Project Report

A Project Report On

“Industrial Visit to SAKAR Industries Limited”

Submitted to

Chimanbhai Patel Institute of Management and Research.

Class: - Semester II (M.B.A)

Division: - A

Project Guide: -

Prof. Richa Pundit & Prashant Barot

Submitted By: -

Himanshu Dhadnekar (33)

Ridhi Choudhary (28)

Neha Jain (56)

Ankush Ghadia (37)

DhanrajSingh Raghuvanshi (50)

CERTIFICATE

This is to certify that a group project report on “SAKAR Ferro

Alloys Limited” has been submitted to Chimanbhai Patel

Institute Of Management And Research (Affiliated to Gujarat

Technical University) in partial fulfillment of practical studies

of Semester II of Master’s Of Business Administration

Programmed 2011-13.

For, Chimanbhai Patel Institute of Management and Research

------------------- ----------------- Coordinator Project Guide

Name of students: Roll No.

Himanshu Dhadnekar 33

Ridhi Choudhary 28

Neha Jain 56

Ankush Ghadia 37

DhanrajSingh Raghuvanshi 50

Place: Ahmedabad Date:

PREFACE

“The ability to capture communicates and leverage knowledge to solve problems is human power.” - Francis Bacon.

The practical training at M.B.A program develops a feeling about the difficulties and challenges in the business world. Only theory knowledge does not impart complete education, practical experience must accompany theoretical knowledge to add the meaning to education.

The main objective of the project is to study and analyze the Manufacturing process at the “SAKAR Ferro Alloys”. It provides a comprehensive version of the company’s performance.

To fulfill the objectives of this project we have tried our level best to present a project report based on our study.

ACKNOWLEDGEMENT

The satisfaction that accompanies the successful completion of any work would be incomplete unless we mention the name of the person, who made it possible, whose constant guidance and encouragement served as a beckon of light and crowned our efforts with success.” We consider it a privilege to express through the pages of this report, a few words of gratitude and respect to those who guided and inspired in the completion of this project.”

We are deeply indebted to Professors- M/s Richa Pundit and Mr. Prashant barot and our respected coordinator of MBA program Dr. Ashwin Dave for giving us the opportunity to undergo project and also provided their timely suggestions & valuable guidance.

They constantly encouraged us and showed the right path from day first till the completion of our project.

In last but not the least, our appreciation is also extended to all our faculty members, parents and friends with whose cooperation and support this project has been made successful.

Thank you.

Table Of Contents Introduction of Sakar Industries Limited. Objectives of the study. Product planning

1.1 Types of products.1.2 Raw materials requirements for products.

Facility Planning.1.1 Layout Format.1.2 Layout location.

Capacity Planning.1.1 Production capacity1.2 Maximum Capacity

Manufacturing1.1 Process of manufacturing.

1.2 Supplier for key components should be identified.1.1 Quality Assurance and Quality control of raw materials.

Process Analysis1.1 Types of processes.1.2 Product processes.1.3 Assembly of product.

Uses of the final products Exports and Import of products Major customers. Conclusions and findings. Recommendations. Bibliography.

Facility Layout

Project layout

It is the first and the foremost step for any production unit to

define its project layout. Project layout at Sakar alloys was a

“CONTINOUS PROCESS”

CONTINOUS PROCESS: - Is the process similar to an assembly line in

which the production process is predetermined in sequence stops,

but the flow is continuous rather than discrete.

Facility Location

Sakar Alloys have selected Sanand plant for the following reasons: -

1. Gujarat is growing state when the industrial growth is concerned, thus offer a best policies, political and economic environments.

2. Subsidies offered by the Gujarat government are profitable for industrial.

3. Infrastructure facilities like transportation, water & electricity supply. As Gujarat is one of best in generating Electricity also provide to states like Maharashtra and Madhya Pradesh.

4. Gujarat is the major hub for shipping industries; it has some of the major docks for transportation carried out from sea routes.

5. Environmental surroundings are favorable.6. Foreign Direct Investment (FDI) is very high in Gujarat thus

globalization is highly supported by Government of Gujarat.

Manufacturing

Processes

The manufacturing process at Sakar Ferro Alloys carried out in

the different units is same in nature. As alloys are the metals

produced with the mixture of two or more metals in their

required proportion.

1. Forming process.

2. Machining process.

3. Assembly process.

In this unit the process are in line and is followed and preceded by

the different processes.

