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ISO/TS- 16949-2009 Certified group.

Zanvar Group of Industries. ISO/TS- 16949-2009 Certified group. Welcomes You. GROUP COMPANIES (FOUNDRY DIVISION). SHRIRAM FOUNDRY LTD. – TS:16949 Shiroli, Kolhapur. Production Capacity – 1200 Mts./month S.J.IRON & STEELS PVT. LTD. TS:16949 Shiroli , Kolhapur.

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ISO/TS- 16949-2009 Certified group.

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  1. Zanvar Group of Industries. ISO/TS- 16949-2009 Certified group. Welcomes You

  2. GROUP COMPANIES(FOUNDRY DIVISION) • SHRIRAM FOUNDRY LTD. – TS:16949 Shiroli, Kolhapur. Production Capacity – 1200 Mts./month • S.J.IRON & STEELS PVT. LTD. TS:16949 Shiroli, Kolhapur. Production Capacity – 1200 Mts./month • ASHTA LINERS PVT. LTD.- TS : 16949 Ashta, Sangli. Production Capacity – 1200 Mts./month • KASTURI FOUNDRY PVT. LTD. TS:16949 Ashta, sangli. Production Capacity – 1500 Mts./month. • SHRIRAM FOUNDRY LTD. Uttarakhand. TS:16949. Production Capacity – 3000 Mts./month

  3. ZANVAR GROUP(PRODUCTION CAPACITY) • Production Capacity at Kolhapur - 2400 Tons/Month. • Production Capacity at Ashta - 2700 Tons/Month. • Production Capacity at Uttarakhand - 3000 Tons/Month. Group Total Capacity (Casting) – 8100 tons/month

  4. GROUP COMPANIES(MACHINING DIVISION) • ED STEELS PVT. LTD. KOLHAPUR. • ALKA ENGINEERING WORKS. KOLHAPUR. • ZANVAR ENGINEERING EXPORTS. KOLHAPUR. • RSZ INDUSTRIES. KOLHAPUR. • ACCURATE ENGG. WORKS. KOLHAPUR. • NEETA ENGG. WORKS. KOLHAPUR. • KOLHAPUR AXLE PVT. LTD. KOLHAPUR. • SACHIN INDUSTRIES. KOLHAPUR. • VISION ENGINEERING. KOLHAPUR. • KASTURI FOUNDRY PVT. LTD. MACHINE SHOP. • ASHTA LINERS PVT. LTD. MACHINE SHOP. ASHTA.

  5. ZANVAR GROUP(Sales in Million USD)

  6. OUR ESTEEMED CUSTOMER (DOMESTIC) CUMMINS INDIA LTD. – PUNE. TATA MOTORS LTD. – PUNE. JOHN DEERE EQUIP. PVT. LTD.– PUNE. MAHINDRA & MAHINDRA LTD. – NAGPUR. ESCORTS LIMITED – FARIDABAD. CARRARO INDIA LTD.- PUNE. EICHER MOTORS LTD. – PITHAMPUR. KIRLOSKAR OIL ENGINES LTD. – PUNE. CLAAS INDIA LTD. – FARIDABAD. TACO HENDRICKSON. – PUNE. WABCO – CHENNAI. VOLVO INDIA LTD.

  7. OUR ESTEEMED CUSTOMERS(OVERSEAS) CUMMINS I. P. O. CONSOLIDATED METCO INC.–USA MEXICO. INTERNATIONAL TRUCK & ENG. – USA. CARRARO SPA.- ITALY, POLAND. CLASS. – GERMANY. JOHN DEERE – FRANCE,MEXICO. OERLIKON - FAIRFIELD – USA. KNORR-BREMSE. – FRANCE. POCLAIN HYDRAULICS. - FRANCE & USA. NEW HOLLAND – UK.

  8. PRODUCTS.1. Total No. of Components – 300 Nos. 2. Weighting from 1 Kg. – 150 Kg. • BRAKE DRUMS • (10 VARIANTS) • BRAKE HUBS • (30 VARIANTS) • VENTILATED BRAKE DISCS/ROTORS (C.G. Iron) (7 VARIANTS)

