CHAPTER-1

INTRODUCTION

Indo Shell Cast Private Limited is an unlisted Private Company incorporated on 21 st July,
1987. It is classified as a Private Limited Company and is located in Sidco, Coimbatore,
Tamil nadu. The company manufactures iron castings. The company offers varities of iron
castings such as Hydraulic, Ductile, Shell moulded grey and gravity die. Indo Shell Cast
Private Limited company has four directors who are responsible for ensuring legal rules and
make decisions. The Corporate Identification Number of Indo Shell Cast Private Limited is
U27310TZI987PTC002013. The registered office of Indo Shell Cast Private Limited
Company is at A14 Sidco, industrial estate, Coimbatore, Tamil nadu.

It is a company limited by shares having an authorized capital of Rs 0.75 crores as per MCA.
Indo Shell Cast Private Limited is an ISO/TUV NORD IATF 16949 : 2016 Certified
company. Indo Shell Cast Private Limited Company having 30 years of casting experience in
shell moulded GS casting, Shell moulded Grey Iron casting. Indo Shell Cast Private Limited
Company specializes in Manufacturing Compacted Graphite Iron, Austempered Ductile Iron
(ADI) and Thermal application to with stand the Thermal shock. Indo Shell Cast Private
Limited manufactures - [Link] and Grey Iron castings using shell moulding, and it 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. Indo shell cast private limited company commenced commercial operations
in 1994. As on February 28, 2022, ISC has a cumulative installed capacity to manufacture
14000 MT per annum of ferrous castings from its two units based out in Coimbatore, TN.
ISC also has three windmills of capacity 1.63 MV and solar capacity of 2.1MW which caters
to around 60% of power requirements. The quality of Indo Shell Cast Private Limited
Company is working together for Customer Satisfaction and fulfillment of all applicable
requirements with effective quality Management system, Strong focus on Continual
Improvement and total involvement of Employees and Suppliers in the field of
Manufacturing and Suppling of Aluminium Die Cast Products. Alloy steel castings, except
investment , Body parts, automobile: stamped Metal , Rolling mill rolls, cast steel Industrial
molds
The integrated technological strength helps the company to deliver custom made solutions to
their customers . The fully equipped manufaturing facilities, including two steel and one iron
cast foundry, machine shop and assembly shop of the company provides an integrated
solution to all the customer need from raw castings to the ultimate end product. Indo Shell
Cast Private Limited is lead by a team of technocrafts, with vast experience in the field of
metallurgy. Indo Shell Cast has enormous plans for future. Indo Shell Cast Private Limited is
a group concern of Unique Shell Mould Private Limited.

With close to five decade leading presence, Indo Shell Cast Private Limited constantly
innovates and excels in manufacturing Casting and machined components using various
processes. Indo Shell Cast Private Limited is one of the largest Shell Moulding Precision
Casting Manufacturer in India. The vision of Promoter and Managing Director that an
illustrious organisation should emerge is realised through his hard work and commitment. 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 fact 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. Indo Shell Private Limited Company is one of the
few foundries certified with ISO/TUV NORD IATF 16949:2016 quality system in [Link]
total number of Employees working in the company is 101 to 500. The Annual Turnover of
Indo shell cast Private Limited is 100 to 500 crores. The nature of business is Manufacturer.
The Legal status of the firm is Limited i.e (ltd./[Link]). Customer specific requirements can
also be met our belief that compliance must be practiced individually before it can be
achieved corporately has empowered our personnel to take an active role in establishing and
maintaining critical quality compliance programs.
Indo Shell Cast Private Limited promote certain services that ensure a long term relationship;
the list of satisfied clientele proves our quality service. Bajaj Auto, Volvo, Maruthi, Ashok
Leyland, Hindustan Transmissions. Indo shell cast primarily focuses on parts between 300
grams to 50 Kilograms. Indo Shell Cast Private Limited is a community of skilled technicians
and professions dedicated to perfect and diversify their art, Operating round the clock
produding 24000 MT annum.

Indo Shell Cast successfully developed a low silicon ductile iron more suitable for induction
hardening applications. Dimentional accuracy of .3 mm. Casting can be supplied in
machined, painted condition for customer requirement. Special process like nitriding,
carburizing is also possible. Raw casting surface finish of 6-8 in shell moulding can be
achieved.

The present day Indo Shell Cast is all to spread its activities in a very balanced and
methodical way that will ensure solutions for variety of needs from raw castings to machined
supply for OEM and then to high precision products.
 CHAPTER-2

INDUSTRY PROFILE
2.1 FOUNDRY INDUSTRY

Indo Shell Cast Private Limited is well established Foundry Industry. A foundry is
a factory that produces metal castings. Foundry Industry is a branch of industries that
produces castings by filling molds with alloys. The annual volume of Foundry production in
the world is more than 80 million tons, of which 25% is produced in the USSR (1972).
Casting is used to produce an average of about 40 percent of stock for machine parts, but in
some areas of machine building, such as machine-tool manufacture the proportion of cast
parts is 80 percent Machine building consumes about 70 percent of all cast stocks,
metallurgical industry consumes 20 percent, and 10 percent is used in sanitary engineering.
Cast parts are used in metalworking lathes, internal-combustion engines, compressors,
pumps, steams, electric motors and hydraulic turbines rolling mills, motar vehicles,
locomotives and railroad cars. Metals are cast into shapes by melting them into a liquid,
pouring the metal into a mold, and removing the mold material after the metal has solidified
as it cools. The most common metals proessed are aluminium and cast iron. However, other
metals, such as bronze, brass, steel, magnesium and zinc, are also used to produce castings in
foundries.

