SIFL

Introduction
Steel & Industrial Forgings Limited(SIFL) is an ISO 9001:2008 certified, Public Sector Undertaking fully owned by Government of Kerala. Steel and Industrial Forgings(SIFL) Athani, Thrissur was incorporated (June 1983) and started commercial production in 1986 as a subsidiary of Steel Industries Kerala Ltd. (SILK) with the object of production and marketing of industrial forgings at an installed capacity of 7950 MT per annum and an assessed capacity of 5340 MT per annum. The entire equity of the holding company (SILOK) was transferred (Jan2008) to Government of Kerala. The company is under the administrative control of Industries Department, Government of Kerala. The company is presently manufacturing forgings for sectors like steel, Engineering, Railways, Earth moving equipments, Ammunition depots. The major customers of the company are Indian Railways, BHEL, BEML, HAL, Ordnance Factories, VSSC, ISRO and some private parties. The company was able to turnaround itself from a BIFR referred Company to a consistent profit making Company with an impressive volume of growth., indicating the acceptability of Companys product range among varied customers base. This is an count of its core competence and reliability in the field of forgings. The company has expanded its activities to aluminum forging for catering to orders from ISRO projects and has installed machinery for aluminum forging using the interest free financial assistance from Vikram Sarabhai Space Centre (VSSC). The company has already set up a machining unit at Shornur, at the leased out land owned by Metal Industries Ltd with a capital outlay of Rs.12 crore.

Capital Structure
The authorized capital of the company as on 31-3-1011 was Rs.20 crore and the subscribed and paid up capital of was Rs. 15.93 crore.

Organization Structure
The overall control of the company exercised by the Board Of Directors appointed by Government of Kerala and the executive function are vested with the Managing Director. The

company has employee strength of 312 nos. as on March 2011 against the sanctioned strength of 471 nos.

Board Of Directors
CDR.(Retd.) K.Shamsuddin CDR.(Retd.)P.Suresh Sri.S.Babu Abraham Shri.A.Sivarajan Shri. Xavier Chittilapilli Shri.M.Radhakrishnan : : : : : : Chairman Managing Director Director Director Director Director

EXECUTIVES WORKMEN TOTAL EMPLOYEES

: : :

Technical,Non Technical & Administrative(65 nos) Skilled(178 nos),Unskilled(36 nos) 280

Bankers & Auditors

Banker : State Bank of Travancore, Main Branch, Thrissur. Auditor : M/s. Abraham & Jose, Chartered Accountants, Thrissure.

Registered Office & Works

Athani, Thrissur

Working Results
The working result of the company for the three years ending on 31.03.2011 are given below: (Rs. In lakh)

Sl. No 1

Particulars Income Sales & other Income

2008-09

2009-2010

2010-2011

5985.33

6033.58 38.91

5880.39 407.38

Stock adjustments (Increase in 381.77 inventory) Total 2 Expenditure Raw material consumed Manufacturing expenses Salaries, wages and allowance Others expenses Total 3 Operating profit Less : Financial charges Depreciation Exceptional/prior items(income) 4 Profit before tax 881.38 50.34 43.37 period 13.44 3063.02 1328.06 701.51 295.98 5388.57 988.53 6377.20

6072.56

5473.01

2474.22 1440.39 820.12 278.43 5013.68 1059.47

2053.33 1464.61 856.00 262.98 4636.92 836.09

77.03 73.68 -

40.86 91.31 -

908.76

703.92

The profit before tax has decreased to Rs.704lakh in 2010-2011 from rs.908 lakh in 2009-2010. The decrease in profit due to lesser quantity of manufacture and sales of highly remunerative jobs like Titanium forgings. QUALITY STANDARDS An ISO 9001:2008 certified organization, our strength and prime aim is strict adherence to quality standards. At SIFL, we believe that our success depends entirely on delivering the quality customer demands. Our policy is to always attain and wherever possible exceed the standards expected by our valued customers. This is achieved by continuous improvement programme in process discipline,

manufacturing methods and Quality Systems. Our success is in regular interactions with National Laboratories, premier forging institutes and of course long term association with our prestigious customers. THEIR TEAM They had a team of experienced professionals and workforce committed to quality and timely delivery. The support from prestigious public and private sector together with guidance from Government of Kerala makes us one among the best performing State Public Sector Units in Kerala

