OKAY FERN , established in 2008 is a well known Investment Casting foundry (lost wax process) and has developed more than 2000 components in different alloys to a host of different industries like Automobile, Defense, Aero space, Switchgear, Surgical, Body implant, Artificial Limbs, Electrical & Electronics. Industries, Instrumentation, Valves & Pumps, Glass Industries etc etc in India as well as European countries
2. Vision…..
To become leading manufacturer of investment casting in
ferrous & non-ferrous alloys by 2018.
Highest quality ensure Material Diversity ,Complexity of
Geometry Dimensional Accuracy with competitive prices.
To achieve above using advanced technology.
Latest know-how, customer centric culture, experienced & skilled
team provide complete solutions
3. Mission
To develop long-term business relations with its customers.
Poised to be Global Investment casting manufacturer.
To grow steadily and become profitable gradually.
4. Strength
On time bulk Delivery.
Superior Investment Castings quality adhering to various
standards.
Flexibility in planning and development of Samples for
approval.
Continuous training of our engineers and technicians for best
efficiency and quality workmanship.
5. Board of Directors
Mr. F.V.Fernandes , Technocrat, having 42 years experience in investment
casting is serving as Director of OKAY-FERN where he provides Engineering
and Management services in Investment Casting Technology.
He has extensive knowledge and experience in Strategic planning,
marketing as well as all facets of Operations Management with strong
leadership and excellent Project management skills.
Mr. N. K Saboo is a Chartered accountant. He has experience spanning 33
years in the field of finance and engineering industry.
Besides OKAY FERN Mr. N.K. Saboo is director of number of companies
including OKAY GROUP OF COMPANIES.
7. Milestone..
Started manufacturing operation in 2008.
In September 2008 our QMS is certified to ISO 9001:2000.
In December 2009 we got certification for PED 97/23/EC & AD 2000 WO
merkblatt by TUV Nord.
In January 2010 production capacity is increased from 12 MT to 40 MT
of saleable castings per month.
In June 2010 added new testing facilities like computerized Tensile
Testing, Impact Testing etc.
In October 2010 QMS is upgraded to ISO 9001:2008 & ISO TS
16949:2009. by TUV Nord
8. Milestone..
Our foundry got approval for military products by Rifle Factory
& Bharat Dynamic Limited.
In 2011 the manufacturing capacity is increased from 40 MT to
80 MT of saleable castings per month.
In December 2011 added Mitutoyo make 2D Linear height gauge
for precise & accurate measuring.
In Nov.2013, the manufacturing capacity is increased from 80
MT to 170 MT & new built up area of 20000 sq. ft. in added.
In Oct. 2014 the manufacturing capacity is increased to 240 MT
per month
9. Milestone..
In 2014 ,OKAY FERN has been awarded as Best industry Award
by District Industrial Centre a nodal agency of the Government of
Maharashtra .
By Sept. 2016 new plant with a capacity of 100 MT per month of
saleable castings will start operation at Pithampur Near Indore.
11. Fact & Figures…
20.6 47.02 86.42 124.96
184.56
240.69269.84
400
600
0
100
200
300
400
500
600
700
2009 2010 2011 2012 2013 2014 2015 2016 2017
Net Sale
Sales
The overwhelming response to our product can be
seen by jump in sales years after year….. Figure in million
13. In-house CAD Facility..
The Dies (Patterns/Tools) are
manufactured using latest CAD
facilities. OFPCP also provides
technical support to its customers to
develop cost saving and more efficient
products.
Die manufacturing activity is
outsource.
Dedicated vendor for die
manufacturing.
14. Wax Pattern Injection….
No. of wax injection presses– 21
including four automatic injection
press with capacity of 6 tonne to 35
tonne.
Central Air Conditioning - 65 tonne
Part weight range 1 gm to 150 Kgs.
15. Wax Pattern Injection…..
Good quality wax pattern are injected
through wax injection press
Quality is ensured by wax pattern
inspection and dimensional checks.
16. Wax Pattern Visual Inspection & Wax Assembly….
100% Wax pattern visual inspection
carried out to ensure good quality.
Wax assembly is made with proper
gating .
