Académique Documents
Professionnel Documents
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AT
AUTOKAST LIMITED
( A Govt of Kerala Undertaking Company)
CHERTHALA
PRESENTED BY,
SARATH KRISHNAN
S3 MTECH
DEPARTMENT OF PRODUCTION & INDUSTRIAL ENGG
ROLL NO#09
INDEX
INTRODUCTION
OBJECTIVE
COMPANY PROFILE
PLANT LAYOUT
ORGANIZATIONAL STRUCTURE
DEPARTMENTAL STUDY
PROCESS FLOW
PROBLEM IDENTIFICATION
SOLUTION
CONCLUSION
2/1/15
INTRODUCTION
Foundry industry is considered as the mother of all industries.
Casting industry is one of the major industry in the global sector.
The product of which is used by almost all people.
Significance of casting industry are:
Automobiles & Auto components.
Railways.
Earth moving industry & Agro machinery.
Pumps, Compressors, Valves etc.
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5.8 5.7
OUTPUT (MT)
3.4 2.6 2.4 2.1
OBJECTIVE
To study the organization profile of the company.
To study the process flow diagram of the company.
To understand the functions of various departments of the
company.
To acquire knowledge regarding the companys performance
COMPANY PROFILE
Autokast Limited was established in the year 1982.
It is a Government of Kerala undertaking company.
On May 21-1984 incorporated as a separate subsidiary on SILK
SG Iron Castings.
Equipped to manufacture 23,000 Metric Tons of castings annually.
Present annual production capacity is 6000 metric tons.
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practice.
Consistent production through harmonious industrial relations.
Strengthen supply chain management.
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PRODUCT PROFILE
Autokast Ltd is a foundry unit producing iron casting for a variety
of industries.
Major product line of Autokast are:
Automotive castings
Machine tool casting
Pump casting
Pressure vessel castings &Valves
Wind mill Castings
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10
SILICO
N
MANGANES
E
SILICON
PHOSPHOROUS
2.5-3.75
1-2.5
0.4-1
0.06-0.12
0.1-1
11
SILICO
N
MANGANES
E
SILICON
PHOSPHOROUS
3.2-4.2
1.1-3.5
0.3-0.8
0.2
0.08
Similar to steel.
Higher grade of iron.
Spheroid shape structure.
High hardness and rest free.
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12
ITEM
MATERIAL
CAST WEIGHT
APPLICATION
Gear Box
/Engine Housing
Grey Iron
40 Kg to 130 Kg
Tractor
HUB
Ductile Iron
1000 Kg to 3300 Kg
Wind Mill
Extender
Ductile Iron
400 Kg to 600 Kg
Wind Mill
Ductile Iron
150 Kg to 1250 Kg
Wind Mill
Yaw Top
Ductile Iron
700 Kg to 1200 Kg
Wind Mill
Claw Beam
Ductile Iron
70 Kg to 110 Kg
Wind Mill
Brake Disc
Ductile Iron
50 Kg to 120 Kg
Wind Mill
Gear Stay
Ductile Iron
150 Kg
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Wind Mill13
SL
NO
ITEM
MATERIAL
CAST WEIGHT
APPLICATION
Grey Iron
200 Kg to 3500 Kg
Machine Tool
10
Valve Body
Butterfly valve
11
Valve Disc /
Vane
Ductile Iron
250 Kg to 5750 Kg
Butterfly valve
12
Sphere
Grey iron
300 Kg to 1200 Kg
Ball Valve
13
Valve Body
Grey Iron
700 Kg to 2200 Kg
Gate Valve
14
15
Discharge Head
Grey iron
100 Kg to 160 Kg
Vertical Pump
16
Dome
40 Kg to 100 Kg
Ash Handling
17
Ash Vessel
Ductile Iron
170 Kg to 600 Kg
Ash Handling
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Vacuum Pump
14
PRODUCT GALLERY
Valve body
15
PRODUCT GALLERY
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16
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SL
NO
NAME OF CUSTOMER
OPERATING SECTOR
MARKET
SHARE
KAMCO
POWER TILLER
17.02%
MECAWBWER BEKAY
ASH HANDLING
8.26%
PIONEER WINCONE
WIND MILL
0.79%
WIND MILL
0.52%
WIND MILL
0.33%
FOURESS ENGINEERING
BUTTERFLY VALVE
8.61%
KAKATHI KARSHAK
SLURRY PUMP