  9. PRODUCTS. • FLYWHEELS / FLY. HGS. • HYD. LIFT HOUSING

  10. PRODUCTS. • TRUMPET HSG. • BRACKETS / SUPPORTS

  11. PRODUCTS. • HOUSINGS • HING HOOD/ SUPPORT/ SPINDLE

  12. PRODUCTS. • BEARING SUPPORTS • PULLEY (12 VARIANTS)

  13. PRODUCTS. • CYLINDER BLOCK • POST BACKHOE SWING

  14. PRODUCTS. BED PLATE • CRANK CASE (10 VARIANTS)

  15. PRODUCTS (CUMMINS) KV Gear Housing 3176918 KV Gear Cover 3643233 V-28 Gear Cover 204555 V-28 Gear Housing 3028947

  16. KASTURI FOUNDRYPVT. LTD. ASHTA. Welcomes You

  17. KASTURI FOUNDRYPVT. LTD. ASHTA. Dedicated machining set up.

  18. KASTURI FOUNDRYPVT. LTD. ASHTA. AGNIPANKHA CUMMINS COVER LINE

  19. KASTURI FOUNDRY PVT. LTD. ASHTA. AGNIPANKHA • QUALITYCIRCLE • GROUPNAME :-“ AGNIPANKHA” • FACILITATORS:- Mr. J. N. Shikalgar. Mr. S. D. Mane. • GROUPLEADER:- Mr. R. R. Goud.

  20. STEERING COMMITTEE OF QUALITY CIRCLE KASTURI FOUNDRY PVT. LTD. ASHTA. CEO Managing Director N. P. ZANVARSO AGNIPANKHA • Co - Ordinator ( Foundry) • Mr. S. C. Sambhare • Mr. A. V. Yewale • Co - Ordinator ( M/C Shop) • Mr. M. S. Niramale • Mr. N. Y. Jadhav • Group Leader • Mr. R. R. Goud • Facilitators • Mr. J. N. Shikalgar • Mr. S. D. Mane CIRCLE MEMBER Sanjay Patil 2)Jitendra kinikar 3) Ranjeet Kore 4) Vinod Mane 5)Kuntinath Bele 6) Kishor Kole 7) Lalaso Mullani 8) Ajit Sutar

  21. KASTURI FOUNDRY PVT. LTD. ASHTA. Information about our circle AGNIPANKHA • Registration Date. - 5 Nov. 2010 • Registration No. – 06 • Meeting Time – 4.00 To 5.00 PM On 2nd & 4th Sunday. • No. of meeting conducted – 12 • No. of case case studies - 03 • Leadership – Rotation after every three months.

  22. KASTURI FOUNDRY PVT. LTD. ASHTA. PROBLEM SOLVED AGNIPANKHA • 1. REJECTION ON OIL HOLE SPM FOR OIL HOLE DRIFT – Jan. 2011 • 2. SIZE VARIATION & REJECTION OF 203.162 O.D. – Jan. 2011 • 3. TOOL MARK ON GASKET FACE - Dec.2010

  23. KASTURI FOUNDRY PVT. LTD. ASHTA. REJECTION ANALYSIS OF OCT. 2010 AGNIPANKHA GEAR COVER - 3643233 DATE - 05/11/2010

  24. KASTURI FOUNDRY PVT. LTD. ASHTA. DETAIL REJECTION ANALYSIS OF OCT. 2010 AGNIPANKHA GEAR COVER - 3643233 DATE - 05/11/2010

  25. KASTURI FOUNDRY PVT. LTD. ASHTA. Gear Cover- 3643233 AGNIPANKHA

  26. KASTURI FOUNDRY PVT. LTD. ASHTA. REJECTION ANALYSIS OF NOV. 2010 AGNIPANKHA GEAR COVER - 3643233 DATE - 02/12/2010

  27. KASTURI FOUNDRY PVT. LTD. ASHTA. DETAIL REJECTION ANALYSIS OF NOV. 2010 AGNIPANKHA GEAR COVER - 3643233 DATE - 02/12/2010

  28. KASTURI FOUNDRY PVT. LTD. ASHTA. Gear Cover- 3643233 AGNIPANKHA

  29. KASTURI FOUNDRY PVT. LTD. ASHTA. REJECTION ANALYSIS OF DEC. 2010 AGNIPANKHA GEAR COVER - 3643233 DATE - 04/01/2011

  30. KASTURI FOUNDRY PVT. LTD. ASHTA. DETAIL REJECTION ANALYSIS OF DEC. 2010 AGNIPANKHA GEAR COVER - 3643233 DATE - 04/01/2011

  31. KASTURI FOUNDRY PVT. LTD. ASHTA. AGNIPANKHA

  32. KASTURI FOUNDRY PVT. LTD. ASHTA. Paroto Chart from Oct to Dec-2010 AGNIPANKHA

  33. KASTURI FOUNDRY PVT. LTD. ASHTA. PROBLEM 1- TO REDUCE REJECTION ON OIL HOLE SPM AGNIPANKHA Problem for Ø8 mm drill hole Drift on oil hole SPM.

  34. KASTURI FOUNDRY PVT. LTD. ASHTA. Problem for Ø8 mm drill hole Drift on oil hole SPM. GEAR COVER - 3643233 AGNIPANKHA 4 5 6 7 2 3 1 1 These are the oil galleries machined on Oil hole SPM .