17. Primary Coating…..
The Wax assembly primary ceramic
coating process ensures dimensional
accuracy and excellent surface finish
Slurry viscosity checks is done before
primary coating
18. Secondary Coating….
Secondary ceramic coating is carried
out for strengthening of the mould.
Shelling room is centrally air conditioned
with AHU , de-humidification system and
wall mounted fans for efficient mould
drying.
19. De-waxing & Pre-heating of autoclaved mould..
After completing the coating process, the
wax is removed by de-waxing process,
which is done by Autoclave Boiler.
The Ceramic moulds are baked at
temperature ranging from 900°C to 1050°C
depending on the geometry and size of the
casting. The molten metal is then poured
in the baked ceramic moulds.
20. Melting Facility……
4 X 500 kg Crucibles / 275 Kw Induction
Furnace.
2 X 190 Kg Crucibles / 125Kw Induction
Furnace.
1 X 25 Kg Crucibles / 125Kw Induction
Furnace.
21. Chemical Analysis :
In house spectrometer with 5 base
(Fe, Ni, Co, Cu, Al) with 26 elements
with Nitrogen
All heats poured are tested on-line
on Spectrometer.
All raw material used are also
tested before using.
Specimens are stored for
particular period.
22. Casting fettling , finishing & Heat Treatment…
In-house Heat Treatment facility available
The casting then undergo the Heat
Treatment as Per the material
specifications.
Heat Treatment graphs cycles are
recorded and documented.
Heat Treatment furnace is calibrated and
certified as per API-6A standard.
Casting surface gets clean after shot
blasting.
23. Casting fettling & Visual Inspection…..
The facility includes :
Separation of Castings.
Belt Grinding.
Shot Blasting.
Casting Finishing.
100% visual inspection of finish
casting
24. In-House NDT and Physical Testing's…..
Tensile Testing
Impact Testing
Magnetic Particle Testing
Radiography Testing (Out-Source)
Dye Penetrate Test
Hardness Test
Microstructure
Material test certificates are provided as per
EN 10204 3.1
25. Quality Management System…….
DIN EN ISO 9001:2008.
ISO/TS 16949:2009.
Pressure Equipment Directive 97/23/EC.
AD 2000 – Merkblatt WO.
EMS 14001 :2004 –Implementation by Oct-2016.
OHSAS 18001:2007 – Implementation by Oct-2016..
AS9000 (Aero Space) – Implementation by Nov.-2016
30. Technical Excellence Achieved..
Centre Seat Support for Two Wheelers.
Earlier this component was made my sheet metal ,
turned part welded together & operations like
broaching , drilling , settings etc.
OKAY FERN has developed this part in single piece
without any machining or welding.
This job is having 4mm gap & having 36 holes.
31. Technical Excellence Achieved..
Side Stand Bracket for Two Wheeler.
Earlier this component was made by forging,
machining, Drilling of holes, turned pin welding
OKAY FERN has developed this part with
integral pin with groove &With cast holes
Machining is totally avoided.
32. Body for Bramhos Missile in LM 25 (Aluminum)
Earlier this component was made by Sand
Casting having more wall thickness & rejection due
to cast defect was more than 80%
OKAY FERN has developed this part with
minimum wall thickness & rejection less
than 5%.
This is helped customer to cut down costly
machining & rejection.
Technical Excellence Achieved..
33. Stay Lever for four wheeler.
Earlier this component was made by forging,
machining & welding.
OKAY FERN has developed this part without
any machining with the cast holes.
Technical Excellence Achieved..
34. This Component is developed for
ALFA LAVAL , SWEDEN
OKAY FERN is the second foundry in the
world to make such type Castings which are
having 586 Spikes of 3 mm Dia & 10 mm
Length.
Technical Excellence Achieved..
35. Initially Castings was Routed through Sand Casting Method
with Lot of Machining & Press fitting of Ball.
OKAY FERN has Developed
This Component which Directly goes for Assembly with
inbuilt Ball & all hole as Cast without any machining.
Technical Excellence Achieved..
36. For Turbo Energy LTD Presently made through
Sand Casting Method having rough in volute finish
.
OKAY FERN has developed this component in
SG Iron having very good in volute finish by
avoiding maximum machining.
