Document Sample

                           Project Report



                        SHAPAR – RAJKOT

                    (For partial fulfillment of MBA)

  Submitted By: -                                       Project Guided:-
  Rathod Vijay A.                                      Mr. Kumar Gaurav

 M.B.A. SEM - III                                      (Lecturer)

                        -: Submitted To:-

                (Affiliated to Saurashtra University)

                      B\H khirsara Police Station,

                            Kalawad Road,


                           Rajkot – 360 003

                      In India, business and industrial management activities is a based for
the development of the country. There are many courses for Business and industrial activates
like MBA, BBA, etc.

                      Unless and until the principles and theories of management are not
applied in the practical field the managers would not be Successful in managing. In reality,
theoretical and practical Aspects are different in business keeping in view the fact of
Increasing complexity in business environment idea of practical training has been introduced
in the course of MBA. One needs to be very practical in today‘s fast moving and expanding

                      The aim of this training is to get an outlook of what we study inside the
class. Also management disciplines are very dynamic so only classroom study would not help
to grasp the entire Knowledge and therefore the students of MBA. Have practical training as
a vital aspect – ‗Applied knowledge is power‘.

                      I am very glad to have got a chance of getting training in a reputed
company –‗PREVAIL CASTING PVT. LTD.’ period of 6 weeks on all the aspects of
management studied.

                      According to me, these type of training shows the actual path before
one step toward it. Because it has been said ―well begun is half done‘‘ and for us it was
perfect beginning.

                      I, Vijay A. Rathod, the student of K.N.V. INSTITUTE OF
BUSINESS MANAGEMENT hereby declare that this project report is my original work
and is a result of my own efforts and dedication under the guidance of Mr. Kumar Gaurav.

                      I am submitting this report to the faculty of my collage for the partial
fulfillment of our requirement of the MBA Program conducted by Saurashtra University.

                      I also declare that this report has been not submitted to any other
organization or university for the award of any degree.

       DATE:                                                   SIGNATURE

       PLACE: RAJKOT                                       (VIJAY A RATHOD)


Since efforts are always needed from many people to give life to the project work, and
I gratefully acknowledge my debt to those who contributed to the same.

Firstly I would like to thank Mr. Kanubhai Patel (Managing Director) for giving me an
opportunity to show my talent and utilize my knowledge along with practical experience in
their company

I would like to thank Mr. Jasmin Kachhadia (Marketing Manager) for giving me an
opportunity to work on the Summer Project “ORGANISATION STUDY OF PREVAIL
CASTING PVT. LTD.” Which has proved to be great experience learning for me.

Finally, I would like to express my profound thanks & gratitude to my Faculty
Mr. Kumar Gaurav for his unceasing efforts, encouragement, help, & unvaluable guidance
which has contributed to the success of the project.
                              K.N.V INSTITUTE OF BUSINESS MANAGEMENT

                                     B/H KHIRSARA POLICE STATION

                                            KALAWAD ROAD, METODA



I hereby certify that Rathod Vijay Ashwinbhai student of MBA Sem. III has completed


LTD.” under my guidance.

                      As per my knowledge this is his/her original work based on available

data and for partial fulfillment of MBA program.

       Date: __________                                    Signature of Guide

       Place: _________                                   Mr. Kumar Gaurav
                             EXECUTIVE SUMMERY

               THE study of master degree is not related with only theoretical aspects but
management people must know how to handle the organization and study of it in a practical
life. For this purpose I have selected and gone in manufacturing sector and have been
approved to get this training in ‗Prevail Casting Pvt. Ltd‘

               Initially I have been inducted towards the entire organization as any employee
gets the induction program training. After it I have started my organizational study and have
gone through every departments of the organization. As I was in manufacturing unit I have
passed my maximum time in to understand production department and its products and
services of the organization. I have been explained the entire process of investment casting
step by step and various other sub processes of other products of the organization. The
operating system of the machinery and dispatch of finished goods. I have also seen
practically as its manufactures unit laboratory testing has to be there of finished goods which
I have been taught has to tested the products in it.

               During this one & half month I have got an experience about working
condition of investment casting industry in Prevail Casting Pvt. Ltd. where I have met many
experience people who gave me knowledge of various departments.

Sr. No               Particular            Page No

  A.     EXECUTIVE SUMMARY                    1

  B.     INDUSTRIAL ANALYSIS                  2

  C.     COMPANY PROFILE & HISTORY            8

  D.     INTRODUCTION                        12

  E.     DETAILS OF DEPARTMENTS              17

              PRODUCTION DEPARTMENT         20

              MARKETING DEPARTMENT          59

              FINANCE DEPARTMENT            68



  G.     FINDINGS & SUGGESTION               81

  H.     BIBLIOGRAPHY                        83

                       Investment casting is a versatile process, used to manufacture parts
ranging from turbocharger wheels to golf club heads, from electronic boxes to hip
replacement implants. The industry, though heavily dependent on aerospace and defence
outlets, has expanded to meet a widening range of applications. Modern investment casting
has its roots in the demands of the Second World War, but it was the adoption of jet
propulsion for military and then for civilian aircraft that stimulated the transformation of the
ancient craft of lost wax casting into one of the foremost techniques of modern industry.