10.74%
L&T UNITS
HEAVY ENGINEERING
7.15%
PREMIER
VALVE
0.31%
10
LG BALAKRISHNAN
VALVE
2.74%
11
SL SMITH
HYDRAULICS
1.96%
17
1.96
0.31 2.74
7.15
17.02
10.74
8.26
8.61 0.33 0.52 0.79
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Kamco
Mecawbwer bekay
Pioneer Wincone
Global Wind farm
Siva wind mills
Fouress Engineering
Kakathi Karshak
L&T Units
Premier
LG Balakrishnan
SL Smith
18
PLANT LAYOUT
Purchase & Subcontract
Department
K
S
E
B
HR & Administration
Department
S
u
b
s
t
a
t
i
o
n
Car parking&2
Wheeler
parking for
Employees
Administrative
Office
Weigh
Bridge
Canteen
Visitors
Car
parking
area
Cycle shed
Cycle shed
Security
Office
Main Entrance
To Alappuzha
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NH 47
To Ernakulam
19
Sub
station
Sub
station
Time Office
Gate 2
Closing
Closing
&Pouring
&Pouring
Melting Bay
Bay
Melting
(Furnace)
(Furnace)
Knock
out
Conventional
moulding core shop
Pump room
4(Induction
furnace)
Scrap
Scrap
yard
yard
11KV
Mechanic
Mechanic
Electrical
Electrical
al
al
Maintenanc
Maintenanc
Maintenan
Maintenan
ee
ce
ce
110 KV
Pump room
3(M.F
furnace)
Sand Storage
Store
Store
Pump room
2 with OH
tank
Laboratory
Laboratory
Pump
room 1
Mouldin
g
Desi
Desi
Pattengn
gn
Patten
Shop Dep
Dep
Shop
art
art
A.S Canal
Fettling shop
Scrap storage yard
Sand Storage Area
Core
shop
Sand Plant
Core shop
High pressure
moulding Bay
Fettling shop bay2
Fettling shop bay 1
11KV
SubstationFor HP
line
Office
room
ORGANIZATIONAL STRUCTURE
Managing Director
Deputy Manager
(Maintenance)
Manager
(Materials)
Engineer
Assistant
Engineer
(Stores)
Assistant
Engineer
(Electrical)
Assistant
Officer
(Materials)
Skilled
Worker
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Assistant Manager
(Mechanical
Maintenance )
Engineer
Skilled
Worker
Assistant Engineer
Skilled Worker
21
ORGANIZATIONAL STRUCTURE
Managing Director
Sr.Manager
(Finance)
Assistant Manager
Assistant Officer
Skilled Worker
Sr.Manager
(Engineering&
MR)
Deputy Manager
Assistant
Manager
Assistant
Engineer
Assistant
Engineer
Skilled Worker
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Manager
(Marketing)
Assistant
Manager
Assistant
Manager
(HRD & A)
Manager
Assistant
Officer
(Marketing)
Skilled Worker
Assistant
Skilled
Worker
(Subcontract)
Assistant
Officer
Unskilled Worker
22
ORGANIZATIONAL STRUCTURE
Managing Director
Sr.Manager
(QC & LAB)
Assistant
Officer
Assistant
Officer
Assistant officer
Skilled Worker
Skilled
Worker(PPC&JPG)
Skilled Worker
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23
ORGANIZATIONAL STRUCTURE
Managing Director
Senior Manager(Production)
Assistant
Manager(Melting)
Engineer
Assistant Engineer
Skilled Worker
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Assistant Manager
(Conventional moulding)
Assistant
Manager(Fettling)
Deputy Manager
(HPL)
Engineer
Assistant
Engineer
Skilled Worker
Unskilled Worker
Assistant
Engineer
Assistant
Engineer
Skilled Worker
Skilled Worker
24
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CATEGORY
NUMBER OF EMPLOYEES
MANAGERS
25
EXECUTIVES
06
Jr.EXECUTIVES
39
STAFF
11
SKILLED WORKERS
120
UNSKILLED WORKERS
02
TEMPORARY WORKMEN
169
APPRENTICES
64
TOTAL
436
25
DEPARTMENTAL
STUDY
Autokast limited has the following departments
Human Resource And Administration Department
Finance Department
Marketing Department
Materials & Subcontracting Department
Production planning and control Department
Engineering and pattern shop Department
Production Department
Electrical and Mechanical maintenance Department
Quality Control and Inspection Department
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26
27
system.