  35. KASTURI FOUNDRY PVT. LTD. ASHTA. DATA ANALYSIS AGNIPANKHA MAN 1.Drill not changed as per frequency. 2. Drill is not re sharp properly. MACHINE 1. Wrong work offset . Drill Drift METHOD 1.Faulty Auto air flow. 2. Wrong tool selection. MATERIAL 1. Hard casting. 2. Soft casting.

  36. KASTURI FOUNDRY PVT. LTD. ASHTA. First Trial AGNIPANKHA This problem arrives due to followingreason in Machine shop. 1. Drill not re-sharp properly. 2. Drill not changed as per frequency. Still No solution find Foundry Machine Shop

  37. KASTURI FOUNDRY PVT. LTD. ASHTA. GEAR COVER - 3643233 Analysis. AGNIPANKHA Second Trial We cut the job at different location for analysis & observe that this drill drift from cross holes which is drilled in first operation.

  38. KASTURI FOUNDRY PVT. LTD. ASHTA. At 3 places. AGNIPANKHA As shown in slide depth of 0.25” (6.35 mm ) hole is 1.010 (25.654 mm) & C. D. of Ø8 mm drill hole is 1.015 (25.781) due to this this drill drift from that hole after slight wear out.

  39. KASTURI FOUNDRY PVT. LTD. ASHTA. As shown in slide depth of 0.25” (6.35 mm ) hole increased from 1.010 (25.654 mm) to 28.62 mm. AGNIPANKHA Trial Implementation Modified the control plan

  40. KASTURI FOUNDRY PVT. LTD. ASHTA. Modified the sequence to improve tool life. AGNIPANKHA 4 5 6 GEAR COVER - 3643233 7 2 3 1 1

  41. KASTURI FOUNDRY PVT. LTD. ASHTA. AGNIPANKHA After that no rejection observed for drill drift from Jan.11 to July 11.

  42. KASTURI FOUNDRY PVT. LTD. ASHTA. Size Wise Rejection Analysis (for Drill Drift) Still Date AGNIPANKHA After Improvement

  43. KASTURI FOUNDRY PVT. LTD. ASHTA. PROBLEM2- TO REDUCE REJECTION OF SIZE VARIATION AGNIPANKHA Ø203. 162 - SIZE VARIATION & UNDER SIZE

  44. KASTURI FOUNDRY PVT. LTD. ASHTA. Problem is for Ø203 O.D. size variation as well as rejection for this bore is observed during last two months data. AGNIPANKHA

  45. KASTURI FOUNDRY PVT. LTD. ASHTA. Brain Storming AGNIPANKHA Insert RCMX 6R Is Currently Used As per 6 R requirement. It wears out after 02 to 03 Jobs, Therefore size variation Occured & In case of Large size variation job get rejected..

  46. KASTURI FOUNDRY PVT. LTD. ASHTA. Action Decided Gear Cover- 3643233 AGNIPANKHA 1. Insert TNMA 0.8R Is Used Instead Of Old Insert RCMX 6R. & Allowance for O.D. is 0.25 Diametrically is given for finish O.D. turning. 2. To maintain 6 R at bottom of O.D. Ø203.162, 0.25 mm groove is maintained With help of cutter of 6R ball nose dia. 32 which is used for roughing & match with finish bore insert i.e. TNMA0.8 R.

  47. KASTURI FOUNDRY PVT. LTD. ASHTA. Improvement AGNIPANKHA Before Insert RCMX RCMX Insert is replaced by TNMA.

  48. KASTURI FOUNDRY PVT. LTD. ASHTA. Cost Reduction AGNIPANKHA INSERT DETAILS Cost RCMX – 6R Manufacturing – Larson & Turbo Size Variation – 2 TO 3 Jobs. Cost - 200.00 Rs. Corner Used – 8 Nos. Per Corner Jobs – 8 Jobs. Per job Cost - 3.125 Rs. Quality Cp – 1.082 Cp k – 0.96 Remark- Process is Poor & take Immediate action

  49. KASTURI FOUNDRY PVT. LTD. ASHTA. Cost Reduction AGNIPANKHA INSERTDETAILS Cost TNMA – 0.8R Manufacturing – WIDIA Size Maintained –15 TO20 Jobs. Cost - 87.88 Rs. Corner Used – 6 Nos. Per Corner Jobs – 64 Jobs. Per job Cost - 0.22 Rs. Quality Cp – 2.25 Cp k – 1.69 Remark- Process is Excellent.

  50. KASTURI FOUNDRY PVT. LTD. ASHTA. After Before AGNIPANKHA RCMX – 6R TNMA – 0.8R Manufacturing – Larson & Turbo Size Variation – 2 TO 3 Jobs. Cost - 200.00 Rs. Manufacturing – WIDIA Size Maintained –15 TO20 Jobs. Cost - 87.88 Rs.

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