Sequence of process: -

S 1: -

In the initial phase the nonferrous metals are heated in the furnace with high degree of temperature around 1000 Celsius.̊

S 2: -

Casting: - Casting is a manufacturing process by which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting.

S 3: -

Forging: - Forging is a manufacturing process involving the shaping of metal using localized compressive forces. Forging is often classified according to the temperature at which it is performed: "cold", "warm", or "hot" forging.

S 4: -

Extrusion: - Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed or drawn through a die of the desired cross-section. The two main advantages of this process over other manufacturing processes are its ability to create very complex cross-sections and work materials that are brittle. It also forms finished parts with an excellent surface finish. Aluminum wires are processed through this process for giving desired shape.

Desired shape is given to the metal. Aluminum Wire rods of different thickness, Aluminum ingots, Aluminum ferrous etc.

S 5: -

Dying, turning, milling: -

Desired moulds are prepared for giving the shape to the hot metal.

Hot molten materials are poured into these dies to acquire its final shape.

For example: -After the molten is generated into the furnace at the high temperature, the molten flow through the channel and reaches desired S 3 sequence of extrusion where moulds give shape to the molten, Now the output is unfinished thick aluminum rods, at this stage the metal is cooled down. S 4 sequence Aluminum wires are stamped well while cooling process to reduce its thickness and then turning the long rods into the lathe machine to give the form of desired thickness wire.

Quality assurance / Quality Control: -The main profile of the quality assurance and quality control department is to maintain the standards defined by the company for each raw material that are used in the production process.

QA / QC for Inward Material

Quality assurance / Quality control: -

This is the second phase where the quality of samples that are drawn from the furnace is measured and Spectro Analysis of the samples is carried on.

Spectro Analysis: -

Spectro analysis is the process of analyzing the components from the samples that are needed in specific quantities in the alloys for further use of the product. Computerized Machine is used for this testing which provides the necessary data according to predefined standards.

QA / QC for Production

Aluminum DE-OX

(De-oxidation aluminum)De-oxidation aluminum consists of alloys with a high share of aluminium (usually exceeding 95 %) in the form of pyramids, cones, ingots or wire rod which are used to remove free oxygen from the liquid steel. Sakar ferro supplies many major steel mills in India with high quality DEOX products.

Available in varying product forms like: 

•Aluminum Ingots: Weight – 5 Kgs, 8 Kgs & 15 Kgs • Aluminum Sticks: Weight – 1 Kgs & 2 Kgs • Aluminum Cubes or Pyramids: Weight- 50 gms & 100gms • Aluminum Shots or Granuals: Size range between 5mm to 10mm  All the above grades can also be made as per customer requirements of purity, diameter, weight and tensile strength.

It has the capacity to produce 2000 MT / month for Aluminum Deox. Which they produce according to their customer demands.

1.1 Scrap sources

One way of classifying scrap is to distinguish it according to its source; from the aluminium

processing (new scrap), and scrap from products after their use (old scrap).

New scrap is generated during the initial manufacturing processes.

All secondary aluminium residues are treated by refiners or re-melters. The composition of

new scrap is well known and in principle new scrap does not need any pretreatment process

before it is re-melted, although cutting to size might be necessary. New scrap could be

considered a by-product and not waste (Paragraph 1.7). New scrap with paint or coating,

excluding cable and composite material of aluminium and plastic may require special

processing.

Old scrap is collected after a consumer cycle, either separately or mixed, and it is often

Contaminated to a certain degree, depending highly on its origin and collection systems.

Since the lifetime of many metal products can be more than ten years and sometimes more

than 50 years, for instance products for building and construction, there has been an

accumulation of metal in use since the start of the industry.

According to industry, currently around 540 Mt of aluminium products are in use and nearly 8

Mt of old aluminium scrap was generated worldwide in the year 2004. Scrap generation has

doubled since 1990 and is expected to increase further mainly due to the continuous increase

of aluminium content in products such as vehicles over the last 15 years and the improved

Collection of packaging materials such as beverage cans. In the EU (data for EU-25), the total

recycled old scrap was 2 Mt in 2004 and the total aluminium in use amounted to nearly 120

Mt.

Another way to classify scrap sources is according to the products in which the metal was

used before it became a waste. The main aluminium scrap sources in this sense are vehicles,

metal Products for construction, cables and wires, electrical and electronic equipment and

packaging.