THEIR CLIENTELE SIFL's blue-chip clientele speaks volumes for the quality of the forgings. Many of them are international names who manufacture Commercial and Agricultural vehicles and Earth Moving equipments. SIFL's technological knowhow and quality standards are manifested best in its contribution to our Nation's Space Research and Aero Space industries. SIFL's most notable achievement is in successfully catering to the stringent quality standards of Defense and Space Research establishments in India and establishing import substitution for customers like Bharath Heavy Electricals Limited, Larsen & Toubro, Indian Space Research Organization and Hindustan Aeronautics Limited.

In fact, a number of complicated and high precision forgings out of Titanium for Indian Navy for their classified project are now supplied by SIFL ... yet another testimony to our expertise. SIFL has received the coveted SIATI award for Excellence in Aerospace indigenization.

Untiring efforts of two decades has saddled SIFL firmly in the Indian Forging Industry Scenario and abroad with best ratings for its products and services. Forgings with exquisite designs and shapes, flawless forms and contours, broad bands and spectra of metals including Titanium and Aluminium, all in wide range of weights and unmatched quality have made SIFL the most sought after Forging company in the country for critical components.

SUPPORTING UNITS Though SIFL is fully equipped with post forging facilities, as a means to supplement the capacity, SIFL has developed and trained various units in and around to do machining jobs suiting to our quality standards. These units, therefore, form an effective backup for SIFL, in meeting the entire range of forging requirements.

FUTURE VISION Having established reputation for making quality forgings in the domestic market, SIFL is launching a major thrust into the world market. SIFL now aims at exports with a new technology base of computerized die designs. And, fortified by such performance, our products are now poised for a big entry into the international arena. MANUFACTURING Main production machinery of SIFL comprise closed die forging hammers of 10 Ton(16000 ft.lb) and 6Ton(10650 ft.lb)capacity. Open die forgings requirements are met with a 1Ton clear space hammer. Other supporting facilities include shot blasting machines, Pneumatic trimming press of 1000Ton and 500Ton capacity, Hydraulic trimming press of 1200Ton capacity, Billet shearing machines and a number of oil fired and electric furnaces for soaking as part of forging process. There is a modern heat treatment plant equipped with number of furnaces both LDO fired and electrically heated and a charging machine which takes care of loading and unloading of heat treatment charges. Our annual capacity is around 7500 Metric Tons. They manufacture closed die forgings in the weight range of 5 kg to 450 kg and open die forgings within 1kg to 75kg net weight per piece and ring rolling upto 650mmOD. The company has got the capability to manufacture forgings out of Carbon steels, Alloy steels, Stainless steels, Maraging steels, Aluminium alloys, Titanium alloys, Inconel (Su 718)etc

DIE DESIGN & DEVELOPMENT SIFL's design & engineering capabilities are ably backed by a well equipped Die Shop, set up along modern lines with Double Spindle Copy Milling Machines, Electrical Die Sinking Machine, CNC Die Sinking Machine, CNC Turning Centre, Radial Drilling machines, Heavy Duty Plano miller, Lathes, Tool & cutter grinders, etc. The design and development of the die holds the key to blemish-free forgings. At SIFL, we design both single-impression and multi-impression dies. The design, of course, is related to the forging drawings. And the decision on the type of die to be used, is based on the specific requirement of each case. The care that goes into the design of each die, also goes into the selection of raw materials and the sequence of operation that follows. To facilitate uninterrupted operations, SIFL is equipped with standby Power Generators. To keep pace with hi-tech developments, SIFL has equipped itself with CAD,CAM facilities like DELCAM for three dimensional modeling of Product, Die & Tool design etc. thereby minimizing the development cycle time ..All these qualities have helped SIFL grow quickly into a premier forging unit, capable of producing forgings with close dimensional tolerances