There are 4 shifts in Autokast:
SHIFT
TIME
General shift
9.00 am to 5.00 pm
A shift
6.00am to 2.00pm
B shift
2.00pm to 10.00pm
C shift
10.00pm to 6.00am
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FINANCE DEPARTMENT
Concerned with the maintenance of accounts and preparation of
financial statements.
Accounts of the company are maintained according to the company
act of 1956.
Functions of finance department
Maintenance of accounts.
Sales of castings.
Purchase of Raw materials.
Budget preparation and payment preparation.
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MARKETING DEPARTMENT
The main objective of marketing department:
Improvement of customer satisfaction.
Reduced rejection of products.
Reduced complains from customers.
Functions of finance department:
Sourcing of customers and evaluation.
30
spares.
Indents for office equipments, stationary and printing items.
Verification and clarification of indents.
Selection of vendors.
Preparation of purchase proposal.
Purchase order preparation and registration .
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31
Functions of Store:
Keeping the receipt of incoming materials.
House keeping.
Issue and disposal of Various spare parts and materials.
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33
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34
PATTERN SHOP
Responsible for pattern inspection, rectification/modification.
patterns are either manufactured according to the design given by
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35
PRODUCTION DEPARTMENT
Divided into 4 divisions:
Melting.
Conventional line.
Fettling.
MELTING
Liquid metal preparation is done in melting.
Cold rolled continuously annealed scrap(CRCA) & Heavy melting
EOT cranes.
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log sheet.
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37
CONVENTIONAL LINE
Non automatic division of the manufacturing department.
Used for large casting ranging from 200 kg to 4000 kg.
Main raw material is silica sand.
It is treated with sodium Silicate, dried & mixed with wood dust and
38
panel.
Used for small casting ranging from 10Kg to 120Kg.
Moulding machine is operated at 6 to 7 kg/cm.
System can produce 80 moulds per hour in box size of 750 x 750 x
400/350 mm
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39
punched on casting.
Dwelling time of 4 to 5 Hours are given for casting to cool down and
40
FETTLING
Unwanted parts of the casting are cutoff cleaned and finished.
Removal of gates, risers from the casting.
Casting are send to shot blasting machine.
Iron shots are blasted at high velocity and proper finishing is
established.
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42
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44
45
SAND LAB
Sand test indicate the moulding sand performance.
Various sand control tests conducted in Autokast limited are:
Infrared speedy moisture tests.
Sand strength machine.
Permeability tests.
Sieve analysis.
Sand rammer.
Clay content test.
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46
MECHANICAL LAB
Test bars are usually used for checking the mechanical properties of
castings.
In case the test value donot conform to the specification two more
47
Impact testing.
universal testing machine.
Non destructive tests.
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1.
Ultrasonic test.
2.
3.
48
CHEMICAL LAB
Wet analysis is done in this lab.
It is the chemical analysis of Carbon, Manganese, Silicon, Sulphur,
SPECTRO LAB
Analysis of chemical combination of metals by spectrometer.
Main principle used is photo electric emission.
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49
INSPECTION
Main function is to inspect whether or not the casting conforms to the
required specification.
Four stages of inspection:
Black casting inspection
In process inspection
After shot blasting
After finishing
Deviations noticed will be send to the concerned product development
team.
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50
PROCESS FLOW
Design and Engineering
Pattern Making
Moulding
Lab Testing
Conventional
High Pressure
Core Making
Mould Preparation
Melting & Pouring
Shaking Out
Fettling
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51
PERFORMANCE ANALYSIS
Production for past seven years
5000
4500
4000
3500
3000
2500
PLANNED PRODUCTION(MT)
ACTUAL PRODUCTION(MT)
2000
1500
1000
500
0
2007-2008
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2008-2009
2009-2010
2010-2011
2011-2012
2012-2013
52
SALES ANALYSIS
4500
4000
3500
SALES (MT)
3000
2500
2000
1500
1000
500
0
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2007-2008
2008-2009
2009-2010
2010-2011
2011-2012
2012-2013
2013-2014
53
1000
500
0
2008-2009
2009-2010
2010-2011
2011-2012
2012-2013
-500
-1000
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54
25
20
15
2012-2013
2013-2014
10
5
0
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55
PROBLEM IDENTIFICATION
Scrap is an important and essential raw material for any casting industry.
