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Page 1: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

www.alicongroup.co.in

Page 2: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified. ALICON GROUP

2

Alicon group is a global consortium of companies involved in Design, Engineering, Casting, Machining and Assembly, Painting and Surface Treatment of Aluminum Components.

Group Sales USD 133 million. One of the largest Aluminum foundry in India and Slovakia. Joint Venture with Enkei Corporation (Japan) Technical Collaboration with Hekikai Koki (Japan) Core Competence:

• Rapid Prototyping • Designing (CAD/CAM/CAE/Simulation) • In house Tool Manufacturing • Die Casting (Sand Casting/GDC/LPDC) • Testing • Machining, Assembly & Painting.

Casting for Automotive, Locomotive, Medical, Energy and Agricultural and Aerospace segments.

DUNS: 650653579

Page 3: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

3

ESTABLISHMENT

ALICON – 44 years of casting the future in Aluminium. India’s pioneer in LPDC. (2819 Employees)

ILLICHMANN – 83 years of proven global track record in Aluminium Castings. (182 Employees)

MANPOWER Total – 3001 Employees Design & Development Team – 153 Engineers

FACILITIES

10 Manufacturing Plants (1 International)

Technology centre

2 Globally competent Tool rooms (1 International)

Quality & Testing Laboratories

Full Fledged Machine Shop (including sub-assembly facility)

CASTING PROCESSES

GDC (Stationary, Tilting & Durville) (0.027 Kg – 42 Kg)

LPDC (Conventional & Pie System) (0.14 Kg – 49.9 Kg)

Sand Casting (0.16 Kg – 300 Kg)

Products Manufactured for AUTO SECTOR:

Crankcase Intake Manifold Cylinder Heads Bridge Fork Top Brackets (Transmission & Engine Mounting) CAC Tank Oil Sump CAM Box Swing Arm

ALICON GROUP

Page 4: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

4

VISION: Become the globally preferred supplier for Light Alloy Casting Solutions. MISSION: Grow the employees, associates and suppliers. Ensure total customer satisfaction. Increase shareholder value. VALUES: Quality, Integrity and Respect. Encourage Entrepreneurship. Ownership and Accountability. Commitment to the Environment and Community.

THE CORPORATE PLEDGE

We amalgamate the best of European engineering, Japanese Quality and Indian Ingenuity to produce exceptional and innovative aluminum casting products.

Page 5: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

5

SALES DISTRIBUTION

LPDC - 63% USD 88.8 million

GDC - 36% USD 50.8 million

Sand Casting – 1% USD 1.4 million

DOMESTIC 81%

GLOBAL vs DOMESTIC SALES PROCESS WISE SALES

* Enkei wheel division formulated as a separate company from April 2010

onwards.

Group sales forecasted to be around USD 150 million for FY 2013-14.

GLOBAL 19%

57 72 75 78

*107

129 133

9

28 25

38

0

20

40

60

80

100

120

140

2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13

Wheel

Foundry

Page 6: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

6

STRATEGIZING – AUTO & BEYOND

DIVERSIFYING DE-RISKING SEIZING OPPORTUNITIES

The 3 words that sum up the core of our well planned holistic business strategy A diversified yet focused strategy tapping customers across several sectors is what we look forward to. A strategy giving us the recognition of a brighter future, a future that looks beyond business.

What we build today is what we carry into the future...

Zero PPM consistently for over 15 months

100% Customer Satisfaction – DELIVERY

& QUALITY

• Strategic approach for significant presence in Agriculture, Energy, Medical & Healthcare, Defense, Infrastructure, Locomotive, Aerospace & Nuclear. • Wider Non-auto customer base access through acquisition of Illichmann Castalloy - Europe.

Page 7: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

7

TWO WHEELER OEM

FOUR WHEELER OEM

TIER 1 & NON AUTO

AND MANY MORE..

Page 8: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

Atlas Castalloy Ltd (1969) Alicon Castalloy Ltd, Pune (1995) Silicon Meadows Design Ltd.(1996) Alicon Castalloy Ltd, Binola (2006) Silicon Meadows Engineering Services Ltd. (2009)

EUROPE

INDIA

• Illichmann Castalloy GmbH, Austria • Illichmann Castalloy s.r.o. Slovakia

8

GLOBAL PRESENCE

Page 9: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

PROPOSED

Alicon Castalloy Limited, Pantnagar - Uttaranchal.

