1. MYCO
INDUSTRIES(M.I.D.C)
CASTING WORLD
Process Flow Chart

2. Inward Material ForProcurement
Aluminium Alloy
Aluminium Bronze Alloy
Brass
Copper Alloy
Gun Metal Alloy
SS 304 (Stainless Steel)
SS 316
Zinc Alloy

3. DifferentMethods of Die Casting(Process)
1. Centrifugal Die Casting
2. Forging
3. Gravity Die Casting
4. High Pressure Die Casting (HPDC)
5. Low Pressure Die Casting (LPDC)
6. Sand Casting
7. Squeeze Die Casting

4. Raw Materials Used forDieCasting
Non-Ferrous Materials-
Aluminium
Brass
Gun Metal
Bronze
Lead
Zinc Alloy
Aluminium Bronze
Ferrous Materials-
Stainless Steel
Spring Steel
NH4(Nay Hard Steel)

5. 1. Centrifugal Casting
Description:-
MS Steel or H-13 (Hot dye steel) is used to make a permanent mold
which rotates continuously about its own axis at high speeds. The
molten metal is poured into the mold and is centrifugally thrown
towards the mold wall where it solidifies after cooling.
Raw Material Specifications:-
Aluminium
1. ALSI 132
2. LM 24
3. LM 4
4. LM 6 (aesthetic look)
Zinc Alloy
1. Zinc 3
2. Zinc 5

6. 2. Forging
This process is involved in shaping of metals by
using compressive forces. This method finds
application in the preparation of names plates, rods
etc. The force is applied by giving blows through
hammering the metal.

7. 3333. Gravity Die Casting
Description:-
Mile Steel (MS) die blocks are made according to the design
requirements. The die casting process takes place on a stationary
surface with the pouring of molten metal into the die blocks
through gravity. Manual control is exercised. It provides good
weight control.
Raw Material Specifications:-
Aluminium
1. ALSI 132
2. LM 24
3. LM 4
4. LM 6 (aesthetic look)
Zinc Alloy
1. Zinc 3
2. Zinc 5

8. 4. High Pressure Die Casting
(HPDC)
Description:-
This method of die casting is specially used for giving the end
product an aesthetic look and for weight control. Here, the molten
metal is forced into the mold cavity created by the dies under a high
pressure. The thickness of the mold wall components should not be
more than 3mm as it leads to shrinkage and creation of pin holes.
Raw Material Specifications:-
Aluminium
1. ALSI 132
2. LM 24
3. LM 4
4. LM 6 (aesthetic look)
Zinc Alloy
1. Zinc 3
2. Zinc 5

9. 5. Low Pressure Die Casting
(LPDC))))
Description:- MS steel is used as the material for making die in this
process. It is a comparatively slow method as that compared to
HPDC. Here, the molten metal is forced into the mold cavity created
by the dies under a low pressure, slowly and steadily. It is similar to
HPDC and mainly used for producing spinning materials like rotors in
motors and others.
Raw Material Specifications:-
Aluminium
1. ALSI 132
2. LM 24
3. LM 6 (Aesthetic look)

10. 6. Sand Casting
Description:-
Mold consists of a handmade wooden pattern of the drawing to create a
negative impression and is then pressed in sand. The mold is then filled
with molten metal (one of the procured metals) and is then left to cool and
solidify. This method does not provide and aesthetic look and weight
control is not possible.
Raw Material Specifications:-
Aluminium
1. ALSI 132
2. LM 24
3. LM 4
4. LM 6 (aesthetic look)
Aluminium Bronze
Phosphorous Bronze
(Copper Alloy)
Gun Metal
1. 85 555
2. 88 10 2
Electrolytic Copper

11. 7. Squeeze Die Casting
Description:- In the previous processes, molten metal is poured
into the mold cavity and solidified on cooling. But in this process of
die casting a dough of the material is prepared and then inserted in
the cavity. The pouring process uses a cylinder at the bottom of the
material tank to push the material into molds.
Raw Material Specifications:-
Aluminium
1. ALSI 132
2. LM 24
3. LM 4
4. LM 6 (Aesthetic look)
Zinc Alloy
1. Zinc 3
2. Zinc 5
Magnesium Alloy

