Transcript ISHAAN ENGINEERING

ISHAAN ENGINEERING
 MISSION:-To become a reliable partner in supplying
aluminum/zinc castings, keeping high quality
standards and performance.
 VISION:-To manufacture and supply products with
ultimate quality, precision and customer satisfaction.
HISTORY
 Ishaan Engineering was established by late Shri Jitendra M.
Shah, Mr. Nimish J. Shah & M/s. Amkay die-casting
Industries.
 M/s. Amkay die-casting industries was established by late
Shri Jitendra M. Shah in 1959 in Mumbai. In 1969 it was
shifted to Vapi, 160 Kms from Mumbai.
 In 1976 we started another unit at Daman, U.T. and then in
1990 in Bengaluru.
 In 1996 M/s. Ishaan Engineering was established at Dadra
& Nagar Haveli. Ever since we have been established, we
have maintained the company’s reputation and continued
the tradition of quality die-casting products and customer
service and satisfaction.
ABOUT US
 Established in 1997.
 Holding a past experience of 54 years in die-casting.
 Presently having 8 PDC machine, 2 GDC machines and 1
Hot chamber machine with output of 1000 metric tons p.a.
 ISO 9001-2008 certified company and also follow SIX
SIGMA quality standards in our manufacturing process.
 Ishaan Engineering is a well know company engaged in
manufacturing of non-ferrous aluminium and Zinc metal
castings for last 17 years.
 We have 2 manufacturing units, one located at Dadra &
Nagar Haveli, Silvasa and second located in Vapi,
(S.Gujrat). Both of our units are just two and half hours
from Mumbai.
COMPANY PROFILE
 The facilities we have are:1.
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8.
CAD/CAM centers.
Tool Designing and manufacturing.
Pressure and Gravity Die-casting machines .
Filling, fettling, grinding and sanding of machines.
Vibro-benz for burr removal.
Drilling and tapping of machines.
Shot blasting of machines.
CNC Turning center.
 Our turn-over grew from ₹4 million to ₹120 million
in the following years of establishment.
 We have CCTV facility, which keeps our plant and
other departments updated to our head-quarter.
 We contribute to environment by changing our
initial oil fired furnaces into electric/gas fired
furnaces, thereby decreasing the amount of
pollution, heat, losses, health hazard and increasing
human and plant efficiency.
OBJECTIVES
 Dispatch of the job as per-committed schedule.
 Procurement of the material as per schedule.
 The products shall be developed as per the committed
time.
 Rejection shall not be more than 3%.
 To increase sales turn over minimum @ 25% every year.
 To reduce customer complaint minimum @ 50% every
year.
 All suppliers to fall within acceptable range of minimum
80% rating.
CONCEPTS OF DIE DESIGN
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2D / PDF drawings.
3D model of component.
3D model of complete Die.
Casting simulations.
Die-casting parameter calculations.
Die steel selection.
Die manufacturing.
Heat treatment.
Stress reliving.
Nitriding.
MATERIAL SELECTION & DIE MANUFACTRING
PROCESS
MOULD
BASE
MATERIAL
• C-45
• MILDSTEEL
• EN-9
PUNCH
CAVITY
MATERIAL
•
•
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HDS-11
HDS-13
BOHLER
ASSAB
THYSSU
N KRUP
• DIODO
• POLDY
DIEMANUFACTURING PROCESS
• ROUGHING
• CNCMACHING
• SPARKING
• HEAT
TREATMENT
(PRIMARY)
• WIRE CUTS
• SPARKING
• CNC
MACHING
• GRINGING
• POLISHING
• ASSEMBLY
HEAT
TREATMENT
• NORMAL
SALT
BATH
• VACCUM
H/T
• HARDNE
RC
48/50
NITRIDING
SAMPLE
• SALT
• SAMPLE
BATH
• GAS
APPROVAL
NITRIDIN
G
OUR DIE CASTING FACILITIES
Pressure die
castings
(8-HMT
Buhler)
Gravity die
casting
80 ton
120 ton(2)
160 ton
180 ton
250 ton (2)
400 ton
Vertical
die-casting
Horizontal
die-casting
 All the furnaces are electronically temperature
controlled.
 In PDC we manufacture aluminium castings ranging
from 20gms to 3kgs.
 In GDC we manufacture aluminium castings ranging
from 200gms to 10kgs.
 Over head cranes for loading and unloading of dies.
 Independent maintenance department.
DIE CASTING PROCESS
SECONDARY PROCESS
Trimming of
castings
Machining CNC /
conventional
Inspection and
checking
Manual cutting / Bend saw
cutting
Shot blasting
Filing, fettling, grinding
and sanding.
Vibro-benz finishing
WHAT DO WE DELIVER
 Specialized in Pressure die-casting (PDC) and Gravity
die-casting (GDC).
 We deliver 3.06 million castings per annum.
 We manufacture 20 gram to 3.00kgs in pressure die
casting and 200 grams to 10.00kgs in gravity die
casting.
 We deliver shot blasted, dully CNC machined castings
ready to assemble.
QUALITY CONTROL INSTRUMENTS
 We at Ishaan Engineering are very particular about our quality measure
and hence consider the following steps for every machine:1.
Digital vernir
2. Bore gauge
3. Dial indicator
4. Finger dial with magnetic stand
5. Thickness gauge
6. Thread gauges
7. Go-No-Go gauges
8. Air gauges
9. Ring gauges
10. Jigs and fixtures
11. Dead center to check ovality
All the instruments are calibrated at regular time period.
CPK / GAUGE R&R
 We maintain 1.66 CPK in end covers bearing bore.
 Run out between bearing bore to spigot diameter is
maintained in 20 microns.
 In conventional machining bore diameter is
maintained with 80 microns.
 We conduct periodically gauge R&R analysis.
QUALITY POLICY
 We at Ishaan engineering are committed to develop
and manufacture consistent quality Aluminium & Zinc
castings as per our customer requirements and supply
to them in time to their total satisfaction.
 We are committed to our continual improvement in
our products & supply quality castings by maintaining
process parameters, technical up-gradation and
implementing “Quality Management System”
involving all employees.
FOCUS AREA
 Setting up an independent Quality-Control
(QC)department.
 Controlling and Monitoring of Parameters during
process.
 Checking of blow holes at regular intervals by various
methods.
 Using Go-No-Go gauges for the final checking.
MILESTONES
 Thin wall, less taper castings
 85 tons output in a month
 1.67 CPK in machining
 2.67% rejection per month
FUTURE PROCUREMENT
 180 ton die-casting machine
 CNC machining center
 Pneumatic power press
 Hanger type shot blasting machines
 Multi spindle drilling and tapping machines
 EDM machine
 Hoist
TOOL ROOM AND DIE MAKING
DIE CASTING AREA
DILLING TAPING AND CNC
DISPATCH
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