Evolution of the Aluminium High Pressure Die Casting in India
CONTENTS INDIA - A VIBRANT ECONOMY HISTORY OF INDIAN DIE CASTING INDUSTRY PRESENT STATUS OF INDIAN DIE CASTING INDUSTRY AUTOMOTIVE - THE LARGEST CUSTOMER OF DIE CASTING IN INDIA CUSTOMER EXPECTATIONS TECHNOLOGY IN INDIAN DIE CASTING INDUSTRY TO MEET CUSTOMER EXPECTATIONS FUTURE OF DIE CASTING IN INDIA ABOUT ALUCAST
INDIA - A VIBRANT ECONOMY 2 nd largest pool of Certified Professionals World’s Largest Democracy - & Highest number of Qualified Engineers 1.3 billion people with Growing in the world Middle Class 3 rd Biggest economy in terms of 3 rd Largest Investor base in the World PPP (Purchasing Power Parity) India’s average GDP growth rate: 7.3% over past 10 years
INDIA - A VIBRANT ECONOMY Political Stability under the Leadership of Prime Minister Mr. Narendra Modi India’s ranking has improved by Implementation of GST Regime over 30 places in past one year in ‘Ease of Doing Business’ Protection of minority investors Target is to break into Top 50 by 2020 ‘Make in India’ not merely a slogan but a driving force for economic development.
INDIA - A VIBRANT ECONOMY FDI inflows in India FDI in Million USD FDI Inflows in India for the past 3 yrs Singapore 29 Bn USD Japan 9 Bn USD USA 8 Bn USD Germany 3 Bn USD Singapore Japan USA Germany Source: Quarterly Fact sheet Govt Of India
INFRASTRUCTURE GROWTH IN 2015 INDIA - A VIBRANT ECONOMY Infra - Development National Highway Awarded Constructed 4,920 3,018 4,349 4,337 17.2 KM Roads per day were built In 2015-16. 3,018 2,902 2,625 2,208 22 KM Roads per day were built In 2016-17. 1,578 Now the target is to go to 40 km/day
CONTENTS INDIA - A VIBRANT ECONOMY HISTORY OF INDIAN DIE CASTING INDUSTRY PRESENT STATUS OF INDIAN DIE CASTING INDUSTRY AUTOMOTIVE - THE LARGEST CUSTOMER OF DIE CASTING IN INDIA CUSTOMER EXPECTATIONS TECHNOLOGY IN INDIAN DIE CASTING INDUSTRY TO MEET CUSTOMER EXPECTATIONS FUTURE OF DIE CASTING IN INDIA ABOUT ALUCAST
History of Indian Die Casting Industry 1954 (63 yrs ago) First PDC machine installed (at Jalandhar, North India) Make POLAK (Czech) Hydraulic System Water Hydraulics Company Graem & Co. Parts Made Castings for Loudspeakers Exactly 20 years later, in 1974, the first indigenous PDC machine was built at Delhi.
History of Indian Die Casting Industry 1965 HMT - a government of India undertaking started manufacturing of PDC machines with license from Buhler-Switzerland. HMT was using design which was already 10 - 15 years old. 1990-91 The government declared liberalisation of Indian economy and made sweeping changes in policies.
Liberalization Private enterprises got 1991 - opening up of incentives for new projects The Indian Economy Foreign Exchange Restrictions Production capacity minimised restrictions removed Imports delinked from Export Manufacturing commitments Activities given fillip
Effects of Liberalization Creation of competitive Rapid up-gradation in Market Economy manufacturing competence Manufacturers create newer Improved utilization of capacity & better parts to acquire & sustain new customers
History of Indian Die Casting Industry Largest Size of Machine in Use It took 26 years for Machine Tonnage to increase It took only 10 years to increase from from 800T in 1974 to 1400T in 2000 1400T in 2000 to 3200T in 2010 1974 1989 1994 1996 2000 2008 2010 Buhler Buhler Buhler HMT Buhler Buhler 840 Buhler 1400 T 1100 T 800 T 660 D T Evolution Evolution 2800 T 3200 T Jaya Hind First machine Jaya Hind Jaya Hind First machine Transmission Jaya Hind Industries Industries - retrofitted with with built in Housing - Industries & Industries (Cylinder (Crankcase) Real Time Real Time Maruti & Sundaram Block) Controls controls Sunbeam Auto Clayton (2 Wheeler (LH Engine Crank Case) Housing Scooter)
History of Indian Die Casting Industry Till 1990 only 2 machine builders were in India. Imports were difficult due to policy restrictions. ❏ Today we can freely import from the World’s Best Manufacturers. ❏ Germany Italy Japan Taiwan Prominent China Machine Makers Switzerland
CONTENTS INDIA - A VIBRANT ECONOMY HISTORY OF INDIAN DIE CASTING INDUSTRY PRESENT STATUS OF INDIAN DIE CASTING INDUSTRY AUTOMOTIVE - THE LARGEST CUSTOMER OF DIE CASTING IN INDIA CUSTOMER EXPECTATIONS TECHNOLOGY IN INDIAN DIE CASTING INDUSTRY TO MEET CUSTOMER EXPECTATIONS FUTURE OF DIE CASTING IN INDIA ABOUT ALUCAST
Present Status of Die Casting in India The Indian Die Casting industry has Availability of educated & skilled now matured and is catering to labour and a large and growing both global and domestic domestic market customers Support services and material suppliers have also kept pace Machines and Equipment built with with die casting process in India latest technologies are being used India is now producing critical parts Companies like FOSECO International, like engine blocks, bed plates / ladder Magmasoft, Buhler and many others frames & other thin wall castings played prominent role in development of die casting industry in India.