Atlas Castalloy Limited, Chinchwad, Pune (1969) (18.64°, 73.79°)

Alicon Castalloy Limited, Shikrapur, Pune.(1995) (18.69°, 74.11°)

Silicon Meadows Design Limited, Chinchwad, Pune (1996) (18.64°, 73.79°)

Silicon Meadows Engineering Services Limited, Viman Nagar, Pune. (2009) (18.57°, 73.91° )

Alicon Castalloy Limited, Binola, (outskirts of Delhi) Haryana. (2006) (28.34°, 76.86°)

9

PRESENCE in INDIA

ALICON GROUP PROFILE

1969 - Atlas Automotives Limited established in Chinchwad with Technical collaboration with Carl Smith – Germany for Low Pressure Die Casting Technology transfer. First in India.

1992 - Pegasus Castalloy Limited established at Shikrapur Pune.

1995 - Pegasus Castalloy Limited and Enkei Corporation Japan join hands together for operations in India and bring Alloy Wheel Technology to India. Pegasus Castalloys Limited changed to Enkei Castalloy Limited.

1996 - Silicon Meadows Design Limited set up for support in Tool Design and manufacturing.

2006 - New plant set up in Binola (Haryana – outskirts of Delhi) to cater to the additional capacity demand in Auto sector.

2009 - Demerger of Enkei Castalloy Limited into Alicon Castalloy Limited for all types of Auto/ Non auto Business and Enkei Wheels India Limited for Alloy Wheels Manufacturing.

2009 - Silicon Meadows Engineering Services established to cater to engineering and design needs of Alicon Group & external clients.

2010 – Illichmann Castalloy merger with the Alicon Group.

2011 – TS16949, ISO 9001, ISO 14001 & OHSAS 18001 certified. In-house R&D Unit recognized by the Department of Scientific and Industrial Research, Ministry of Science & Technology, Government of India.

PROPOSED

Alicon Castalloy Limited, Bhiwadi - Rajasthan.

Page 10: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

10

Zarnovica / SLOVAKIA

GDC & LPDC

Vienna (Wien) / AUSTRIA

Marketing & Logistics Centre

ILLICHMANN FACILITY - AUSTRIA & SLOVAKIA

Page 11: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

83 years of proven track record.

Magma & Pro-Cast Soft Casting Simulation.

Specialty in Handling Low Volume

Intricate Castings.

44 years of proven track record for cost competitiveness learning's from Indian Market.

One of the Largest Foundry in India which offers frugal engineering solutions

Pioneer Users of Pro-Cast and Magma in India.

Capabilities of Handling both low and High Volume.

Value Added services like machining, painting and surface treatment.

To serve the customer with low and high volume parts from Europe and India locations.

De-risking customers from currency fluctuation.

Providing the better options by using strengths & ability of both the organization.

11

ILLICHMANN INTEGRATION WITH ALICON GROUP

Page 12: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

SILICON MEADOWS ENGINEERING, PUNE, INDIA.

SILICON MEADOWS DESIGN CENTER, PUNE, INDIA.

12

ILLICHMANN DESIGN CENTER, AUSTRIA

ENGINEERING & DESIGN CENTRES – INDIA & EUROPE

Page 13: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

ALICON CASTALLOY LIMITED BINOLA, DELHI, INDIA

ATLAS CASTALLOY LIMITED CHINCHWAD, PUNE, INDIA

ALICON CASTALLOY LIMITED SHIKRAPUR, PUNE, INDIA

ILLICHMANN CASTALLOY, GMBH & S.R.O

13

PRODUCTION FACILITIES – INDIA & EUROPE

Page 14: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

CORE SHOP FACILITY TILT GDC DIE CASTING FACILITY CELL – CASTING & MACHINING (ONE PIECE FLOW)

CORE SHOP FACILITY TILT GDC DIE CASTING FACILITY LPDC DIE CASTING FACILITY

14

RAPID PROTOTYPING FACILITY

SAND CASTING FACILITY

PLANT FACILITIES – INDIA & EUROPE

Page 15: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified. CYLINDER HEADS – THE ALICON EXPERTISE

Cylinder Heads constitute about 54% of the products manufactured at Alicon. Hence deep expertise developed.