                       Investment casting expanded greatly worldwide during the 1980s, in
particular to meet growing demands for aircraft engine and airframe parts. Today, investment
casting is a leading part of the foundry industry, with investment castings now accounting for
15% by value of all cast metal production in the UK.

                         Meaning of Investment casting

                       A casting process in which an expendable pattern is surrounded by an
investment compound and then baked so that the investment is hardened to form a mold and
the pattern material may be melted and run off also called Precision casting.

                       Investment casting is also known as the lost wax process. This
process is one of the oldest manufacturing processes. The Egyptians used it in the time of the
Pharaohs to make gold jewelry (hence the name Investment) some 5,000 years ago. Intricate
shapes can be made with high accuracy. In addition, metals that are hard to machine or
fabricate are good candidates for this process.
                       It can be used to make parts that cannot be produced by normal
manufacturing techniques, such as turbine blades that have complex shapes, or airplane parts
that have to withstand high temperatures.

                       The types of materials that can be cast are Aluminum alloys, Bronzes,
tool steels, stainless steels, Satellite, Hastelloys, and precious metals. Parts made with
investment castings often do not require any further machining, because of the close
tolerances that can be achieved.

                       Energy made a statistically significant contribution to economic
performance in terms of returns to scale. Those small enterprises, which were less energy
intensive, achieved higher returns to scale than those, which were more energy intensive.
Therefore, it is imperative for Indian Policy Makers to include ‗energy efficiency
improvement‘ programmers as part of the strategy for enhancing SSI competitiveness.

The Beginnings of Investment Casting

                       It was the successful solution of these problems that laid the
foundation for the modern investment casting industry.

                       One buoyant niche market relies on special techniques (including hot
isostatic pressing after casting) to produce components with fatigue strengths equal to
forgings. Castings can now be made for applications with oscillating stress.

                       The technique of investment casting is both one of the oldest and most
advanced of the metallurgical arts. Investment castings are at work in the fiery combustion
chambers of jet aircraft and in the sub-zero vacuum of space. Yet, the root of this technology,
the cire perdue or ―lostwax‖ method dates back to at least the fourth millennium B.C. The
artists and sculptors of ancient Egypt and Mesopotamia used the rudiments of the investment
casting process to create intricately detailed jewelry, pectorals and idols.
                       Remarkably, civilizations as diverse as China‘s Han Dynasty, the
Benin Kingdom in Africa and the Aztecs of pre-Columbian Mexico employed similar
techniques. The cross-cultural adoption of this complex process implies a great degree of
commerce and communication in antiquity. In Renaissance Europe, the Italian Sculptor,
goldsmith and author, Benvenuto Cellini, cast his bronze masterpiece ―Perseus and the head
of Medusa‖ using the lost wax process. Cellini detailed his achievement in his famous
autobiography, one of the classics of world literature. The investment casting technique was
largely ignored by modern industry until the dawn of the twentieth century, when it was
―rediscovered‖ by the dental profession for producing crowns and inlays. The first
authenticated record of the use of investment casting in dentistry appears in apaper written by
Dr. D. Philbrook of Council Bluffs, Iowa in 1897.

                       However, the true significance of this process was not realized until
Dr. William H. Taggart of Chicago published his research in 1907. During World War II,
with urgent military demands overtaxing the machine tool industry, the art of investment
casting provided a shortcut for producing near-net-shape precision parts and allowed the use
of specialized alloys which could not readily be formed by alternative methods. The
investment casting process proved practical for many military components—and during the
postwar period it expanded into many commercial and industrial applications where complex
metal parts were needed, however, the process was still relatively obscure. It was in this
period that Hitchiner Manufacturing Co., Inc. was founded. In the decades that followed,
many innovations such as the shell process, the steam autoclave, conveyorization,
automation, and robotics have modernized and transformed the process. In today‘s world,
investment castings touch all of our lives. When we fly on an airplane, drive an automobile,
play golf, use a utility tool, power tool or hand tool, we are using investment castings.
                          Investment Casting in the UK

Investment casters in the UK produce about 12% of world production, and by value the
industry accounts for 13-14% of UK casting output (significantly more than steel castings).
These are impressive figures and confirm the growing importance of investment casting.

                    Modernization of Investment Casting

                      Lost wax casting has been used for at least six millennia for sculpture
and jewellery. About 100 years ago, dental inlays and, later, surgical implants were made
using the technique. World War II and then the introduction of gas turbines for military
aircraft propulsion transformed the craft into a modern metal-forming process.

                       Turbine blades and vanes had to withstand higher temperatures as
designers increased engine efficiency by raising inlet gas temperatures. Initially, forged alloy
steels were used but soon more heat-resistant alloys were needed, leading to the development
of special nickel-base and to a lesser extent cobalt-base alloys, which became known as
‗superalloys‘. Further alloy developments allowed turbine operation at even higher
temperatures and greater efficiencies, but the materials became more refractory and less
forgeable by traditional methods although becoming more costly to machine (particularly to
the demanding airfoil configurations).
            Current scenario of Investment Casting Industry

                      Investment casting markets increased steadily over 40 years to the mid
1980s, when demands for new aircraft boosted both the sales of investment castings and
industry capacity. The market continued expanding up to 1990, when annual worldwide
turnover reached about £3,000 million. Over the next few years, aerospace and defence
demands dropped and output decreased, in some countries by as much as 15-20%. Since
1994, however, general commercial demand has picked up and with recent aircraft orders
turnover is approaching its previous high.

