FORGING UNIT (MM FORGING) INDUSTRIAL BUILDING

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M M Forgings Limited (MMF), was originally incorporated in 1946 as Madras Motors Ltd carrying out trading and retail of motor cycles from Enfield, UK and manufactured by Royal Enfield, India.

MMF growth has been made possible because of the vision and commitment of its founder Late Sri S. E. Krishnan, FCA and his passion for manufacturing made the Company to diversify into manufacturing from trading activities, commencing its first manufacturing facility of forging in Singampunari (Sivagangai District), Tamilnadu during 1974 with a capacity 780 MT.

Founded on the tradition and philosophy of steadfast commitment to achieving “Total Customer Satisfaction” through excellent quality, on time deliveries and competitive pricing, the Company has grown steadily in strength and stature to attain its present recognition of being one of the largest exporter of Forgings in India in its product range and has created a niche in the International Market.

MMF has been the recipient of EEPC (Engineering Export Promotion Council) award for export excellence for 27 consecutive years, being the largest exporter of steel forgings from South India with 60% of its sales being exported.

The company has continuously expanded by adding state of the art forging facilities and machining capabilities to cater to the requirements of its international customers.

The Company is totally committed to meeting customers’ requirement in all respects and this is reflected in the company’s Quality Policy which is given below:

“We at M M Forgings are committed to enhance customer satisfaction with total involvement, through continual improvement of our quality management system.”

MMF is public limited company listed in BSE / NSE with a market cap of close to ₹1,500 crores having its Registered office and Corporate Office located in Industrial Estate, Guindy, Chennai

MMF had achieved a Gross Revenues of ₹633 crores during FY 2017-18 and has been providing employment for about 3,000 people.

The company has been showing consistent performance over the past five decades on all fronts including employment generation, turnover, and profitability besides contributing to the state and central exchequers.

The key promoters have more than 3 decades long experience in the forging industry and operations.

Key Performance highlights

During 2017-18, the company has crossed the ₹200 Crores mark for the first time in domestic sales, ₹350 Crores mark in export sales thereby crossing ₹600 Crores in overall sales.

Particulars 31.03.2016 31.03.2017 31.03.2018
Sales Turnover (₹ in Crores) 489.50 460.42 600.91
PBT (₹ in Crores) 69.29 55.14 82.09
Net Profit (₹ in Crores) 50.09 43.42 68.51
Net Worth (₹ in Crores) 279.59 314.60 369.08

The Company is certified ISO 9001 and IATF 16949 for its Quality Management certified by TUV-SUD.

The Company enjoys good Credit Rating with CARE A1+ (short term bank facilities) & CARE A+ (long term bank facilities)

MMF was originally incorporated in 1946 as Madras Motors Ltd carrying out trading and retail of motor cycles from Enfield, UK and manufactured by Royal Enfield, India.

Forging activities overtook dealership as Plant 1 steadily reached 3,000 MT capacity during 1974 to 1990.

The trading dealership was closed during 1990.

MMF commenced its Second forging facility in Viralimalai (Pudukottai District), Tamilnadu during 1991 with a capacity of 3,000 MT.

The name of the company was changed to M M Forgings Limited with effect from 1st April 1993 to reflect the Company’s line of activity.

The Company tapped the IPO market with a public issue during April 1994 for expansion of Plant 2 to 12,000 MT with funding from IDBI and ICICI.

MMF acquired an unit called Gears India during 1998 to foray into machining activity.

MMF commenced its next forging as well as state of the art machining facility in Padappai near Chennai, Tamilnadu during 2003.

Manufacturing Facilities

As of now, MMF has got 3 manufacturing facilities in Tamilnadu

1. Singampunari (Sivagangai District) near Madurai

2. Viralimalai (Pudukottai District) near Trichy

3. Padappai (Kanchipuram District) near Chennai

The company manufactures closed die hot forgings. The company supplies machined forgings for wide range of applications in diverse industries varying from commercial vehicles, Automobiles, Construction and other industries.

Production for FY 17-18 has been around 46,000 MT of forgings.