About 72 different types of Cylinder Heads manufactured over the last four decades [(4W (10%), non-auto (25%) and 2W (65%)].

Clients ranging from local to international OEMs who have a brand loyalty towards us owing to our immaculate quality.

Certified by International Organizations and awarded by Clients and hence recognized and preferred within the engineering fraternity.

Types of Cylinder Heads Manufactured in LPDC & GDC:

Diesel Cylinder Head for multi-cylinders. Diesel Cylinder Head for single cylinder. Petrol Cylinder Head for multi-cylinders. Petrol & CNG Engine for single cylinder.

15

Types of Al alloys used in Cylinder Heads:

AC4B AC4C LM9 LM16 LM25

AlSi7Mg AlSi9Mg AlSi10Mg AlSi11Mg Alsi12Mg

AlSi9Cu3 AlSi12CuMgNi LM9+2%Cu

CYLINDER HEAD, 54%

CRANK CASE, 9%

MANIFOLD, 6%

BRACKETS, 5%

HEAD COVER & BFT, 2%

OTHERS, 11%

NON AUTO, 13%

Page 16: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

16

LEADING DOMESTIC FOUR WHEELER OEM

Single Cylinder; DIESEL; Water Cooled. LPDC

LEADING DOMESTIC NON-AUTO OEM

Single Cylinder; DIESEL; Air Cooled. GDC

LEADING GLOBAL TWO WHEELER OEM

Single Cylinder; PETROL; Water Cooled. LPDC

LEADING DOMESTIC NON-AUTO OEM

Single Cylinder; DIESEL; Air Cooled. LPDC

LEADING DOMESTIC FOUR WHEELER OEM

Single Cylinder; DIESEL; Water Cooled. LPDC

LEADING GLOBAL TRUCK OEM

Single Cylinder (x8); DIESEL; Air Cooled. LPDC

LEADING DOMESTIC FOUR WHEELER OEM

Four Cylinder; PETROL; Water Cooled. GDC

LEADING DOMESTIC FOUR WHEELER OEM

Two Cylinder; DIESEL; Water Cooled. LPDC

PRODUCT GALLERY – CYLINDER HEADS

Page 17: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

17

AIR INTAKE PASSAGE A

AIR FLOW JOINT COMP

JOINT INTERCOOLER INLET JOINT INTERCOOLER OUTLET

AIR INTAKE PASSAGE B

INTAKE MANIFOLD

Single source supplier for 6 components for a new 1.6L diesel engine for Internationally renowned OEM and parts exported to the UK.

PRODUCT GALLERY – 4W

Page 18: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

18

Innovative Eco-friendly thin wall casting. Wall thickness is min 3.5 +_0.5mm.

DROSSELKLAPPENSTUTZEN, R5 TFSI

DAMPER FLAP CONNECTOR

TTRS

A3RS

EGR values under development.

PRODUCT GALLERY – 4W

Page 19: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

19

INTAKE MANIFOLD

INTAKE MANIFOLD

MANIFOLD

INTAKE MANIFOLD

PRODUCT GALLERY – 4W

Page 20: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

20

W201 INTAKE MANIFOLD

INTAKE MANIFOLD INTEGRATED MANIFOLD – NANO

INTAKE MANIFOLD – 3L

PRODUCT GALLERY – 4W

Page 21: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

21

TRANSMISSION CASTING LH & RH

PRODUCT GALLERY – 4W

Page 22: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

22

TOTA

L V

OLU

MES

FY 10 - 11 FY 11 - 12 FY 12 - 13

YOY Growth

8%

YOY Growth

37%

• Alicon Business share in the Indian Two wheeler segment is about 38%.

• Every 3rd Cylinder Head in the 2 wheeler segment on Indian roads is an Alicon Group product.

• Won several accolades from Customers in Capacity Enhancement, Quality Improvement, Design & Development and Delivery.

