FRONT AXLE BEAM AND STUB AXLE

[EIRI/EDPR/3677] J.C.: 1764

INTRODUCTION

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.

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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.

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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.

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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.

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 CONTENTS

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 ARE 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 MARK OR FEATURE BEFORE DRILLING,
SUCH AS BY
SPOT DRILLING
CENTER DRILLING
DEEP HOLE DRILLING

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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

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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

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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

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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)

COST ESTIMATION

Plant Capacity 1120 Nos/Day

Land & Building (40000 sq.mt.) Rs. 46 Cr
Plant & Machinery Rs. 116.40 Cr
Working Capital for 2 Months Rs. 32.83 Cr
Total Capital Investment Rs. 197.24 Cr
Rate of Return 15%
Break Even Point 21%

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