MMF has also got an in house tool designing and development facility at Ambattur Industrial Estate, Chennai, Tamilnadu with advanced CAD / CAM facilities in all its forging plants.

The company is also involved in precision machining of its forgings. Machining capability includes CNC, VMC and HMCs.

The company produced around 20 million forged parts and 5 million machined parts in the financial year 2017-18.

The major products include Front Axle Beams, Stub Axles, Crankshafts, Connecting rods, Housings and Spindles.

Green Power

MMF has also invested in Green energy and has the following facilities:

The company has wind farms in Tamilnadu located at

• Panakudi, Tirunelveli District
• Meenakshipuram, Theni District
• Kulasekharamangalam,Tirunelveli district
• Kallapalayam, Coimbatore District

8.0 MW Wind farm with a capacity to generate 207 lakhs units in Panakudi, Tirunelveli District

4.2 MW Wind farm with a capacity to generate 80 lakhs units in Meenakshipuram, Theni District

0.6 MW Wind farm with a capacity to generate 10 lakhs units in Kulasekaramangalam, Sankaran Koil Taluk, Tirunelveli District

2.5 MW Wind farm with a capacity to generate 52 lakhs units in Kallapalayam, Coimbatore District

The company also has Solar farms in Tamilnadu at the following sites:

• Aruppukottai, Virudunagar district.
• Viralimalai factory [Rooftop], Trichy district.

2.1 MW Solar farm with a capacity to generate 31.90 lakhs units in Aruppukottai District

0.3 MW capacity in Roof top solar generation with a capacity 3.30 lakhs units in Viralimalai

The Company during the year 2017-18 has generated 267.78 lakh units from its Wind farms and 32.23 lakh units from Solar farms

[equivalent to avoiding the generation of approximately 24,714 tons of CO2 (Wind farms) and 2,974 tons of CO2 (Solar farms) respectively]

Facilities

MMF is a diversified forging manufacturer with a total capacity of 65,000 MT as at FY 16 and increasing to 100,000 MT (during FY 19) by investing in new manufacturing equipments and also to modernise the existing units located at Tamilnadu., viz..Singamunari, Viralimalai and Padappai.

The facilities include

 State of the art manufacturing facilities with Forging Presses, Hydraulic Press, Hydraulic Hammer, Air Hammers, a battery of Friction Drop Hammers, Upsetter, Cross Wedge Rolling, Screw Presses and several pre-forming equipments

 Product weight ranges from 300 gm to 100 kg

 Spectrometric Analysis of Raw Material, Clemex imaging software for microstructure

 Battery of band saws, circular saws and various capacities of Shearing Machines to cut steels

 Induction Billet Heating

 CNC machines for Die Sinking including High Speed Machining Centres for high accuracy & repeatability in Die Making. Modern die manufacturing facilities enable surprisingly low lead time for development, high level of repeatability ensuring consistent quality

 Latest CAD CAM Centre for Tool Design & Manufacture

 Forging process is optimized by the use of simulation software

 Exclusive R&D center for continuous technology improvement

 Highly accurate Heat Treatment furnaces

 Sealed Quench Furnaces for atmosphere controlled heat treatment

 All factories have dedicated feeders for quality power and are equipped with sufficient captive Diesel Generator based power plants – a total of more than 6,000 KVA.

 Dedicated UPS for all CNC machines.

MMF had Technical Collaboration with Tokai Corporation, Japan during the period Jan 1996 – Jan 1999.

At all levels the organization is tuned to achieve total customer satisfaction

On time delivery and superior quality are hall marks of MMF

Satisfied MNC customers globally depend on MMF for their critical forging requirements

Long term contracts with Shipping Lines to ensure on-time delivery

Flexibility to export from multiple ports in Tamilnadu to eliminate delivery delays

In short, MMF takes pleasure and pride in providing customers with a one stop shop for their forging requirements

Credit Rating

The Company enjoys good Credit Rating as below:

(i) CARE A1+ (short term bank facilities) for Rs.10 crs

(ii) CARE A+ (long term bank facilities) for Rs.819 crs

Subsidiary Company in Uttarakhand

During the last quarter of FY 2017-18, the company acquired M/s. DVS Industries Private Limited, located in Rudrapur, Uttarakhand engaged in machining of crankshafts for Commercial vehicle and Tractor segment.