FORGING & HEAT TREATMENT FACILITIES The billets for forging are heated in oil fired or electric furnaces, closely controlling the temperature to reduce the scale formation and overheating so that the metallurgical properties are ensured in the final product. In addition, in-process inspection is carried out at all stages and 100% inspection for visual defects after forging. The accepted forgings are duly heat treated to ensure its mechanical properties. By providing heat treatment services in-house, SIFL is able to maintain greater control over heat treating process. The facility comprise batch furnaces both oil fired & electrical, continuous electrical heating furnaces, solution treatment etc. to carry out annealing, normalizing, hardening, tempering, iso-thermal annealing, solution treatment etc or other operations as specified by our customer. Close temperature control and process monitoring with the help of temperature recorders ensures uniform properties duly supported by evaluation of metallurgical properties through representative test pieces.

TESTING/INSPECTION FACILITIES Surface conditioning is done by shot blasting/grinding and final inspection is carried out once again to ensure quality requirements. Non-conformities are taken care of by timely corrective and preventive action. Calibration of electrical furnaces of SIFL are done by NABL accredited laboratories like HAL,STIC,CUSAT etc. SIFL has set up a system of total quality control consisting of an array of state-of-the-art specialty equipments where your products go through a series of rigorous tests, the destructive test including tensile, jominy and impact testing, wet analysis, carbon-sulphur determination, insitu metallography(where microstructure can be observed without destroying the job) and nondestructive tests using Spectrometer, Microscope, Magnaflux crack detection, Die Penetrant, Ultrasonic flaw detection etc. They are now equiped with a new digital ultrasonic flaw detector which has got a range of 5mm to 5m in steel. Setting and control of quality standards at all stages right from the receipt of raw material to the finished product through quality plan makes us deliver superior quality forgings with close dimensional tolerances and metallurgical properties. QUALITY STANDARDS RECOGNITION OF OUR QUALITY SYSTEMS Certification from DGQA,DGAQA, Ministry of Defense, Govt. of India. Assessed and approved by NQA Quality Systems Registrar against the quality assurance system standards ISO-9001:2008 for manufacture and supply of forgings. Facilities certified by premier inspection agencies viz: IBR, Indian Registry of shipping , Engineers India Ltd. Best vendor award from BEML. Evaluated by the Central Boilers Board and has been granted recognition as a "Well Known Forge". RDSO, ISRO,Certifications/Approval. SIATI 2003 Award for excellence in Aerospace indigenisaiton.

Kerala's Best PSU Award Winner - 2006 - 2007, 2007- 2008. Special Award for notable achievement in Enterprise Performance,

2008-2009, 2009-2010

An ISO 9001:2008 certified organization, Their strength and prime aim is strict adherence to quality standards. At SIFL, they believe that our success depends entirely on delivering quality products to customer.

Their policy is always to attain and wherever possible exceed the standards expected by our valued customers. This is achieved by continuous improvement programme in process discipline, manufacturing methods and Quality Systems. Their success is in regular interactions with National Laboratories, premier forging institutes and of course, long term association with their prestigious customers.

As envisaged in our Quality Policy, they put into practice the theme of standing committed to the complete satisfaction of customer needs of good quality forgings competitively priced and delivered on time. They achieve this through continuous improvement of quality and efficiency of our work at all functions and levels adhering to a firmly established Quality Management system. Their objectives include inculcating quality and cost consciousness among employees, establishing Quality Management System and ensuring compliance by all and customer satisfaction.

After establishing the Quality System to ISO requirements and achieving the goal of recertification to the revised standards of ISO 9001:2008 within a short time span, they are aiming further to improve and attain a total quality culture.

QUALITY OF INPUTS At SIFL, the raw material required for any forgings are bought only from prime manufacturers in the country viz SAIL, VISL, MUSCO etc. These prime manufacturers have been approved as vendors based on the evaluation of their capability and quality systems.