PRODUCT GALLERY – 2W

Page 23: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

23

CYLINDER HEAD BRIDGE FORK TOP

HEAD LAMP COVER

BRIDGE FORK TOP

PRODUCT GALLERY – 2W

Page 24: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

24

FRONT WHEEL HUB REAR WHEEL HUB

FRONT FORK ARM

SWING REAR ARM

PRODUCT GALLERY – 2W

Page 25: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

25

CARRIER FOOT REST

SWING ARM WHEEL HUB

CYLINDER HEAD COVER

CYLINDER HEAD

PRODUCT GALLERY – 2W

Page 26: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

26

PRODUCT GALLERY – TRUCKS

HOUSING FLYWHEEL

CONNECTION WATER INLET

HOUSING OUTER CASE 6 CYLINDER (N6)

CAC TANK (MODULE -1)

Page 27: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

27

UN DISCLOSED MODEL

UNDER DEVELOPMENT.

UN DISCLOSED MODEL

UNDER DEVELOPMENT.

INTAKE MANIFOLD

COVER VALVE - ROCKER ARM COVER

CYLINDER HEAD 115E

PRODUCT GALLERY – TRUCKS

Page 28: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

04.2013 Together We Make It Happen www.alicongroup.co.in

Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

28

CYLINDER HEAD

OIL SUMP FLYWHEEEL HOUSING

ASSEMBLY THERMOSTAT BODY ( 3.0 L )

THERMOSTAT COVER (5.0 L)

WATER DISTRIBUTION RAIL ( 5.0 L )

PRODUCT GALLERY – TRUCKS

Page 29: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

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Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

29

SMALL COMMERCIAL VEHICLE-MINI-TRUCK

Component : Cylinder Head Weight : 6.6 kg Process : Low Pressure Die Casting Supply To : TML Patnagar Supply From : India Vehicle : Tata Ace

Component : Cylinder Head Weight : 2.7kg Process : Low Pressure Die Casting Supply To : Greaves Cotton Supply From : India Vehicle : Tata Ace Zip/Magic Iris

Component : Crank Case Weight : 9.2kg Process : Low Pressure Die Casting Supply To : Greaves Cotton Supply From : India Vehicle : Tata Ace Zip/Magic Iris

We are having the highest SOB in Tata Ace-Cylinder Head since its launch in 2005

We also supply Cylinder Head and Crankcase to Greaves cotton from 2012 The above parts gets assembled in Tata Ace Zip and Tata Magic Iris

AN ASSOCIATION OF TRUST FOR 8 YEARS (2005 – 2013)

PRODUCT GALLERY – MINI-TRUCKS

Page 30: Alicon Castalloy Ltd, Pune - Alicon Group Companiesalicongroup.co.in/images/Alicon Latest Presentation.pdf · and Assembly, Painting and Surface ... PROCESS WISE SALES GLOBAL vs DOMESTIC

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Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

30

PRODUCT GALLERY – AGRICULTURE

PIPE

INSPECTION COVER

VALVE COVER

CLUTCH COVER FRONT BEARING HOUSING

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Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

SKI AND SEA DOOS

AERO ENGINES

31

• A total of 10 components being supplied including Cylinder Heads & Housing Halves.

• Housing halves left / right 3500 units / year. • Cylinder Heads left / right 6500 units / year.

HOUSING

COVER

CYLINDER HEAD

CYLINDER HEAD

HOUSING VALVES

PRODUCT GALLERY – AERO & MARINE

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Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

32

PRODUCT GALLERY - RAILWAY

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Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

33

MACHINED CT FLANGE MACHINED FAST EARTHING SWITCH ENCLOSURE

FAST EARTHING SWITCH BEHIND HOUSING

HOLDER CONTACT SPHERE TOGGLE LEVER T155/3 MECHANISM

PRODUCT GALLERY – ENERGY

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Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

34

PRODUCT GALLERY – NON-AUTO

PULLEY FOR AERIAL TRAMS & ROPEWAYS

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Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

35

HOUSING

DOORLOCK

VALVE HOUSING CONSOLE

PRODUCT GALLERY – LOCOMOTIVE

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Casting The Future

TS 16949 | ISO 9001 | ISO 14001 | OHSAS 18001 certified.