Foundries are one of the largest contributors to the manufacturing recycling movement,
melting and recasting millions of tons of scrap metal every year to create new durable goods.
Moreover, many foundries use sand in their molding process. These foundries often use,
recondition, and reuse sand, which is another form of recycling.
 Figure:-2.1 Foundry Industry

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 casting 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/Textiles Machinery, Aero &
Sanitarypipes & 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 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.
Foundry sand testing is a process used to determine if the foundry sand has the correct
properties for a certain casting process. The sand is used to make moulds and cores via
a pattern. In a sand casting foundry there are broadly two reasons for rejection of the casting-
metal and sand-each of which has a large number of internal variables. The defects arising
from the sand can be prevented by using sand testing equipment to measure the various
properties of the sand.
 Figure:- 2.2 Profile of Indian foundry industry

2.2 EXPORTS

The Exports are showing Healthy trends approx 25-30% YOY till 2011-12 after that there
was slow down in export. The exports for the year 2005-2006 are approx USD 800 Million.
However, the current exports for FY 2010-21 are approx USD 2.8 billions which is lower as
per last year due to covid.
 Figure:-2.3 Export data up to 2020-2021(PY)

Figure:-2.4 Productioin in million tonnes

2.3 IMPORTS

There is a total of 54 countries India imports Foundry from. The dollar value of
Foundry import in 2020-2021 (Apr-Nov) stood at 115.86 USD Million and 368.95 USD
Million in 2018, which shows a growth of 56.98% from the previous year’s import
value which was 235.03 USD Million in 2017. Year on year the import of Foundry in
India grew by 49.51% during 2014 to 2018.
 Figure:-2.5 Import data up to 2020-2021(PY)

2.4 ROLE IN MANUFACTURING SECTOR

The new manufacturing policy envisages the increase in the share of manufacturing in the
GDP to 25% from current 15% & to create 100 Million additional jobs in next 10 years.
Since all engineering & other sectors use metal castings in their manufacturing, the role of
foundry industry to support manufacturing is very vital. It is not possible to achieve the above
goal without the sustainable corresponding growth of the foundry sector.

2.5 INVESTMENTS

India would need approx. $ 3 Billion in investment in meet the demand of growing domestic
industry and strong export drive. Following the economic reforms that 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 length 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 corporates 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.

2.6. TECHNOLOGY
Government of India (GOI) has encouraged technology transfer through JV with foreign
companies and GOI has cooperated with UNIDO with many foundry clusters. India 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 [Link] Institute of
Indian Foundry men have plans to strengthen and develop various foundry clusters.

CHAPTER-3

[Link] Profile
Indo Shell Cast Private Limited was started as a small scale unit in the industrial town of
Coimbatore, South India in the year 1973. In 1994, they received the biggest quality award
“National Award for Quality Products” from the President of India. In 1995, it was promoted
as a public limited company. The company has obtained ISO 2015 Certification from
RWTUV, Germany in 1996. In 1999, they received the “Best Vendor Award” from TVS-
Suzuki. And also they have received the “Quality Award” from Yamaha, Honda motors. Indo
Shell Cast Private Limited is manufacturing ductile Iron, Grey Iron, CG Iron, ADI, Ni Resist
& Shell molding, has a history of continuous improvement, the plant is established in the year
1992. 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. To ensure consistent delivery of high- quality products, we periodically
undertake thorough maintenance of the plant and the machinery. Indo Shell Cast Private
Limited is one of the renowned company that is engaged in the production of wide range of
aluminium castings components. With over three decades of experience and expertise in the
industry, Indo Shell Cast has earned a trusted name for quality among Industrial, Automotive,
Locomotive & Aerospace customers. 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

Figure:- 3.1 Indo Shell Cast Private Limited (Company)

3.1 LOGO OF THE COMPANY

3.2 TAGLINE

Casting the future… with quality !

3.3 VISION

To be a leading, most Trusted and Customer Preferred aluminium casting supply partner
Worldwide and can be an Ideal place to work in. Working together for Customer Satisfaction
and fulfillment of all applicable requirements with Effective and Efficient Quality
Management System, Strong focus on Continual Improvement and total involvement of
Employees & Suppliers in the field of Manufacturing and Supplying of Aluminium Die Cast
Products. It is the vision of Indo Shell Cast Private Limited to be a World Class Organization
all respects. The vision will be met by,

 Attaining Market leadership by exceeding Customer expectations and outperforming

competitors in Quality, Delivery and Cost.
 By our ongoing commitment to Continual Improvement of our Products, Processes
and Service.
 By total employee involvement, obtained through education and training for
continuous growth.
 To be a premier Supplier to our Customers while holding the highest regard for our
People Community and Environment.
 Complying with all applicable customer specific requirements, statutory and
regulatory requirements, Product Safety, Product Environmental requirements and
Corporate Social Policy requirements.
 Monitoring and Continually Improving our Environmental Performance Periodically.

3.4 MISSION
The Mission is to meet customer expectations by continuously improving their infrastructure,
technologies, processes and fostering employee engagement. To deliver Greater values to the
customers by supplying High quality aluminium Castings to different industrial
segments .The Mission is to meet customer expectations by continuously improving their
infrastructure, technologies, processes and fostering employee engagement. To deliver
Greater values to the customers by supplying High quality aluminium Castings to different
industrial segments meeting customer specific requirements with Cost effectiveness and
assuring Prosperity to all our stakeholders.

3.5 COMPANY’S MOTTO

Commitment to excellence. Dedicating themselves to openness, honesty and the highest

moral and ethical standards. We value and encourage creativity and innovation, strategic
[Link] strive to exceed client expectations. Our primary concern is to get the job done
right the first time-on schedule.