The key sources of aluminium scrap are

Construction and building 7%

Cable, wire, EEE and others 21%

Packaging 28%

Transportation facility and vehicles 44%

Environmental and health aspects

Energy use and GHG emissions

The production of secondary aluminium is estimated to consume 5 – 7 GJ per tonne due to the

improvement in recent years and the average total emission is about 350 kg of CO2 emission per

tonne of metal production. It has been reported that the production of one tonne of aluminium

from scrap requires only 7 % of the energy required for primary production (excluding bauxite

production).

Other air emissions

Dust and air emissions from scrap processing are generally at a low level. However, emissions

of hazardous air pollutants may be generated by the secondary metal production in a furnace,

e.g. dioxins and furans, metals/metal oxides. In the EU such emissions are controlled according

to permits under the IPPC directive. Emissions from furnaces are being managed by process

control and special flue-gas treatment. Risks related to scrap transportation and storage

Scrap metal in itself does not pose any risk to the environment, i.e. there are no environmental

risks in the transportation and storage of the metal itself. There is also no convincing evidence

of substantial leaching from coated or painted aluminium scrap metal. However, if metals are

contaminated with oil or mixed with other wastes, this may create hazards in relation to

transportation or storage. For example, oil or any other liquid attached to scrap metal, when

exposed to rain, may cause contamination to its surrounding environment.

Coatings and paints

Coatings can be divided into organic coatings (powders, pastes, liquids, film or sheeting),

inorganic coatings (manufactured from ceramics and cement mortar) and metallic coatings.

The mechanical handling of scrap and scrap processing removes some coatings as an effect of

the processing. In the case of shredding scrap metal, the processing in the hammer mill removes

most of the paint/coatings from the metal except for zinc coatings which remain mainly on scrap

fragments after shredding. The removed paint/coatings are separated from the scrap metal and

are collected into the shredder residue.

Some processes have a specific decoating step. Residual paint/coatings are removed in the metal

works as part of the process, either contributing to slag generation or air emissions. PVC and

other halogenated coatings may contribute to the generation of dioxins and furans. However, a

link on the composition of the input materials and the emissions of these substances has not

been demonstrated. The emissions are determined by the process and by treatment of the fluegas

Industries served:

Rolling and extrusion mills

Can sheet

Transportation

Steel

o Automotive

o Packaging

o Engineering

o Building and construction

o Electronics

MeltingAleris operates both reverberatory and rotary furnaces. Solid scrap aluminum is converted into liquid form during

the melting process. Throughout the melting process, additional alloying elements can be added to achieve a

specified chemistry required for various end-use needs. The molten metal can be cast into various shapes such

as ingot, RSI or Deox. 

Manufacturers rely on Aleris for recycled aluminum material that is processed in a consistent, high-quality

manner.  In a process known as tolling, Aleris accepts, inspects, shreds, separates, de-lacquers and melts

aluminum owned by its customers. After the melting process is completed, Aleris casts the aluminum and

delivers it to the customer. Products can be delivered to customers in the following forms:

Molten

Ingot

Sow

Deox cone

Casting Process

In casting, the molten aluminum from the melting process is poured into a mold allowing it to solidify into

particular shapes:

Low-profile sow

Several sizes of ingot

2-way sows

4-way sows

Deox cones

Aluminum DeoxidizersAleris produces a full range of aluminum deoxidizers for use in iron and steel production. All grades are produced

to conform to American Society for Testing and Materials (ASTM) Specification B-37-96 and meet steel industry

standards. Aluminum deoxidizers are available in a wide variety of shapes including:

Briquettes

Cones

Pyramids

Shot

Shreds

Uses of aluminium deox:

Deox Aluminum (ie. Grade 1) is produced in Shot, 2 and 4-ounce Cones and Pyramids, and 5-poundNotchbar form for use as a deoxidant in steel making

Deoxidation of steel through ladle refinement

An ingot is a material, usually metal, that is cast into a shape suitable for further processing.Non-metallic and semiconductor materials prepared in bulk form may also be referred to as ingots, particularly when cast by mold based methods.

INTRODUCTION

The ingot chain conveyer casting process is very commercially important to the aluminum industry, with hundreds of machines in operation and millions of tones cast every year by this method. In this process, cast iron moulds on a conveyer are fed with molten metal, usually by a wheel type filling system. The ingot moulds have a translational motion synchronized with the motion of the wheel. The flow thus generated is complex and highly three dimensional. These moulds are water cooled using a water spray or by immersion into a water bath. The machine is run at a speed such that the