36

HOUSING

HOUSING

PRODUCT GALLERY – NON-AUTO

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Vaccum pump components for Automotive sector Quantity : 5,000 pieces per annum Process : Gravity Die Casting

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PRODUCT GALLERY – NON-AUTO

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PRODUCT GALLERY – NON-AUTO

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INTAKE MANIFOLD

PRODUCT GALLERY

FA II HOUSING

DB HOUSING

BATTLE TANK VENTILATOR

OIL SUMP

CAM BOX

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RAPID PROTOTYPING (OBJET AND LOM METHOD) PROTOTYPES BASED ON RESIN MAX. SIZE 320 X 320 X 200 MM PRESENTATION- AND FUNCTIONAL MODELS

MODEL CONSTRUCTION – RAPID PROTOTYPING – CASTED PRODUCT

THIN WALL CASTING 1.8MM

CAD SYSTEM PRO-ENGINEER WILDFIRE 2 INTERFACE FOR STEP IGES VDA AND OTHERS TOOL DESIGN MAGMA CASTING SIMULATION

TECHNOLOGIES

• Gravity die casting

• Sand casting

• Low pressure die casting

• Rapid prototyping

• X ray Inspection

• CAD – Pro Engineer

• Magma casting

• Solidification

ALLOYS APPLIED

• Al Si 7 Mg Al Si 9 Mg

• Al Si 10 Mg

• Al Si 12

• Al Si 12 Cu Ni Mg

• Al Si 8 Cu 3

• Al Si 6 Cu 4

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TECHNOLOGY AND METHODS AT ILLICHMANN

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SAND CASTING - EUROPE

MOTOR CARRIER

CRANK SHAFT

CYLINDER HEAD COVER

CYLINDER HEADS

CYLINDER HEADS

GEAR HOUSING

GEAR HOUSING

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DESIGN & ENGINEERING CAPABILITIES

TOOLING SOLUTIONS

CAE CAD REVERSE

ENGINEERING TECHNICAL

PUBLICATIONS

CAD

CAE

CAM

PDM

TOOLING NEW PRODUCT DEVELOPMENT

COMPUTER AIDED ENGINEERING

COMPUTER AIDED DESIGN

REVERSE ENGINEERING

TECHNICAL PUBLICATIONS

83 26 9 28 5 2

We have a highly qualified and experienced R&D Team of 153 Engineers within the following disciplines:

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PHYSICAL COMPONENT BEING SCANNED GEOMETRY | COUNTOUR | COORDINATE MEASUREMENT

2D DRAWINGS & 3D MODEL OF THE PART AS OUTPUT

ENGINEERING CAPABILITIES – REVERSE ENGINEERING

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DURO DZ HEAD LIGHT & SPEEDO CASE COVER.

MOJO HEAD LIGHT AND SPEEDO CASE COVER ASSEMBLY. SPEEDOMETER

REAR GRAB RAIL FUEL TANK

CHAIN COVER

SEAT COVER REAR MUD GUARD

CAD models obtained from Reverse Engineering. CAD comparison using white light scanning .

Finite Element Analysis carried out for Headlight and Speedo Case Assembly.

BEYOND MANUFACTURING – REVERSE ENGINEERING & FEA (CAE)

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TEMPERATURE

FRACTION SOLID

FILL TRACER

TENSILE STRESSES

ENGINEERING CAPABILITIES – CASTING SIMULATIONS (MAGMA)

SOLIDIFICATION

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TOOL ROOM FACILITIES - INDIA

Presently manufacturing 20 tools per month.

Equipped with State of Art Machines

• CNC- MAKINO, MICRON, HARTFORD

• VMC

• EDM

Quality Assurance Equipments:-

• CMM

• FARO ARM

Additional Machinery for 2013-14

• 5th Axis VMC from DMG.

• CNC Wire EDM and Wire Cut Machine.

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Dedicated Core making workshop. Core making by the following 3 process:

• Shell Core Moulding • Hot Box Moulding • Cold Box Moulding.

Capable of making complex cores for intricate castings.