3.6 EVOUTION OF THE COMPANY

Indo Shell Cast is Promoted by Shri. S.V. Jagadesan, as a group company of Indo Shell Cast.
Unique Shell was established in the year 1983 for manufacturing Aluminium Components in
Pressure Die Casting and Gun Metal & Bronze Components in Shell Moulding. Today, the
company has successfully entrenched as a leading player in the field of manufacture of
Aluminum Components worldwide. Aggressive marketing strategies, World class quality
Caastings, 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 extenmded its marketing operations across the globe. Castings are exported to
various countries in Europe and USA as per customer specifications.

 1990 – Started Manufacturing of Gravity Die Cast Aluminium Components.

 2000 – Upgraded as Private Limited Company and title become as “Unique
Shell Mould India Private Limited
 2000 – Plant II was established for Manufacture of Low Pressure Die Cast
Aluminium Components and Expansion for Gravity Die Casting Components.
 2002 – Upgraded Quality Management Systems in line with ISO 9001
standards.
  2003 – Engineering division was established as dedicated Tool Room for all
manufacturing process ( GDC, PDC, LPDC and Shell Moulding).
 2004 – Implemented Environment Management System and accredited to ISO
14001 standard.
 2006 – Machining Division was established for machining of Components with
CNC turning centers, 3 & 4 axis Vertical Machining Centers.
 2008 – Upgraded Quality Management Systems in line with ISO TS 16949
standard.
 2012 – Plant III was started as a green field project with the plan to expand
Low pressure die casting operation.
 2013 – Manufacturing processes were consolidated in different plants.
 [Link] I – High Pressure Die Casting & Bronze Shell Moulding process.
 [Link] II – Gravity Die Casting.
 [Link] III – Low Pressure Die Casting.
 [Link] division – Tool & Die manufacturing for all processes
 [Link] Division – Component Machining.
 2017 – Upgraded Quality Management Systems in line with IATF
 16949 standard Lead by a team of technocrats, with vast experience in the
field of metallurgy, Unique Shell Mould has enormous growth plans for the
future.

3.7 MANAGEMENT

The Firm has been promoted by a team of well- experienced technocreafts with engineering
background. Their experience, professionalism, dynamism, expertise and quality conscious
approach have been further enriched technical guidance from theiroverseas customers for
parts two decades. The Company continuously undertakes modernization activities to
improve on its quality and productivity. With a solid infrastructure in place, and an
environment fully .With With a solid infrastructure in place, and an environment fully
embracing new technologies, we are supplying indigenous products to quality-conscious
customers. The campus of Indo Shell is fortified with greenery, since we are more concerned
about Environmental-friendly processes throughout the production cycle. Rapid changes in
technology translate into incredible oppourtunities. This is entirely true with the IT
innovations. All the department at Indo Shell are equipped with state-of-the-are computers
and latest softwares. The company has many facilities like advanced Zee track dual track
induction furnaces which enable power saving of 20 percentage and productivity
improvement of 30 percentage.

3.8 QUALITY POLICY

The products moulded out from Indo Shell Cast are exceptional in quality. Indo Shell Cast 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/TUV NORD. Indo Shell Cast Private Limited is determined to improve
productivity and focus continuously on innovation and up-gradation of its products and
products and people. Quality is not just a goal; it is our basic strategy for survival and future
growth. Working together for Customer Satisfaction and fulfillment of all applicable
requirements with Effective and Efficient Quality Management System, Strong focus on
Continual Improvement and total involvement of Employees & Suppliers in the field of
Manufacturing and Supplying of Aluminium Die Cast Products. Our quality management
systems allow us to streamline the quality maintenance and thereby aid in attaining 100%
Quality. Our Quality Assurance Laboratory and other well- equipped infrastructure facilities
help in manufacture of high- end products which find application in the Automobile,
Compressor and Valve industries.
Indo Shell Cast has also an impressive clientele who rely on our high- quality products.

3.8.1 Accreditations for the Quality Process

 ISO 9001- 2015 Certification by TUV NORD.

 We have been accredited with ISO 9001:2015 certificate. We have installed IATF
16949:2016 - certification.
3.8.2 Highlights of Quality Planning & Analysis of Shell
 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
 Pareto analysis for defect analysis.
 3.9 CORPORATE DATA

Company Name Indo Shell Cast Private Limited

Address A – 14, Sidco Industrial Estate,

Coimbatore: 641021

Year of Establishment 21st July 1987

Number of Workers 150

Status Legal Status of Firm

Limited Company (Ltd./[Link].)

Total Factory Area 8 acres

[Link] kumar
Board of Directors [Link]
[Link]
[Link]

Company CEO [Link]

 Bankers Bank of India
Main Branch , Coimbatore.

3.10 AWARDS AND CERTIFICATIONS

Here are some achivements and milestones for Indi Shell Cast Private Limited.

 1992: Productivity Award from Indian Institute of Foundary men- Coimbatore

Chapter
 1996-1997: Best performance Award From Hindustan Motors Limited for the Year
 1999: Self Certification Award From Sundaram Clayton Limited (Deming’s Award
Winner), Approval from VOLVO Sweden to produce Safety Critical Parts, Approval
from Trellborg Automotive U.K.
 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 Kirloskar’s “Foundry of the Year 2002” from Indian
Institute of Foundry man,Approved from Cummins-USA, FMC-USA .
 2003: Narashiman awards from Indian Institue of Foundry men for best mordenized
foundry the year 2003, best supplier award from rane TRW steering systems limited,
approval from lveco-Italy.
 2004: Sidha steel award “Best Foundry Executive” from M/s Sidha steel (P) Ltd. For
the year 2004.