Expansion

MMF strived with its excellence and vision to look into the future market conditions by expanding machining facility in Viralimalai in addition to the existing facility available in Padappai (Chennai, Tamilnadu).

MMF during the year 2016 added another forging facility in Viralimalai to cater to heavier jobs for truck industry.

The present Executive Directors, Mr.Vidyashankar Krishnan (Managing Director) and Mr.K.Venkatramanan (Joint Managing Director) have rich experience and expertise in the field of Manufacturing, Accounts, Marketing etc and are ably supported by a strong, experienced and technically qualified Human Resources team and longstanding workforce.

MMF expanded its facility by foraying into Northern Region by taking over an operating company DVS Industries Private Limited, Pant Nagar, Uttarakhand, during Feb 2018, which has Crankshaft machining facilities for commercial vehicles. DVS is now a wholly owned subsidiary of MMF.

The company has continuously expanded by adding state of the art forging facilities and machining capabilities to cater to the requirements of its domestic and International customers.

Description

INTRODUCTION
KEY PERFORMANCE HIGHLIGHTS
MANUFACTURING FACILITIES
GREEN POWER
THE COMPANY ALSO HAS SOLAR FARMS IN TAMILNADU AT THE
FOLLOWING SITES:
FACILITIES
THE FACILITIES INCLUDE
CREDIT RATING
THE COMPANY ENJOYS GOOD CREDIT RATING AS BELOW:
SUBSIDIARY COMPANY IN UTTARAKHAND
EXPANSION
COMPANY AND MANAGEMENT
PARTICULARS OF BOARD OF DIRECTORS:
INTRODUCTION ABOUT PRODUCT
FRONT AXLE BEAM AND STUB AXLE
FRONT AXLE BEAM
STUB AXLE
USES AND APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW CHART
FOR FRONT AXLE BEAM
FOR STUB AXLE
PRODUCTION PROCESS FOR FRONT AXLE BEAM AND STUB AXLE
MACHINING
THERE ARE FOLLOWING MACHINING OPERATION IS GIVEN BELOW:
(1) MILLING OPERATIONS
THERE ARE FOLLOWING TYPES OF OPERATIONS IN MILLING PROCESS
(A) FACE MILLING
MOUNTING THE WORKPIECE
DEPTH OF CUT
(B) GANG MILLING
(2) DRILLING PROCESS
ESTABLISHING A CENTERING MARKS OR FEATURE BEFORE DRILLING,
SUCH AS BY
SPOT DRILLING
CENTER DRILLING
DEEP HOLE DRILLING
GUN DRILLING
MICRO DRILLING
DRILLING IN METAL
(3) BOARING OPERATIONS
(4) TURNING OPERATION
TURNING SPECIFIC OPERATIONS INCLUDE:
HARD TURNING
FACING
PARTING
GROOVING
NON-SPECIFIC OPERATIONS INCLUDE:
BORING
KNURLING
(5) DEBURRING OPERATIONS
WHAT IS BURR AND HOW DOES IT OCCUR?
(6) CLEANING PROCESS
(7) MAGNETIC PARTICLE INSPECTION
PROCEDURE
1.0 MAGNETIC PARTICLE INSPECTION – SCOPE
2.0 MAGNETIC PARTICLE INSPECTION -DESCRIPTION OF METHOD
3.0 MAGNETIC PARTICLE INSPECTION – EAUIPMENT AND MATERIALS
4.0 MAGNETIC PARTICLE INSPECTION – PARTS TO BE EXAMINED
5.0 MAGNETIC PARTICLE INSPECTION – SURFACE PREPARATION