GRADE AFS No. -ASTM

(BSS) HOT TENSILE STRENGTH –

PSI (Kg/cm2)

LOSS ON IGNITION

( % )

SCRATCH HARDNESS

A 67 – 74

(77 – 82) 142.33 - 206.23

(10 – 14.5) 2.0 – 2.6 65 – 80

B 55-60

(63 - 68) 213.34-256.01

(15.0-18.0)

2.0 – 2.6

65 – 80

C 55 – 60

(62 – 67) 401.09 – 500.66 (28.20 - 35.20)

2.8 – 3.5

75 – 90

D 70 – 75

(77 – 82) 192.01 – 234.68 (13.50 – 16.50)

2.3 – 3.0

65 – 80

KS 47 55 - 60 156.45 - 213.34 (11.00 – 15.00 )

2.0 – 2.5 65 - 80

65/24D 70-75 15 - 20 3.0 to 3.5 80 - 95

SPECIFICATION FOR CORE SAND

DIFFERENT CORE COLOURS

CORE SET

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CORE MAKING CAPABILITIES

SAND MIXER MACHINES COLD BOX CORE

COLD BOX - TYPE NOVA (1) Silica Sand VFS 45~50 (2) Core Strength 85 (3) MK 0.303 (4) Silica Sand PH 7.2 (5) Resin less than 1%

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CORE MAKING METAL MELTING CASTING KNOCKING

BAND SAW

HEAT TREATMENT

FETTLING LEAK TESTING INSPECTION PACKAGING

CUSTOMER DEDICATION – ONE PIECE FLOW - DURVILLE SYSTEM (GDC)

PIONEERS OF THE UNIQUE Durville (DRC) SYSTEM IN GDC

• Dedicated work space for a product.

• Core making, Metal Preparation, Die casting, Mechanical Decoring, Heat treatment, Sand Blockage

Inspection, Washing, Leak Testing, Final Inspection, Packaging and Dispatch in a confined area.

• Speedy manufacturing and enhanced customer satisfaction.

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PIONEERS OF THE UNIQUE PIE SYSTEM IN LPDC

Completely enclosed system. Pressurized furnace.

No exposure to atmosphere (negligible moisture contamination).

No metal transfer from melting to holding.

Advanced technology with latest feature for temperature control, pressure control and metal quality round the clock.

High Productivity, low rejection and process repeatability achieved via this process.

Low Maintenance required.

INNOVATIONS - PIE SYSTEM (LPDC)

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MANUFACTURING FACILITIES – ONE PIECE FLOW

Our plants are well organized with a quick feedback through one piece flow which enables us to detect defects at an early stage during WIP and consequently give a rapid feedback to the casting operators which helps us reduce rejections.

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MACHINERY & EQUIPMENTS - EUROPE

4 HIGH-END LPDC MACHINES FOR QUALITY CASTINGS IN EUROPE.

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T4 Solutionizing.

T5 Precipitation Hardening

T6 Solutionizing & Precipitation Hardening

T7 Solutionizing & Precipitation Hardening with air quenching

TB7 Solutionizing, precipitation hardening & Stabilizing

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HEAT TREATMENT

TYPE CAPACITY

CONTINUOUS 250, 350, 400. (in kg/hr)

DROP QUENCH 600, 800, 1000 (in kg/batch)

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MAZAK HMC

STATE OF ART MACHINERY

HASS HMC

DOOSAN DNM 650

MAKINO VMC • Quick pallet changer • Zero loading / unloading time

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4 axis horizontal high speed machining centers with manual loading (VMC, HMC & Turn Mill).

Washing (pre machining specifications < 2.0 mg). Leak testing; dry and dip type (1 to 2 cavities) and

Bench flow testing. Helium Leak Testing. CMM, Auto-gauging and Gage inspection, opening

detection holes (Fakir plate).

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QUALITY TESTING LABORATORY

INSERT FITMENT MACHINE LEAK TESTING MACHINE BENCH FLOW TESTING

HOT TENSILE TESTING SIEVE SHAKER SCRATCH HARDNESS TESTER

CORE GAS DETERMINATION

BENDING STRENGTH TESTING

SALT SPRAY TESTING

XYLON X RAY EQUIPMENT ZOLLER TOOL PRESETER

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LEAK TESTING MACHINE INSERT FITMENT MACHINE BENCH FLOW TESTING

TESTING FACILITIES

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HOT TENSILE TESTING SIEVE SHAKER SCRATCH HARDNESS TESTER

CORE GAS DETERMINATION BENDING STRENGTH TESTING SALT SPRAY TESTING

TESTING EQUIPMENTS

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The scan data is aligned to the CAD model by best fit alignment to find least error.

