Professional Documents
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Autokast LTD
Autokast LTD
UNIVERSITY
Submitted to
KERALA TECHNOLOGICAL UNIVERSITY
BACHELOR OF TECHNOLOGY
IN
ELECTRICAL AND ELECTRONICS ENGINEERING
Submitted By
Mr. PRATHYUSH.M
(Reg. No.: PRP16EE028)
DEPARTMENT OF ELECTRICAL AND ELECTRONICS
ENGINEERING
CERTIFICATE
HOD
ACKNOWLEDGEMENT
A training work owes its success from commencement to completion, to the people in
love with researches at various stages. Having been a part of a prestigious organization like
AUTOKAST LTD., CHERTHALA for 1 day, I would like to acknowledge all those who made
my tenure a great learning experience.
First of all I thank the god almighty for showering his choicest blessings on me for the
successful completion of the industrial training undertaken by me.
I take this opportunity to express my profound gratitude and sincere regards to the
workers of Autokast, who seemingly helped me to understand their work better.
Last but not least I would like to express my love and affection towards my parents
who have been supportive and have encouraged me in all my endeavours.
PRATHYUSH M
TABLE OF CONTENT
1. INTRODUCTION 1
2. INDUSTRY PROFILE 03
3. COMPANY PROFILE 05
3.2 Vision 05
3.3 Mission 05
3.4.2 Goals 06
Organization structure 10
Department profile 11
Manufacturing department 11
Findings 19
Suggestions 19
6. CONCLUSION 21
7. REFERENCES 22
LIST OF FIGURES
CHAPTER 1
INTRODUCTION
An ISO 9001-2008 Company Autokast has different production lines each of which caters
different market segments, the different production lines are,
2) Moulding
3) Melting
4) Pouring
This study is about the major functioning of the AUTOKAST LTD, CHERTHALA.
This study mainly based on the details collected from each department .Each and every
activity of the department functions are carefully studied with the available data .This
study is beneficial to the future managers as they are put in to real life application. A
study on the entire department can help to improve the process and there by overall
improvements in the company’s performance can be made.
CHAPTER 2
INDUSTRY PROFILE
2.2WORLD SCENARIO
There are about 35,000 foundries in the world with annual production of 90 million tones,
providing employment to about 2 million people. USA tops the list in alloy production
followed by China, Japan, Germany, and the CIS. In terms of number of foundries China
has the highest score (9374), followed by India (6000) and then CIS (4000). The share of
Iron foundries is the maximum i.e. almost 56%, followed by steel with 14% and then the
non-ferrous ones with 30%. The global market potential of metal is estimated to be about
US$30 billion. The growing environmental concerns and globalization of economies have
led to a closure of some 8000 foundries in Europe.
India ranks 6th country in the world for producing an estimated 6 Million MT of various
grades of Castings. The various types of Castings which are produced are ferrous,
nonferrous, Aluminium alloy, graded Cast Iron, ductile Iron, Steel etc. for application in
automobiles, railways, pumps compressors and valves, diesel engines, cement/electrical/
textile machinery, amongst others. The Grey Iron Castings have a major share of 70 per
cent of the total Castings produced. There are approximately 4,500 units engaged in
Castings, out of which 80 per cent can be classified as small- scale units and 10 per cent
each as medium and large-scale units.
The Industry is a labour intensive one, employing about 5, 00, 000 people directly and an
additional 1,50,000 people indirectly. The small units are mainly dependent on manual
labour. However, the medium and large units are semi or fully mechanized and some of the
large units are world class.
The Industry is organized in clusters in various regions like Agra, Belgaum, Chennai,
Howrah, Coimbatore, Chennai, Kolhapur, Ludhiana, Pune and Rajkot.
CHAPTER 3
COMPANY PROFILE
A.CUSTOMER SATISFACTION
2.Minimize reworks
C.EMPLOYEE INVOLVEMENT
Meetings conducted under various shop councils & Defect Analysis review Committee.
3.4.2 GOALS
serving customers by supplying quality castings at right time
Autokast produces Castings in Grey Iron and spheroidal graphic Iron or nodular Cast
Iron.
3.5.1.2 GREY CAST IRON
Grey Iron can be readily cast into desired shapes by pouring into moulds. So it is the
most commonly used type of Cast Iron for the manufacture of Castings. The other
distinguishable characteristics of Grey Iron are:
Lowest melting point of all ferrous alloys.
Carbon in Grey Iron is found in the form of graphite flakes.
Low cost combined with hardness and rigidity, High compressive strength.
High resistance to whether etc
Applications
Machine tool structures.
Gas or water pipes for underground purposes.
Cylinder blocks and heads for internal combustion engines etc.
3.5.1.3 SPHEROIDAL GRAPHITE IRON
Spheroidal Graphite Iron or Nodular Cast Iron is a higher grade of Iron, because unlike
structures in Grey Iron, the graphite in Spheroidal Graphite (SG) Iron is precipitated as
Spheroids. This is attained by adding some spheriodising agents, which changes the
solidification characteristics and account for notarization.