6.0 MAGNETIC PARTICLE INSPECTION – EQUIPMENT AND
CONSUMABLE CONTROL
7.0 MAGNETIC PARTICLE INSPECTION – LIGHTING CONDITIONS
8.0 MAGNETIC PARTICLE INSPECTION – DIRECTION OF MAGNETISING FIELD
9.0 MAGNETIC PARTICLE INSPECTION – SEQUENCE OF OPERATIONS
10.0 MAGNETIC PARTICLE INSPECTION – EVALUATION OF INDICATIONS
11.0 MAGNETIC PARTICLE INSPECTION – ACCEPTANCE CRITERIA
12.0 MAGNETIC PARTICLE INSPECTION – PERSONNEL QUALIFICATION
16.0 MAGNETIC PARTICLE INSPECTION – REFERENCED DOCUMENTS
(8) INSPECTION PROCESS
FUNDAMENTALS OF INSPECTION
TYPES OF INSPECTION
INSPECTION PROCEDURE
EXAMINATION
DECISION
ACTION
INSPECTION ACCURACY
INSPECTION VS. TESTING
AUTOMATED INSPECTION
FEEDBACK PROCESS CONTROL
TIMING OF INSPECTION
OFF-LINE INSPECTION METHODS
ON-LINE/IN-PROCESS AND ON-LINE/POST-PROCESS INSPECTION METHODS
(9) ANTI RUST OILING PROCESS
UNDERSTANDING THE RUSTING PROCEDURE
INCONSISTENT ATOMS
CORROSION ON A BUSINESS SCALE
OILING PREVENT RUSTING: RUST REMOVER OILS
AUTOMOTIVE RUST REMOVAL TREATMENT
RUST REMOVING CHEMICALS
DEBURRING MACHINE
LINEAR DEBURRING MACHINES
DOUBLE-SIDED DEBURRING MACHINES
DISC BRUSHES
MOST USED MATERIALS:
MARKET OVERVIEW
MARKET SIZE
INVESTMENTS
GOVERNMENT INITIATIVES
ACHIEVEMENTS
ACHIEVEMENTS
ROAD AHEAD
INTRODUCTION
MARKET SIZE
INVESTMENTS
ACHIEVEMENTS
GOVERNMENT INITIATIVES
ROAD AHEAD
AUTOMOTIVE AXLE & PROPELLER SHAFT MARKET DYNAMICS
DRIVERS
RESTRAINTS
OPPORTUNITIES
CHALLENGES
OBJECTIVES OF THE AUTOMOTIVE AXLE & PROPELLER SHAFT
MARKET STUDY
RESEARCH METHODOLOGY OF AUTOMOTIVE AXLE & PROPELLER
SHAFT MARKET
TO KNOW ABOUT THE ASSUMPTIONS CONSIDERED FOR THE STUDY
PASSENGER CARS
LIGHT COMMERCIAL VEHICLES
HEAVY COMMERCIAL VEHICLES
FRONT AXLE
REAR AXLE
DEAD AXLE
LIVE AXLE
TANDEM AXLE
FRONT PROPELLER SHAFT
REAR PROPELLER SHAFT
INTER-AXLE PROPELLER SHAFT
DETAILED EXPORT DATA OF FRONT AXLE BEAM
EXPORT DATA OF RIGHT STUB AXLE
IMPORT DATA OF FRONT AXLE BEAM
IMPORT DATA OF RIGHT STUB AXLE
PLANT LAYOUT
SUPPLIERS OF FRONT AXLE BEAM
SUPPLIERS OF STUB AXLE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF STEEL FORGING
SUPPLIERS OF CUTTING FLUID
SUPPLIERS OF PACKING MATERIALS
SUPPLIERS OF DEGREASING CHEMICAL
SUPPLIERS OF PICKLING CHEMICALS
SUPPLIERS OF OIL AND GREASE
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF MILLING MACHINE
SUPPLIERS OF CNC LATHE MACHINE
SUPPLIERS OF BOARING MACHINE
SUPPLIERS OF POWER HACKSAW
SUPPLIERS OF GRINDING MACHINE
SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANE
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP

APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

Additional information

Plant Capacity

1120 Non/Day

Land & Building

(40,000 sq.mt.)

Plant & Machinery

US$.16628571

Rate of Return

15%

Break Even Point

21%