LASER SCANNING - COMPARISON CAD VS REALITY

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XYLON X RAY EQUIPMENT

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OPERATIONAL SOURCE: 150 – 250 kV DEPTH :100 – 150 mm

Y.TU 160-D06 with Diaphragm

Specimen XRD 0820

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ZOLLER TOOL PRESETER

Tool Setter to measure cutting tool accuracy.

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TESTING SYSTEMS

FARO ARM – CMM INSPECTION

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SAFETY & ENVIRONMENT PRACTICE OF LDD CREATING DECISIVE LEADERS 5S METHODOLOGY

5S METHODOLOGY EMPLOYEE ENGAGEMENT NURTURING TEAMS SINCERITY & INTEGRITY

EMPOWERMENT INNOVATION & CUSTOMER DELIGHT GREETING & HIGH SPIRIT

PERSEVERANCE IN CASE OF FAILURE VISION & BENCHMARKING FOLLOW ALICON VECTOR

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BEP Management Kaizen Break-Even Point

Improve Value Added Ratio * Reduce Fixed Cost * Increase Productivity

MIND SOUL BODY HEART

Together, We Make It Happen

ALICON VECTOR

• One Path, One Goal • Holistic Member Engagement • We Measure what we Value • We live the Alicon DNA

ALICON STRENGTH – OUR EMPLOYEES

KAIZEN TRAINING YOGA SESSIONS

FAMILY GATHERINGS TECHNICAL TRAINING

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Alicon practices several green initiatives which includes maintaining green areas with treated effluent water and enhancing green cover around our premises.

ENVIRONMENT FRIENDLY FOUNDRY

0

200

400

600

800

1000

2009-10 2010-11 2011-12 2012-13

TREE PLANTATION DRIVE

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Largest footprint in India & having presence in India, Europe & USA.

Provide value added solution through knowledge sharing between group companies.

Design Engineering Casting of Aluminum Component Value Added services like machining, painting and surface treatment.

One of the biggest foundry infrastructure in India. Ability to handle both low & high volumes. Total solution for Aluminium castings under one roof.

CORE BUSINESS

STRENGTH

FOOT PRINTS

COMMITMENT

Alicon Group is a single point contact for all engineering solutions.

ALICON GROUP CONCEPTS

It is easy to grow but difficult to sustain but at Alicon we have been

growing at a rapid pace and yet emerging as the No. 1 supplier choice.

QUALITY : Zero PPM

Full Traceability Zero Warranty Claims Project Management

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Alicon group focuses on producing exceptional and innovative aluminum castings. To consistently achieve this, we have strategically integrated our PQCDDME with international technology, strong customer support & employee development plans.

Alicon group believes that it’s core strength is in its people and continues to invest in the development of its human capital.

Alicon group is committed to strong customer support & takes advantage of time zones to provide 24x7 support to its global clientele.

Strong In-house Design & Tool Room facilities & Technical JV with world leaders.

Focus on Productivity, Quality, Cost, Delivery, Development, Morale & Environment (PQCDDME) with full focus on continuous improvement.

STRATEGIC INTEGRATION TECHNOLOGY

STRONG CUSTOMER SUPPORT

EMPLOYEE DEVELOPMENT

WHY ALICON GROUP

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ALICON CASTALLOY LIMITED І Gat No. 1426, Shikrapur, Tal. Shirur, District Pune – 412208. Maharashtra, INDIA. (18.69°, 74.11°)

Tel : +91 (0) 2137 677100 І Fax : +91 (0) 2137 677130

CONTACT US

India Contact :

MR. SHEKHAR DRAVID |VP - Business Development | EMAIL : [email protected] | PHONE : +91 98607 94387

www.alicongroup.co.in

MR. RAJEEV SIKAND Group CEO EMAIL : [email protected] PHONE : +91 98905 60099

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NAMASTE – The heart & soul of our culture.

NAMASTE