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Vacuum Moulding
Castings

To design, establish, and operationalize a state-of-the-art vacuum foundry for producing high-quality Grey and Ductile Iron castings, aimed at supplying global OEMs (automotive, heavy machinery, energy sectors) and positioning the company as a market leader in quality, reliability, and profitability.

Key Areas of Work

1. Greenfield Project Planning and Foundry Design

  • Feasibility study and business case development (technical, financial, market analysis).

  • Foundry layout design for optimal flow — molding, melting, vacuum pouring, fettling, machining, inspection.

  • Technology and machinery selection (vacuum systems, furnaces, molding lines, sand systems, core shops, finishing lines, testing labs, machine shop and paint shop).

  • Vendor selection, technical evaluations, and procurement support.

  • Facility planning compliant with global EHS (Environment, Health, Safety) standards.

2. Process Engineering and Vacuum Technology Deployment

  • Develop and establish in house design and development team to make all the patterns/core boxesjigs/fixtures/pallets.

  • Define and standardize vacuum melting and pouring processes for Grey and Ductile Iron.

  • Develop metallurgical standards to achieve exceptional casting properties (mechanical strength, density, defect-free surfaces).

  • Design mold and core making systems suitable for vacuum processes to minimize porosity and inclusions.

3. Operational Excellence Strategy from Day 1

  • Implement Lean Foundry principles from startup (5S, Standardized Work, Poka-Yoke systems).

  • Deploy world-class quality assurance systems (SPC, real-time defect monitoring, non-destructive testing - NDT).

  • Introduce energy-efficient operations focusing on lower kWh/ton of casting.

4. Building Quality Leadership for Global OEM Approval

  • Establish ISO 9001/IATF 16949 compliant Quality Management System (QMS) for automotive-grade supplies.

  • Build advanced inspection capabilities (CMMs, 3D scanning, NDT testing, metallurgical labs,100% actual product fitment test).

  • Facilitate approvals and audits from global OEM customers (PPAP, APQP frameworks).

5. Profitability and Cost Optimization Framework

  • Optimize metallurgical recipes for high-yield, cost-effective production.

  • Reduce wastage, scrap, and rework through predictive analytics and process control.

  • Design flexible batch production to serve multiple industries with minimal changeover losses.

  • Drive energy optimization — energy audits, renewable integration (solar rooftops), waste heat recovery.

6. Smart Foundry: Digitalization and Industry 4.0

  • Implement smart sensors for process parameters (temperature, pressure, vacuum levels, flow rates).

  • Real-time monitoring dashboards (OEE, scrap rates, cycle times, energy consumption).

  • Predictive maintenance systems to minimize downtime.

  • Digital twin simulations for production planning and troubleshooting.

  • Develop and  implement SAP for real time data and MIS systems.

7. Workforce Capability Building and Organization Development

  • Recruitment and skill development for key roles (foundry engineers, metallurgists, maintenance experts, production planners).

  • Training programs on vacuum technology, world-class manufacturing practices, problem-solving, and customer excellence.

  • Establish performance-based culture with KPIs linked to profitability and customer satisfaction.

8. Business Growth Strategy and Future Scalability

  • Develop a Go-to-Market strategy targeting global OEMs across automotive, construction equipment, material handling, Aerial work platforms, tractor industry, Heavy crane industry, renewable energy, and rail sectors.

  • Strategic roadmap to expand capacity, diversify product mix (thin wall castings, high-strength applications) as market grows.

  • Partnership strategies for international certifications and co-development programs with key OEMs.

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