22.5 kg ingots are solid when they reach the end of the conveyor where they are knocked out, cooled further and stacked into bundles. A typical production rate is around 18-20 tones per hour (Whitely, 1997). There are several major issues related to the manufacture of aluminum ingots of good quality at a competitive production rate. One of the important quality attributes of the ingots is the amount of dross present and the appearance of the ingot. This dross is produced during the filling of the mould. Smelter operators have a need to increase casting machine throughput. Inevitably this means that the filling time is reduced and there may be greater potential for more turbulence and dross generation. Some new machines with longer lines are running at rates of 24 tones per hr and there are plans for 30 tones per hour machines

Process:

The ingot chain conveyer casting process is very commercially important to the aluminum industry, with hundreds of machines in operation and millions of tones cast every year by this method. In this process, cast iron moulds on a conveyer are fed with molten metal, usually by a wheel type filling system The ingot moulds have a translational motion synchronized with the motion of the wheel. The flow thus generated is complex and highly three dimensional. These moulds are water cooled using a water spray or by immersion into a water bath. The machine is run at a speed such that the 22.5 kg ingots are solid when they reach the end of the conveyor where they are knocked out, cooled further and stacked into bundles. A typical production rate is around 18-20 tones per hour (Whitely, 1997). There are several major issues related to the manufacture of aluminum ingots of good quality at a competitive production rate. One of the important quality attributes of the ingots is the amount of dross present and the appearance of the ingot. This dross is produced during the filling of the mould. Smelter operators have a need to increase casting machine throughput. Inevitably this means that the filling time is reduced and there may be greater potential for more turbulence and dross generation. Some new machines with longer lines are running at rates of 24 tones per hr and there are plans for 30 tones per hour machines.

Pre-Processing

The pre-processing stage involves the creation of solid geometries for the different parts of an ingot casting assembly required for the SPH simulations. These are the feed launder, the ingot wheel and the ingot moulds. Using engineering drawings provided by ODT Engineering and including some design modifications, seven different solid models were developed using the CAD package SOLIDWORKS. The basic difference in these models was in the design of the wheel and/or the feed launder. The ingot mould geometry remained unchanged for all seven cases. An example of the SOLIDWORKS model for the base case consisting of the three component types is the solid models produced were then used to generate meshed surfaces with the 3D meshing software. An inflow flag is assigned to nodes at the boundary of the feed launder. Fluid particles (in this case liquid aluminum) are generated from these inflow locations at the end of the launder opposite the wheel and they flow along the launder, into the wheel and finally down into the ingot mould. Simulations

QA / QC for Inward Material

Abstract:

To provide a method for producing an aluminum ingot whose oxides is reduced by preventing the surface of molten aluminum from being oxidized. The method according to the present invention includes a melting step (melting furnace 1) of melting an aluminum base metal into a molten aluminum or molten aluminum alloy; a holding step (holding furnace 2) of holding the resulting molten aluminum or molten aluminum alloy; a dehydrogenation step (dehydrogenation unit 3) of removing hydrogen gas from the molten aluminum or molten aluminum alloy; a filtration step (filter 4) of removing inclusions from the molten aluminum or molten aluminum alloy; and a casting step (casting device 5) of solidifying the molten aluminum or molten aluminum alloy into a predetermined shape, wherein at least one of the above steps is conducted in the atmosphere of a protective gas containing fluorinating gas, carbon dioxide gas, and nitrogen and/or argon ..

An aluminum or aluminum alloy ingot (hereinafter referred to as aluminum ingot) is produced by a melting step of melting an aluminum base metal into a molten aluminum; a holding step of holding the resulting molten aluminum; a dehydrogenation step of removing hydrogen gas from the molten aluminum; a filtration step of removing inclusions from the molten aluminum; and a casting step of pouring the molten aluminum into a water-cooled mold so that the molten aluminum is solidified into a predetermined shape. 

In the production process (for example, the melting step and casting step) for producing the aluminum ingot from the aluminum base metal, the molten aluminum is heated to 700° C. or higher. Since aluminum is active metal, the molten aluminum will react with air to generate oxides. 

In order to prevent the surface flaw and cracking of the end-product and ensure the predetermined performance of the end-product, a plurality of oxides removing processes are performed between the melting step and the casting step, such processes including an in-furnace refining process, an in-line refining process and a filtering process (performed immediately before the casting step). Particularly, since the filtering process can remove even very fine oxides having a size of approximately 10 μm, the quality of the aluminum alloy can be ensured, which means the quality of the end-

product can be ensured.

Uses:

Ingots require a second procedure of shaping, such as cold/hot working, cutting or milling to produce a useful final product. Additionally ingots (of less common materials) can be used as currency, or as a currency reserve as with gold bars.