SUPPLIERS OF CNC LATHE MACHINE

SUPPLIERS OF BOARING MACHINE

SUPPLIERS OF POWER HACKSAW

SUPPLIERS OF GRINDING MACHINE

SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES

SUPPLIERS OF DG SETS

SUPPLIERS OF EOT CRANE

SUPPLIERS OF POWER TRANSFORMERS

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF ELECTRIC MOTOR

SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS

SUPPLIERS OF AIR CONDITIONING EQUIPMENTS

SUPPLIERS OF AIR COMPRESSORS

SUPPLIERS OF PLATFORM WEIGHING MACHINE

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

SUPPLIERS OF SHOT BLASTING MACHINE

SUPPLIERS OF JIGS AND FIXTURE

SUPPLIERS OF SUBMERSIBLE WATER PUMP

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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