3.11 RANGE OF CASTINGS:

High Pressure Die casting: 60 tons to 600 tons. Low Pressure Die Castings. Well equipped
LPDC Machines for production of cylinder heads, brake housings and other complex parts.
Indo Shell Cast Private Limited is a community of skilled technicians and professionals
dedicated to perfecting and diversifying their art. Operating round the clock, our current
annual production is around 3000 tons of Grey Iron S.G. Iron Castings.
Weight range of casting 50 Gms to 15 Kgs
Accuracy Right Dimension Right Dimension Accuracy

Raw direction +-0.4MM

Machined Dimension +-5MM

Production per month 850 tonnes

 CHAPTER - 4

[Link] Structure

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 Production

Head of the Department Accounts

Head of the Department Sales

CHAPTER -5
5. Department Profile

Indo Shell Cast Private Limited

Sales Financial Production HR R&D

Department Department Department Department Department

Manufacturing Purchase Planning

QC Department
Department Department Department

Warehouse
Department
Planning Packing Supply
Department Department Department
5.1 LIST OF DEPARTMENTS
 Purchase Department
 Warehouse Department
 Planning Department
 Production Department
 Supply Department
 Sales Department
 Financial Department
 HR & Personnel Department
 Manufacturing Department
 Quality & control Department(QC)
 Research & Development Department.

5.1.1 Purchase department

A purchasing department or procurement department in a company is an organizational unit

that fulfils responsibilities. The purchasing department of a company is responsible for
procuring the goods, raw materials & services required to operate the organization
effectively. Now, every organization has its specific needs when it comes to the sourcing and
procurement of equipment, raw materials, and services. Based on these needs, an
organization sets the purchasing department’s responsibilities and streamlines its
procurement plans to guard against demand-supply hurdles. A manager responsible for
a purchasing department of a large furniture company is a typical internal stakeholder. His or
her job is to ensure availability and quality of materials, good prices and efficient supply
chain operations. This translates to experiential goals such as the need to be informed about
the market situation and prices, to be able to control and prioritize deliveries, and to establish
a trustful working relationship to people inside and outside his organization. part of an
Employee Experience initiative would be to find out about this experience, and designing
everything to support these goals. A possible outcome could be a new reporting system, that
delivers all relevant information for specific business roles in a dashboard.

Role of purchase department

 Strategic Purchasing: In this role, the purchasing department plans high-level

procurement activities based on the organization’s business goals. Strategic
purchasing department responsibilities help in sourcing goods strategically (e-
sourcing) at economical prices and optimum quality. Decisions such as in-house
manufacturing or procurement from external suppliers are taken at the strategic
purchasing stage.

 Operational Procurement: This role is also defined as “tactical purchasing”, where

all the purchase department responsibilities are focused on taking care of business
operations and administerration. Repeat orders, inventory restocking, and invoice
payments are maintained to keep the production line running at its optimal
capacity. Operational procurement primarily caters to the long-term needs of the
company.

Figure 5.1.1 Flowchart of purchase department

  Requision Stage: All the important departments shall be provided with material
requisition notes. They continuously develop alternative solve of supply and
investigate they assibilated of attentive type of material reduce last or to improve
upon the effectiveness of material.

 Preserving Requision: On receipt of the requisition for a particular item, the

purchase in charger shall verify the quantity available in store. Purchase in charge
shall also take into consideration the item.

Functions of Purchase department

All purchasing department functions are aligned with the business objectives of an
organization.

 Identify business requirements for goods, materials, and services

 Find reliable suppliers to meet these requirements

 Run Quality control and Product Testing

 Comparing and negotiates prices

 Coordinating Deliveries and storage operations

 Maintaining Compliance and Moritoring performance

 Set up the order Quantities and making bid requests on supply contracts

 Manage budgets based on ROIs and payments

 Assesing the needs of the company

 Conducting research

 Develop Strategies
5.1.2 Warehouse department

The Warehouse is a function is a vital part of industrial concern, public and private
undertakings. It is designed to snit the particular moods of the organization itself. The
expression store in most organization is an area in which all kinds of materials intended to be
used in correction with production, distribution, maintenance, packaging, operating activities
etc. are stored, received and issued. In other words “store” is a general terms describing
goods which are kept in soreness and stock lard, all needed for production. It also covers
finished products awaiting disport to consumers, scraps and other arising and packagers hold
pending return to suppliers. However, the range value and complexity of terms held by any
particular stores will depends upon the size and complexity of the operations involved.
Different types of organization have different types of items in stock. For example,
production operation will have raw materials component parts, work-in-progress packaging
and associated materials. A distribution operation will have finished stock, component parts
and part completed work. An engineering and maintenance operation will have spare parts
tool, equipment, clearing and servicing materials. This storage of different materials is in one
particular location. The store keeper maintains every records of purchase.

It is the duty of the Warehouse department to receive materials or goods from all sources,
consignment must be checked in detail to ensure that proper quality and quantity have mean
supplied suitable document must be prepared for pocking of stock records and stock account
as well as to provide evidence of receipt with which supplier will no cleared for payments. It
also ensures interrupted flow of physical material into introduction as well as guide against
unauthorized usage damages or determination of materials.

Functions of Warehouse department

 Inspection and acceptance of incoming products.

 Identification and temporary storage.
 Movement of goods where needed.
 Inventory accounting and records management, and finally.
 Packaging and shipment.
 Stock taking.
 Inventory control.

Process of Warehouse Department

 MATERIAL RECEIPT BOOK

MATERIAL ISSUE REGISTER

STOCK REGISTER

Figure 5.2 Process of Warehouse Department

Material Receipt Book

This is the main book used for the purpose of store accounting. It keeps a date-wise record of
the materials received in the stores. The material receipts book provides the following
information: Name and address of the supplier.