12. A Typical Pressure Die Casting Machine

13. Sales
And
Purchasing

14. SalesGrowth(Turnover)for last7 years.
FiguresinEuro
2.64
3.91
3.8
5.8
4.94
3.33
6.18
Amount(in lakhs)
2008-09
2009-10
2010-11
2011-12
2012-13
2013-14
2014-15

15. Purchasing
Internal requirements and incoming orders are recognized.
A purchase manager attends to the request. He makes a
purchase indent and raises a quotation as well as asks for
the lead time permissible from the customer. Low priced
and fast delivery suppliers are selected to meet the needs.
Grading is done according to the inspections conducted.
The grading system is as follows-
A- No inspection.
B- Little improvement needed.
C- Lot of improvement needed.
Raising a purchase order:- Specifications of the material,
the terms and conditions and the material quantity,
amount and its taxes are drafted. This draft is called a
Purchase Order (PO)

16. Statutory
5% (as cast) on semi-finished product.
12.5% VAT on finished goods material where full rate of
duty without any exemption or any form.
2% CST charge on materials sales outside of Maharashtra
against C-form.
Excise duty charged at 12.5%.
OCTROI/LBT is charged on full invoice value for
materials purchased outside Mumbai. For plastic
granules and aluminium ingots this is 5.5%
14% Service Tax.
A TDS of 2% is charged if the total invoice value of labour
charges exceeds 75,000/-. Also, if the company fails to
provide a pan card, this charge goes up to 20%.

17. Supply Chain Management Model
1. Through telephonic enquiry (new customer) or timely scheduling (regular customer)
orders are received.
2. After confirmation, 2D or 3D drawings on AutoCAD are prepared by the supplier as
per the desired dimensions or the customer himself sends these drawings.
3. If the quantity required is 100-200 pieces, a wooden pattern is made and sandcasting
is used in the production.
4. Inspection of the raw material used in die casting is done by spectroscopy post which a
chemical analysis report of the same is produced. Thus, a material test certificate is
made. This testing is outsourced.
5. After the detailed analysis and inspection of the raw material a die of the product is
prepared according to the given specifications.
6. The following actions then take place in the given order-
1. Casting of the product
2. Drilling
3. Filing
In case of an aesthetic look as desired by the customer, powder coating, electroplating or
anodizing is done. These processes are outsourced as well.

18. 7. The product which is ready to be dispatched undergoes inspection for the
required specifications and thereby a report is prepared which is emailed to
the customer. This inspection is carried out by instruments such as Vernier
Caliper and Micrometer.
8. After careful inspection the product is packed and labeled and ready to be
dispatched.
9. This dispatch takes place via local transport services assigned by the customer
company. A quotation of the transportation charges are fixed beforehand
where the prices are assigned per kilogram.
10. A Lorry Receipt (LR) or consignment booking document is generated by the
transport and emailed.
11. A copy of this, original and two more copies are sent physically to the customer
as well as e-mailed along with the invoice prepared. Invoice preparation is
done by Tally software.
12. A dispatch notification is also emailed to the company.

19. 13. A Goods Receipt Note (GRN) is sent by the customer company after receiving
the goods. If damage or lack of goods is observed, another report is prepared
and emailed.
14. A customer company has a certain document called Vendor Form which is an
evaluation report of its suppliers. Thus from time to time, this form is sent to
the supplier grading them on certain fundamental aspects.

20. In order to reduce the taxation on out of state
transport, the government issues another document
called the C form. This form is issued to any company
on a quarter yearly basis for concession on the taxes
levied.
In order to reduce the taxation on out of state
transport, the government issues another document
called the C form. This form is issued to any company
on a quarter yearly basis for concession on the taxes
levied.
H-form is used for exemption on
taxation of export material
H-form is used for exemption on
taxation of export material
Crucial Documents

21. A.R.E-1 documents are prepared
against bond and CT1 for export.
A.R.E-1 documents are prepared
against bond and CT1 for export.
ER-1 document is prepared on a monthly
basis for the goods sold to the customer
for excise duty.
ER-1 document is prepared on a monthly
basis for the goods sold to the customer
for excise duty.

22. 1.Filing1.Filing 2. Drilling2. Drilling
Departments

23. 3. Linishing3. Linishing 4. Vibro Finishing4. Vibro Finishing

24. 5. Shot Blasting5. Shot Blasting 6. Moulding6. Moulding