All

their die blocks

are imported

from

the prime die manufacturers viz

M/s

EDELSTAHLWERKE BUDERUS A.G, Germany... which itself asserts that at SIFL, we do not compromise on QUALITY. In fact, SIFL's ISO 9001:2008 quality system covers the whole ground Acceptance plan and testing of 100% raw material supplies. Setting and control of quality standards for forging as per quality plan. Corrective and preventive actions are implemented promptly for minimizing defects to a zero level. Certification of facilities by IBR, EIL, IRS and other inspection agencies. In-depth testing and research, based on specific customer requirements. Continuous vendor evaluation. Strict implementation of established

processes. Calibration and maintenance of testing, measuring equipments. Constant and continuous consultation with customers and suppliers on all technical aspects. Maintenance of high vendor rating with customers. and thermal control

PRODUCTS SIFL's critical forgings are supplied to various sectors like Aerospace sector, Defense sector, Railway sector, Heavy Engineering sector, Earth Moving sector, Agriculture sector, and Automobile sector. SIFL is equipped to manufacture high pressure application forgings like Gate/ Valve Bodies, Choke Bodies etc. in Carbon and Alloy steel material, to meet the requirements of Oil Field Equipment manufacturers, Thermal Power Stations, Refineries, Petro-Chemical Industries and Nuclear Plants. The company has made significant contribution in Aerospace/Aeronautical sector by way of developing complex forgings for various Aero engines. The latest of which involves the supply for project CHANDRAYAN by ISRO.

So far the company fast developed about 800 different types of forgings and the development of new components are continued. Forgings are also being exported to countries like USA,Indonesia,Malaysia and Middle East.

List of Major Customers and Products

SL.NO

CUSTOMERS

PRODUCTS

AIRCRAFT & SPACE SECTOR 1. HAL, Bangalore Titanium Alloy steel & Nickel Alloy Forgings 2. 3. 4. IISU, Trivandrum LPSC, Trivandrum VSSC, Trivandrum AUTOMOBILESECTOR 5. 6. 7. 8. Ashok Leyland, Madras Mahindra & Mahindra TELCO. Ltd, Pune VST Tillers & Tractors DEFENCE SECTOR 9. 10. 11. Heavy vehicles Factory, Avadi Ordinance Factory, Trichy Vehicle Factory, Jabalpur Flange Front LH & RH Cold Swaging Blank RAFD Houlings, Steering Knuckles, Diffcages, Axle Arms, Hubs Crank Shafts Crown Wheel, Stub Axle, Crank Shafts Crank Shafts B51-S Alluminium Alloy Forgings Alluminium Forgings Alluminium Forgings, 15CDV6 Forgings

Steering Knuckles Carrier HEAVY ENGINEERING SECTOR 12. 13. 14. 15. BEML, Earth Mover Divn. BEML, Hydraulic & Power Divn. BEML, Rail Coach Divn. BEML, Truck Divn. Gears, Hubs, Shafts Bevel Gears etc. Guide, Lower, Spring Seats Hubs, etc.

15. 16. 17. 18. 19. 20. 21. 22.

BHEL, Bhopal BHEL, TRichy Elgi Equipments, Coimbatore Hindustan Motors, Tiruvallur Hindustan Motors, Hosur Kirloskar Pneamatic Company, Pune KSB Pumps, Coimbatore L & T Komotsu Ltd, Bangalore

Gears, Pinions Valve Bodies, Chocke Bodies Crank Shafts, Con Rods Stub Yoke, Sleeve Yoke, Flanges Fly Wheels, Flanges Crank Shafts Yoke , Body Various Tooths, Sprocket Hubs, Motor Housing

RAILWAYS 23. Diesel Component Works, Patiala Connecting Gears 24. Diesel Locomotive Works, Varanasi Connecting Gears, Hubs 25. Southern Railway Main Gearing Caps Rods, Main Bearing Caps, Rods, Main Bearing Caps,

Major Raw Material Suppliers

1. Mahindra & Mahindra Ltd. 2. Misra Dhatu Samskar Nigam Ltd. 3. Steel Authority of India Ltd. (SAIL) 4. Super Forgings & Steel Ltd. 5. Tata Iron & Steel Company Ltd. 6. Visweswaraya Iron & Steel Ltd. (VISL)