Material Issue Book

The material should be issued form stores immediately and after requisition, materials
supply is taken into this register. According to the production pattern, i.e., count of yarn in
this
case, they issue the materials. Store keepers gets copy of material, individual card has been
allotted.

Stock Register

Stock register was also maintained by the storekeeper and the stocks have also been
maintained in effective manner. The stocks have been entered in separate book in detailed
account by the store keeper, in this register it s hows the records of remaining stocks,
required stock in an accurate way prepared by the store keepers.

5.1.3 Planning Department

Production planning is a strategic plan which manufacturers do whenever they want to
produce goods. Production planning includes confirming product to be made, production
volume, capacity planning, materials required, scheduling timelines etc. Planning includes
operation sequencing, machining process planning, assembly process planning, and assembly
line planning, as well as the communication of plans throughout the organization and
extended enterprise.

Types of Production Planning in Planning Department

Flow Method – Flow method is a demand-based manufacturing model that minimizes the
production lead time by speeding up the production line. The manufacturing process starts
based on the work orders, and once it starts, it does’t stop until all finished goods are
produced.

Process method- The process metrhod is more or less what most people picture whjen they
think about production. With the process method there will generally be different types of
machinery completing separate tasks to put together the finished goods.

Mass Production Method- The Mass Production method is primarily focused on creating a
continuous flow of identical products. Its similar to Flow method but at a much bigger scale
which cut production costs. When Uniformity is just as critical as efficiency, you need to use
“standardized process” to guarantee all products look exactly the same.

Figure 5.1.3 Production Planning process

Production Planning process
The production planning process involves the following steps:

 Estimate product demand -- This will a give a rough outline of how many
products should be produced in a given time period. This estimate is generated by
combining analysis of historical production trends with new potentially relevant
trends in the market.

 Weigh production options -- This involves accounting for the resources on hand
and exploring ways to most effectively use them based on projected demand
estimates.

 Choose the most efficient option -- The use of resources that is the least costly
and most time-efficient should be chosen.

 Monitoring and evaluation -- As the plan is carried out, companies monitor what
is happening compared to what should be happening according to the plan, and
evaluate how well those two match up.

 Adjust plan -- This involves altering the plan so that future production plans meet
customer goals more efficiently and are more successful in their execution.
5.1.4 Production Department

A production department is a group of functions within a business that is responsible for

the manufacture of goods. This can include just a few specialized functions with all other
work outsourced, or a fully functioning department that converts raw materials,
assembles components into finished goods, and packages them. The production
department can be the largest organization within a business. It may employee
mechanics, machine setup specialists, maintenance personnel, and machine operators. A
key focus of the production department is efficiency. To that end, the bottleneck
operation within the facility is closely monitored and supported so that throughput
(revenue minus variable costs) is maximized. While it is generally profitable to reduce
costs where possible in this department, that is not the case with the bottleneck
operation, which should be fully supported at all times.

Functions of Production Department

 The production department manufactures goods for the business which are then
sold in order to bring revenue for the business.
 The production department is also responsible for the designing of the goods or
products of the business which are sold to other businesses or to the general public.
 Every aspect of production is controlled by the production department. By
controlling production, the department efficiently uses things such as labor,
machines and materials judiciously in order to prevent any wastage.
 The department improves on the products of the business by bringing changes and
innovations.
 The production department makes sure that it produces goods or products at very
low costs in order to maximize profit.
 The production department works in collaboration with the purchasing department
of the company in order to make sure that materials needed for production are
always available.
  The department also makes sure that the machines and equipments used in
production are serviced and properly maintained all the time.

Name of the products produced and uses of products:

Some of the products produced in Indo Shell Cast Private Limited are.

Rocker liver: This product is used as an engine component and it has 25 to 30 products.
Cam shaft: It is used in the engines of two-wheeler vehicle and has 25 to 30 types of
products.

Crank shaft: This used in the three-wheeler for the rotation herd while running

Cam follower: This is used engine components tin the vehicle like truck, marine etc.

Hydraulic housing cast: It is a hydraulic application used in solenoid valves and control
valves.

Distributor truck: It is used as the hydraulic motor application.

Control over: It is an earth moving application used for fork lift.

Filter head: It is a hydraulic application used in the filter head.

Housing brake lever: It is used as engine components and for the efficient working of the
brake lever.

Piston: It is used in the refrigerator for compression. The most frequent customer is Godrej
Limited.
5.1.5 Supply Department

A Network between company and its suppliers to produce and distribute a specific product to
the final buyer, it includes different activities, people, entities, information and resources.
Supply Chain activities involve the transmission of natural resources, raw materials and
components into a finished product and and deliver to the end consumer. It is an integrative
approach consist of all stages involved directly or indirectly, in fulfilling customer requests.
Its efficiency deals with the enforcement of driving componentson their new product
development, marketing, operation, distribution, finance and consumer services.

Functions of Supply Department

 Aligning flows: As money, materials, and information are passed between customers
and suppliers, supply chain management keeps them flowing up and down a supply
chain.
 Coordinating processes: Supply chain management increases profitability by
aligning the processes used to plan, source, make, deliver, and (when necessary)
return a company's products and services.
 Designing complex systems: Simulation tools can predict how a supply chain will
behave and show how small changes can cause major disruptions in the flow of
materials.
 Managing resources: Supply chain managers are responsible for using people,
processes, and technology to meet the needs of customers.
 Figure 5.1.5: Supply Chain Management Flow

5.1.6 Sales Department

A sales department is responsible for selling products or services for a company. The
department comprises a sales team that works together to make sales, increase profitability
and build and maintain relationships with customers to encourage repeat purchases and brand
loyalty. The sales department consists of a set of business activities and processes that
help a sales organization run effectively, efficiently and in support of business strategies and
objectives. The sales department generally includes sales, sales support or business
operations.