CONTENTS INDIA - A VIBRANT ECONOMY HISTORY OF INDIAN DIE CASTING INDUSTRY PRESENT STATUS OF INDIAN DIE CASTING INDUSTRY AUTOMOTIVE - THE LARGEST CUSTOMER OF DIE CASTING IN INDIA CUSTOMER EXPECTATIONS TECHNOLOGY IN INDIAN DIE CASTING INDUSTRY TO MEET CUSTOMER EXPECTATIONS FUTURE OF DIE CASTING IN INDIA ABOUT ALUCAST
Volvo AUTOMOTIVE - BMW BMW MAN THE LARGEST CUSTOMER Volkswagen Scania Volkswagen Skoda Skoda JLR Renault Nissan Renault Nissan Audi Mercedes Benz Mercedes Benz Mercedes Benz Bharat Benz INTERNATIONAL Ford Ford Ford KTM MANUFACTURERS Toyota Toyota Toyota Triumph 7 Honda Honda Honda Ducati GM GM Harley Davidson GM Fiat Fiat Fiat Piaggio Hyundai Hyundai Hyundai TVS Honda Maruti Suzuki Maruti Suzuki Maruti Suzuki Maruti Suzuki 2011 1990 2000 2017 Tata Motors Tata Motors Tata Motors Tata Motors Mahindra Mahindra Mahindra Mahindra 30 Hindustan Motors Hindustan Motors Force Motors Force Motors Premier Force Motors Hindustan Motors Hindustan Motors Force Motors Ashok Leyland Ashok Leyland Ashok Leyland Ashok Leyland DOMESTIC Source : ACMA MANUFACTURERS
Automotive Clusters in India
CONTENTS INDIA - A VIBRANT ECONOMY HISTORY OF INDIAN DIE CASTING INDUSTRY PRESENT STATUS OF INDIAN DIE CASTING INDUSTRY AUTOMOTIVE - THE LARGEST CUSTOMER OF DIE CASTING IN INDIA CUSTOMER EXPECTATIONS TECHNOLOGY IN INDIAN DIE CASTING INDUSTRY TO MEET CUSTOMER EXPECTATIONS FUTURE OF DIE CASTING IN INDIA ABOUT ALUCAST
Quality Inventory & Management Just-in-time System Supply Near CUSTOMER Concurrent Zero EXPECTATIONS Engineering PPM Process Prototype Control to final through latest Subassembly technology
CONTENTS INDIA - A VIBRANT ECONOMY HISTORY OF INDIAN DIE CASTING INDUSTRY PRESENT STATUS OF INDIAN DIE CASTING INDUSTRY AUTOMOTIVE - THE LARGEST CUSTOMER OF DIE CASTING IN INDIA CUSTOMER EXPECTATIONS TECHNOLOGY IN INDIAN DIE CASTING INDUSTRY TO MEET CUSTOMER EXPECTATIONS FUTURE OF DIE CASTING IN INDIA ABOUT ALUCAST
Die Casting Technology in use Tool Design and Engineering CAD SYSTEM COMPUTER SIMULATION PROCAST FLOW and SOLIDIFICATION CAD SYSTEMS CAD SYSTEMS MAGMA FLOW ANALYSIS AUTOCAD UNIGRAPHICS NX MAGMA SOLIDIFICATION ANALYSIS SDRC NX I-DEAS AUTOCAD INVENTOR FEA ANALYSIS: I-DEAS, ANSYS and NASTRAN PRO-E CATIA
Die Casting Technology in use UPGRADATION UPGRADATION AUTOMATION ENHANCEMENT QUALITY Enhanced High degree of Large Die Casting Quality Management manufacturing Units invested automation of Systems in place, duly capacity. machines for adequately in modern certified by production, inspection, machines and International Agencies. Capability to meet material handling and equipment with latest customer’s technologies. traceability. requirements well established.
CONTENTS INDIA - A VIBRANT ECONOMY HISTORY OF INDIAN DIE CASTING INDUSTRY PRESENT STATUS OF INDIAN DIE CASTING INDUSTRY AUTOMOTIVE - THE LARGEST CUSTOMER OF DIE CASTING IN INDIA CUSTOMER EXPECTATIONS TECHNOLOGY IN INDIAN DIE CASTING INDUSTRY TO MEET CUSTOMER EXPECTATIONS FUTURE OF DIE CASTING IN INDIA ABOUT ALUCAST
FUTURE OF DIE CASTING IN INDIA The automobile and electrical industry in India consumes 70% of die cast ● Aluminium parts. ● The recent past has seen the birth of many alternate sources of power to propel vehicles. ● Most of these involve disruptive technologies and are in a nascent stage. ● The future will demand lighter materials as compared to Steel & Cast Iron to compensate for the additional weight of lithium ion batteries. ● Thus increasing the percentage of use of Aluminum and other composite materials. ● The future is still unclear on the way forward, if it is electric or hybrid and this will significantly change the dynamics of the Aluminum High Pressure Die Casting Industry.
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