S G Iron
CHAPTER 4
FUNCTIONAL AREAS
Autokast was established in the year 1982 as a subsidiary of steel Industrials Kerala
Ltd. (SILK) a Govt. of Kerala undertaking for the manufacture of grey iron spheroidal
graphite iron castings. Autokast limited was started on with the aim of manufacturing
all type of ferrous casting unit under the steel industrials Kerala ltd (SILK). On May
21-1984 incorporated as separate subsidiary on SILK and renamed as Autokast
Limited, which is located at S N Puram near Cherthala is a modern industrial casting
unit an ISO 9002: 2008 company.
The manufacturing department of Autokast limited is divided into four division’s .They
are,
1. Melting
2. Conventional line
3. High pressure line
4. Fettling
4.4.1 MELTING
Before pouring into the mould, the metal to be cast has to be in the molten or liquid
state. The raw material melting process is done in the melting department. For the
preparation of liquid metal the Raw Materials like CRCA(cold rolled continuously
annealed)scrap and HMI(heavy melting )scrap are brought to the Induction Furnace.
The scrap is charged to the furnace with the help of electro magnet hooked in EOT
cranes, the furnace can withstand a capacity of 6T with holding attachment and with a
change over control system. Furnace is heated to about 1450 degree Celsius(including
the loss due to transportation of liquid metal from the furnace to the pouring
moulds).the slag is skimmed off from the molten metal by adding coagulant. The liquid
metal is tested for its grades in comparison with the standards (eg: different grades of
IS 210 for Cast Iron). The samples are tested at each stage of melting. The extra/excess
chemicals components are added/removed to achieve the specification. Temperature of
the liquid metal is adjusted by the electrical settings of the furnace and measured with
measuring instrument (pyrometer) and is recorded in the log sheet. Finally the molten
metal is tapped into clean pre heated laddle and required quantity of inoculants is added
to the stream for the purpose of homogeneous structure of metal Castings. Liquid metal
is carried in this laddle and is poured into the previously prepared moulds for the
testing of final chemistry laddle sample is taken.
4.4.4 FETTLING
Fettling is the process by which unwanted parts of the Casting are cut off, cleaned and
finished .this includes removal of gates, risers from Casting etc. . .The Castings are
STAGE 3 - MELTING
Before pouring into the mould, the metal to be cast has to be in the molten or liquid
state. A furnace is used to melt the metal. A furnace contains a high temperature zone
or region surrounded by a refractory wall structure which withstands high temperature
and being insulating minimizes heat losses to the surroundings. Metal to be remelted is
placed in the high temperature region of the furnace. Scrap Iron, which is the most
important raw material, is melted in furnace into molten Iron. In Autokast Induction
Furnace is used to melt metals. Pyrometer is used to calculate the temperature.
STAGE 4 – POURING
It is the process by which the molten metal is poured into the pre-prepared sand
moulds. Pouring is a complicated process, in which many things are to be noted. The
metal should be poured at the right temperature. If it is too hot it will produce a
technical defect called blowholes in Castings, and if it is too cold due to premature
POURING EQUIPMENT
Pouring Laddles: Laddles are used to carry molten metal from the furnace to the
Moulding boxes.
Laddle handle
Trolley
Rails
Cranes , Hand wheels ,Tilting levers
STAGE 6 – FETTLING
Fettling is the name given to cover all those operations which help giving the Casting a
good appearance after the same has been shaken out of the sand mould. Fettling is the
process by which unwanted parts of the Castings are cut off, cleaned and finished.
Fettling includes:
Even after Fettling, there may be minute sand particles attached to the Castings. These
are removed by shot blasting. Shot blasting is the process by which Cast Iron shots are
blown to the surface of the Castings to remove the adhering sand
CHAPTER 5
FINDINGS, SUGGESTIONS AND RECOMENDATIONS
5.1 FINDINGS
AUTOKAST LIMITTED is producing quality product
The company has not tapped its fully available capacity
The company has a bunch of highly committed suppliers
The company enjoys a good brand image and good will of the customers
As a result of efficient monitoring and quality control procedure ,wastage and
rejection are minimum
Lack of raw material is a problem
Labour problems and industrial dispute are some problems
Lack of demand of the product
5.2 SUGGESTIONS
CHAPTER 6
CONCLUSION
Through this industrial training, I have gained a lot of knowledge which we cannot
obtain from books and other references. I was able to learn the various production
aspects associated with foundry /casting industry. I had the opportunity to have through
hand on exposure to various engineering activities involved on manufacture of casting
industry. It was offered platform to learn about aspect such as molding, pattern making
fettling and various machineries. Through this training I was able to gain insights more
comprehensive understanding about the real industry working condition and practice.
REFERENCES
http://www.autokast.com/foundry.htm
http://shodhganga.inflibnet.ac.in/
2. Book references:
American foundry men’s society foundry sand handbook
Quality manual of AUTOKAST LTD
Foundry sand handbook -APS 6 the edition 1952
Foundry technology-PR Beeles, Bultenworthslondon 1972