Sales are activities related to selling or the number of goods sold in a given targeted time
period. The delivery of a service for a cost is also considered a sale. The seller, or the
provider of the goods or services, completes a sale in response to
an acquisition, appropriation, requisition, or a direct interaction with the buyer at the point of
sale. There is a passing of title of the item, and the settlement of a price, in which agreement
is reached on a price for which transfer of ownership of the item will occur. The seller, not
the purchaser, typically executes the sale and it may be completed prior to the obligation
of payment. In the case of indirect interaction, a person who sells goods or service on behalf
of the owner is known as a salesman or saleswoman or salesperson, but this often refers to
someone selling goods in a store/shop, in which case other terms are also common, including
sales clerk and retail clerk.
 Figure 5.1.6: Chart of Sales Department

Responsibilities of sales manager:

 To ensure a clear sale strategy is in place for demand and that it is communicated to
the
sales term efficiency and review regularly.
 To constantly review and maintain confirmed provisional and offered business in line
will all turn down to ensure the right business has been taken at the right line for the
right price.
 Analysis and reporting of actual performance venues competitors.
 To work with the head of sales and marketing and the senor sales manager to compile
and implement the sales and marketing strategy and be active in 5 years planning
process.
 To support the development of the sales and event terms ensure consistent and
professional sales practices through the development.
 Due to the sales operation flexibility is a key requirement for this role. The role will in
volume working line weekends and evening in order to fulfill appointments and
customer requirements.

Functions of Sales Department:

Sales Correspondence: Any incoming letter must be replied in a short time. The letter
should be tactful, simple in language, helpful and every customer must feel that his enquiries
are being considered.

Service: Industry is rapidly adopting the principle that service is an essential part of the sales
itself. Manufacturers often find it essential to see that their products are properly installed.
This is not only a service to the customers but also a protection against complaints and
general dissatisfaction of the customers.

Packing: Packing to be used for products depends upon the type of product to be packed.

Sales Correspondence: Any incoming letter must be replied in a short time. The letter
should be tactful, simple in language, helpful and every customer must feel that his enquiries
are being considered. Quotations for the supply of products should be sent to large number of
customers and try to capture large markets.

5.1.7 Financial Department

The Finance department plans and manages company money, making sure a business can
access cash in sustainable ways. This department can be as simple as a few people managing
invoices or as complex as a team of hundreds with multiple levels of management. A Finance
Department manages a firm's long-term and day-to-day monetary operations and strategy.
Finance groups oversee incoming and outgoing payments, budget creation, cash management
(treasury), accounting, financial reporting and many other tasks related to the finances of the
company.

Roles and Responsibilities of a Finance Department

The contributions of finance department to any company and how these contributions
positively affect organisational performance will greatly depend on factors such as the extent
to which the owner/ manager is involved in his company. The roles and responsibilities of a
finance department,

[Link]: This is the most basic function of the finance department. It involves the
day-to-day recording, analysis and interpretation of a company’s financial transactions. This
will include the tracking of all expenses (purchases, payments etc.) and sales of finished
products. In some startup companies, this role is often carried out by a bookkeeper who
might be replaced by more specialized payables and receivables clerks as the company grows
or expands its operations.

[Link] of company’s cash flow: It is the duty of the finance department to manage
all cash flows into and out of a company and ensure that there are enough funds available to
meet the day-to-day running of the company. This area also encompasses the credit and
collections policies for the company’s customers, to ensure that vendors and creditors are
paid correctly and on time; and that the company is also paid correctly and as when due.

[Link] and sourcing longer-term financing: It is the duty of the finance department to
advise companies on the best financing mix that could yield the company the best profit and
also help them source longer-term financing at the lowest cost such that there is a profit level
of liquidity.

Functions of Financial Management

Its primary functions include:

 Accounting. Daily account record keeping is a finance department function that

entails reconciling a company's financial registers to make suitable business decisions.
 Examining financial statements and reporting.
 Preparing and forecasting budgets.
 Managing operations systems.
 Figure 5.1.6: Organization of Finance Function

5.1.8 HR & Personnel Department

The head of the human resource and personnel department is Mr. N. Devaraj the human
resource personnel department is concerned with the most effective use of people to achieve
organization and industrial goals. It is the way of managing of people at people at work. So
that they give their best of times capability to the organization. The human resource and
personnel manager solves if any problem arising between the management and workers
group. The human resource department acts as intermediaries between the both. The various
credit and incentive plan are given by human resource and personnel department. The credit
facilities are arranged by the help of various banks, according to the type of loan.
A separate file is being maintained for each worker and the activities of each worker is
such as attendance, application for leave, casual leave, sick leave, any notice to the worker is
noted in the file on the respective workers. This department which carries employee-oriented
activities such as maintaining ESI, PF,etc.…, in the organization. They strive to good
productivity by motivating employees.

Figure 5.1.7: Responsibilities of an HR department

Responsibilities of HR Department

 Helping employees with the onboarding process: Responsibilities of HR

departments typically include onboarding new employees and implementing training
programs. Other facets of this human resources job include aiding employees in
filling out applicable paperwork and getting fresh hires set up on payroll and benefits.
 Developing plans to meet company objectives : HR departments often help create
various business plans to meet the company’s objectives and provide reports on
progress by collecting key data. Plans under the aegis of human resources
 responsibilities include lining out policies for compliance with local, state and federal
laws and creating hiring and training guidelines.
 Creating systems to motivate employees: Employee relations and creating
empowered employees are key aspects of human resources responsibilities. HR
departments often focus on motivating employees by implementing team-building
activities or other employee engagement initiatives that help boost morale, improve
cooperation and spur healthy competition with things like merit-based pay increase
programs.
 Conducting disciplinary actions: Though generally considered a negative part of the
job, effective human resources professionals use disciplinary action as an opportunity
to help employees improve performance. By ensuring employees adhere to the rules
put forth in company policies and procedures, HR departments have a chance to aid
those who may need help with counseling or flexibility during tough times. This, in
turn, reduces recruiting and hiring expenses by maintaining experienced staff with
sometimes temporary issues.
 Processing terminated and retiring employees: One of the more unpleasant human
resources responsibilities is processing terminated employees. This may include
providing layoff paperwork to help the employee file for unemployment benefits,
clearing severance pay with payroll specialists in the HR department and conducting
exit interviews .