Autokast Limited is spending an annual cost to Scrap suppliers almost
6 crore rupees.
This include both cost of Material, and Ordering Cost.
Since Good quality Scrap is a Scare material especially in India.
Cost of scrap now obtaining from suppliers is high.
Good quality scrap is vital as this result less amount of power needed for fusion
by suitably selecting the best suppliers who will meet the target of the company.
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56
Current
average
demand
of
Autokast
Limited
per
month=2400/12=200Mt.
Current number of suppliers in Autokast limited=5.
Demand is shared between these 5 suppliers.
Average quantity shared by them for one month =200/5= 40MT.
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NO
SUPPLIERS
LOCATION
Coimbatore
Asma steels
Calicut, Ernakulam
Ernakulam
Vijaya traders
Palakkad
Technovative Engineering
Bangalore
58
2/1/15
SCRAP MATERIALS
Rs 31,200/-
Rs 34,000/-
HMS
Rs 28,500/-
MS SCRAP CRCA
Rs 34,000/-
CAST IRON
Rs 29,500/59
ORDERING COST IN
PERCENTAGE
ASMA STEELS
5% per each MT
5% per each MT
VIJAYA TRADERS
8% per each MT
TECHNOVATIVE ENGINEERING
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60
Ordering cost of Sri Ambal steel traders= 31500400.1=Rs 1,26,000/ Ordering cost of Asma steels =31500400.05=Rs 63,000/ Ordering cost of Calicut import and exports =31500400.05
=Rs 63,000/ Ordering cost of Vijaya traders=31500400.08=Rs 1,00800/ Ordering cost of Technovative Engineering=31500400.16
61
SOLUTION
We have to select the best supplier who can meet the target of
Autokast Ltd.
Also by reducing the suppliers we can reduce the ordering cost to a
considerable value.
The main selection criteria includes following:
Pricing structure.
Delivery.
Quality.
Service.
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63
64
Pricing structure
Timeliness
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CALCULATIONS
Delivery
Costs
Service
structure
Quality
Quality of
incoming
lots
Personnel
Facility
Costs
Capability
65
NO
SUPPLIER
WEIGHT
0.3188
0.1858
Asma steels
0.1644
Technovative Engineering
0.0812
Vijaya traders
0.0538
0.35
0.3
0.25
0.2
WEIGHT
0.15
0.1
0.05
0
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TECHNOVATIVE
ENGINEERING
66
d1
d2
0.35694
0.11275
0.34704
0.28228 0.23131
0.39828
0.6326
0.17466
0.34406
0.11803
0.22575 0.29811
0.29536
0.4976
0.19856
0.316224
0.1545
0.17586 0.27249
0.26161
0.4898
0.09762
0.151567
0.11703
0.08693 0.32295
0.056566
0.1490
0.17178
0.095001
0.23636
0.24651 0.33142
0.21261
0.3908
a max
0.35694
0.34406
0.34704
0.28228
b min
0.09762
0.095001
0.11703
0.08693
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67
d1 =
d2 =
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68
NO
SUPPLIER
WEIGHT
0.6326
Asma steels
0.4976
0.4898
Technovative Engineering
0.3908
Vijaya traders
0.1490
0.8
0.6
WEIGHT 0.4
0.2
0
AHP METHOD
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We get Sree Ambal steel traders as first priority, so more order should
120 MT/Month}
Calicut import and exports =60 MT per Month. {Maximum capacity is
60 MT/Month}
Asma steels =60 MT per Month. {Maximum capacity is 60
MT/Month}
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=Rs 94,500/Ordering cost of Asma steels =31500600.05=Rs 94,500/Total ordering cost per month=252000+94500+94500=Rs 4,41,000/Ordering Cost saved per month= 5,54,400-4,41,000 =Rs 1,13,400/Ordering cost saved per year By Autokast Limited
=1,13,40012=Rs 13,60,800/2/1/15
71
CONCLUSION
We have selected the best supplier who can meet the target of
Autokast Ltd.
RANK
SUPPLIER
Asma steels
Ordering cost saved per year By Autokast Limited using the new
suggestion=Rs 13,60,800/-
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REFERENCES
1. Emrah Onder,Sundus Dag,(2013),Combining Analytical Hierarchy
International
journal
of
research
in
engineering
and
science,vol:1,issue:2,pages 2320-9356.
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THANK YOU