 Communicating and implementing business changes: Often, HR departments work

toward creating internal business changes that benefit both the company and its
employees. Human resources responsibilities in this regard include updating
employee handbooks and communicating changes across the workforce via email
notices, posts to internal company portals or holding meetings to answer questions or
concerns.

5.1.9 Manufacturing Department

The manufacturing function is primarily responsible for implementing and operating the
production system in order to produce the product. Manufacturing may also include purchase,
distribution, and installation as well as the physical manufacture of the component. This
department gives substance to what developed by Engineering Department. It has the
most current machinery, means and tools, that alongside continuous training, it allows
getting the most performance in each area.
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 Silicon sand

 Catalyst- Hexa Methelyne terminate
 Ani Veining Agents- Iron Oxide
 Acid phenol formaldehyde resin
Sand process:
In sand process they used to get the pure sand by two processes.
 Resin Sand
 Reclaimation Sand
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.
 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.
 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 he resins 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 mixtures for an hour.
  Otherwise, we use warm coating which gives 5 mixtures for an hour.
 For each process they use separate dust remover.

Figure: Process Reclamation Sand

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.

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 withing 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.
From this process we can get,
 Body Brake Valve
 NC-6
 Saw India
 1004

Figure: Core Making

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 Dying and Coating:

  In this process the core is made to dry be using a big oven.
 For different type 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.

5.1.10 Quality Department

The main aim of the quality department is to maintain the quality of the product. The foundry
has formulated a quality systems and assurance to bring about improvement in all aAreas. All
the products which directly affect the quality of parts shall be subject to inspection and for
testing by authorized company inspection perusal. In manufacturing, quality control is a
process that ensures customers receive products free from defects and meet their needs. When
done the wrong way, it can put consumers at risk. For example, the recent defect found in
Takata airbags resulted in the biggest automotive recall in history. The recall includes almost
69 million airbag inflators and may cost billions of dollars. The recall will last until the end of
2019 and take until 2020 to resolve.

Procedures:

1. Raw material inspection:

In a foundry the inspection for raw material is taken.

2. In process Inspection:

The parts produced or procured by the company shall be inspected and tested as required
throughout their intermediate stages of manufacture by authorized company inspection
personnel

3. Final inspection:

The final inspection and testing shall be performed is approved ITP and quality assurance
procedure QA proof. All works operation, including those subs contracted and non-
conformance correction have been completed and all acceptance. All products observed
during final inspection to be nonconfirming shall be identified and processed in accordance
with quality assurance procedure.

Objectives:

 Controlling the quality of products throughout various types.

 Interaction with customers regularly to understand their needs and to incorporate their
requirements.
 Continuous up gradation of human resource through training programmers.
 Indo Shell Cast Private Limited is strongly committed to retain the supremacy in our
segment of business by achieving “total customer delight”.
 The company achieved by the supplying casting of customer requirements at right
cost on time and every time.
 Effective team work.
 Providing a clean and safe work environment.
 Optimizing the inventory turnover.
 Improving people productivity by good production capacity.
 Reducing the cost of poor quality
  Promoting the concept of deft prevent.
 Carry out socio-environment.

Control:
At Indo Shell Cast, 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 reduce the
risk of final inspection, enabling mitigation of the quality costs.

 The head of each functional area identifies the various quality records to be generated
and maintained by this functional area against each of the applicable procedure for
this functional area.
 These identified records are listed down at the end of each procedure.
 All the quality records are retained generally for a period of one year.
 The various records formats are approved and controlled as per documents control
procedures.
 The calibration related records are maintained for the lifetime of the equipment.
 The pattern and Cirebon related records PPAP records and APQP records and product
plus one year.
 The sale department takes the responsibility of informing the various departments
concerned will in advance account such contractual requirement.

5.1.11 Research & Development Department

A company's research and development department plays an integral role in the life cycle
of a product. While the department usually is separate from sales, production and other
divisions, the functions of these areas are related and often require collaboration. A
thorough understanding of the functions of the research and development department
allows you to maximize those duties at your small business, even if you don't have a big
department.

With the aid of R&D activities, Indo Shell Cast has developed and fine-
tuned the following process.
  Magnesium treatment for modularization with cored-wire for ductile iron production.
 Producing impeccable compacted graphite iron economically.
 Developed ADI treatment methods to achieve desired properties without adding any
expensive alloying elements.
 Effective gating system has been developed to produce safety critical parts.
 Developed various core making techniques suitable for hydraulic parts.
 Developed new method for automatic inoculation.
 Designed & developed indigenous mould making machines suitable for parts up to
50kgs.
 Develop various customer specific grades like Ductile Iron 900-5 etc.
 Exploring various avenues in various cost saving projects with enhanced quality of
the products in various manufacturing process such as thermal reclamation of resin
coated sand, hot coating process, application of producer gas etc.

Functions of Research & Development Departrment

New Product Research: Before a new product is developed, a research and development
department conducts a thorough study to support the project. The research phase includes
determining product specifications, production costs and a production time line. The
research also is likely to include an evaluation of the need for the product before the design
begins to ensure it is a functional product that customers want to use.

Existing Product Updates: Existing products of the company also fall under the scope of
research and development. The department regularly evaluates the products offered by the
company to ensure they are still functional. Potential changes or upgrades are considered.
In some cases, the research and development department is asked to resolve a problem with
an existing product that malfunctions or to find a new solution if the manufacturing process
must change.

Quality Control Checks: In many companies, the research and development team handles
the quality checks on products created by the company. The department has an intimate
knowledge of the requirements and specifications of a particular project. This allows team
members to ensure the products meet those standards so the company puts out quality
products. If the company also has a quality assurance team, it may collaborate with research
and development on quality checks.
Innovation and Staying Ahead of Treads: The research and development team aids the
company in staying competitive with others in the industry. The department is able to
research and analyze the products other businesses are creating, as well as the new trends
within the industry. This research aids the department in developing and updating the
products created by the company. The team helps direct the future of the company based on
the information it provides and products it creates.

Products and service offered

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.

CUSTOMISED 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 Moly S.G. Iron, C.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 latest Quality requirements.

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

Two Wheeler

Three Wheeler

ISC 004 ISC 005

 Four Wheeler

ISC 006 ISC 007 ISC 008

ISC 009 ISC 009 ISC 010

ISC 011 ISC 012 ISC 013

ISC 014 ISC 015 ISC 016

ISC 017
Hydraulics

Hydraulics

ISC 018 ISC 019 ISC 020

ISC 021 ISC 022 ISC 023

ISC 024 ISC 025 ISC 026

 ISC 027 ISC 028 ISC 029

Earth Movers

Earth Movers

ISC 030 ISC 031 ISC 032

ISC 033

Other Appliances
 Other Appliances

ISC 034 ISC 035 ISC 036

ISC 037 ISC 038

Components of Four Wheeler

Cam Follower: In the Automotive industry Cam-Follower mechanism is

used to drive fuel pumps. Furthermore, when multiple cams are
incorporated within a single shaft it is called a camshaft. The mechanism
is developed by incorporating three members they are, a driver member
named Cam, a frame that supports cam and follower, the follower is
guided by the frame and lastly, the driven member named as a follower.
engineers often use a higher pair links mechanism that is renowned
as Cam and Follower Mechanism. This pair of higher links are used to
move links spontaneously or periodically. Although, cam and follower
mechanisms are also used by engineers for ensuring zero or minimum
degree of error. The device that is known as Cam in the 3rd century was
devised by Hellenistic water-driven automata.

Auto Vibration control Parts: Active vibration control systems, also

called active vibration isolation or active vibration cancellation, are
isolation systems that dynamically react to incoming vibrations. That is,
they sense incoming vibrations and react to them, rather than passively
reducing their effect by virtue of their mechanical structure.
Active vibration control in vehicles often involves the isolation of a
particular transmission path, particularly of engine orders through engine
mounts.

Components of Two Wheeler & Three wheeler

Camshaft: A Camshaft is only a shaft on which cams are installed. The camshaft is mounted
on bearing in the lower part of the cylinder block, most in-line engines. In some engines, it is
placed on the cylinder head. A cam is a device that changes the rotary motion of the camshaft
into linear motion of the follower or filter. The cams have a high spot or lobe. The follower
riding on the cams will move away from or towards the camshaft as the cam rotates.

Gear Wheels: A gear is a rotating circular machine part having cut teeth or, in the case of
a cogwheel or gearwheel, inserted teeth (called cogs), which mesh with another (compatible)
toothed part to transmit (convert) torque and speed. Gears. component consisting of a toothed
wheel attached to a rotating shaft. Gears operate in pairs to transmit and modify rotary motion
and torque (turning force) without slip, the teeth of one gear engaging the teeth on a mating
gear.

Other Appliances

Fuel control fly weight: Gas turbine engines are primarily controlled by the amount
of fuel supplied to the combustion chambers. With this in mind we can say that, the very
simplest fuel control for a turbine engine is a fuel valve operated by the pilot.

Figure: Fuel Control Fly Weight

Valve Handle: A handle is used to manually control a valve from outside the valve body.
Automatically controlled valves often do not have handles, but some may have a handle (or
something similar) anyway to manually override automatic control, such as a stop-check
valve.

Butter Fly Valve Disc: A butterfly valve regulates flow by starting, slowing, or stopping
media. The disk opens and closes with a low-torque rotation of 90 degrees and works for any
compatible application.

Figure: Butter Fly Valve Disc

Pressure Die Casting Parts

Die casting is a fairly specialised process which has developed more predominantly within
the 20th century. The basic process comprises of: molten metal is poured/injected into a steel
mould and via high velocity, constant and intensifying pressure (in pressure die casting) and
cooling the molten metal solidifies to form a solid casting. Typically, the process itself only
takes a few seconds and is a quick way of forming metal product from raw material. Die
casting is suited to materials such as tin, lead, zinc, aluminium, magnesium to copper alloys
and even iron alloys such as stainless steel. The main alloys utilised today in pressure die
casting are aluminium, zinc and magnesium.

Low Preassure Die Casting

Low-pressure die casting is a method of production that uses pressure – rather than gravity –
to fill molds with molten metal such as aluminum and magnesium. In this process, the
holding furnace is located below the cast and the liquid metal is forced upwards through a
riser tube and into the cavity. The pressure is applied constantly, sometimes in increasing
increments, to fill the mold and hold the metal in place within the die until it solidifies.

Gunmetal & Bronze Die Casting

Gunmetal is an alloy where Lead contributes 2% of its share replacing the Zinc which makes
the alloy easy to cast. Gunmetal Casting is used for Gears and Bearings. Gunmetal Casting is
originally used for making guns and now has largely been replaced by steel.