                      Based on data published in early 1996, annual world turnover is
estimated as £2,800 million. North America (essentially the US) accounts for about half,
Western Europe a quarter, and the Pacific Rim countries 20%. Within Western Europe, the
UK remains the biggest national producer with output of £300 million, followed by France
(£185 million) and Germany (£135 million). Britain is home to about 50 of the 125 or so
western European investment casting foundries, employing roughly 5,500 people in an
industry which leads the European community.

                        Prevail Casting is a leading manufacturer of investment casting by lost
wax process, established in 1991. Our expertise and technology are based on years of
experience in production of Investment Casting. ―Customer Satisfaction‖ is our major
concern. It is always our best endeavor to supply the right part at right time at right cost.

                        Prevail Casting is a foremost producer of investment casting.
Established in1991, Prevail Casting employs the lost wax process while playing the part of
the versatile manufacturer. Our expertise, know-how and technology are founders of an era of
experience in production of investment casting.

                        Customer delight drives everything we do in Prevail Casting and
―Customer satisfaction‖ is our core interest. It is forever our paramount endeavor to deliver
the precise parts at exact time at accurate price tag.

                        Our key products are Investment castings by Lost Wax Process as per
customers‘ requirements. We can supervise Investment Casting parts with weight from a few
grams to 90 kg for a lone portion. We can furnish the fully machined castings in equipped to
assemble stipulation.
                        Prevail Casting is a foremost producer of investment casting.
Established in1991, Prevail Casting employs the lost wax process while playing the part of
the versatile manufacturer. Our expertise, know-how and technology are founders of an
era of experience in production of investment casting.

                        Customer delight drives everything we do in Prevail Casting and
―Customer satisfaction‖ is our core interest. It is forever our paramount endeavor to deliver
the precise parts at exact time at accurate price tag.

                        Our key products are Investment castings by Lost Wax Process as per
customers‘ requirements. We can supervise Investment Casting parts with weight from a few
grams to 90 kg for a lone portion. We can furnish the fully machined castings in equipped to
assemble stipulation.
                 COMPANY PROFILE


                       SARDAR NAGAR MAIN ROAD,

                              RAJKOT 360001


                       TALUKA : KOTDA SANGANI

                          DIST. : RAJKOT- 360002

                    PH: +91-2827-252272 / 252871 / 252872

                           FAX : +91-2827-252271

   E-MAIL :      


   CONTACT               1. Mr. KANUBHAI PATEL
                         [MANAGING DIRECTOR]

                           Mob. : +91 98795 81681

                  2. Mr. ATUL PATEL [DIRECTOR-FINANCE]

                           Mob. : +91 98795 81881

                        3. Mr. JASMIN KACHHADIA

                        [MARKETING EXECUTIVE]
                           Mob. :+91 98795 81285
BRANCH OFFICE                   Mr. RAJIV PURI

                        B 3 101 TUSHAR RESIDENCEY

                    NR. KUNAL ICON OPP. HAPPY THOUGHTS

                             PIMPALE SAUDAGAR

                               AUNDH ANNEXE


                             Mob. : +91 9370145657

                          Email :

ESTABLISHMENT:                        1991

   G.S.T. NO.          24092500131 Dt. 12th September 2005

 INVESTMENT:               8.3 CRORE (APPX.) IN INR

                          ROAD, RAJKOT – 360002

BUILT UP AREA :                  34000.00 sq.ft.

  CAPACITY :                500 X 500 X 300 mm Max.

 SINGLE PIECE                     70 Kg. Max.

                    BOARD OF DIRECTORS


2. Mr. SHAILESH PATEL               DIRECTOR

3. Mr. ATUL PATEL                   DIRECTOR


                  Leading Organizations


               Investment Casting in India

   NAME OF THE COMPANY                CITY       STATE


          NABS INDIA                 CHENNAI    TAMILNADU








      KAJECO INDUSTRIES               AGRA         UP




There are many different departments in the company, their name & details are

                PRODUCTS

                ISO CERTIFICATES

                PROCESS

                LABORATORY


                MACHINERY


                STORAGE DEPARTMENT


             MARKET RESEARCH






Definition of Production
                       “The production function relates the output of a firm to the amount
of inputs, typically capital and labor.’’
                       It is important to keep in mind that the production function describes
technology, not economic behavior. A firm may maximize its profits given its production
function, but generally takes the production function as a given element of that problem. (In
specialized long-run models, the firm may choose its capital investments to choose among
production technologies.)

General Process of Investment Casting

Casts can be made of the wax model itself, the direct method; or of a wax copy of a model
that need not be of wax, the indirect method. The following steps are for the indirect process,
which, in total, can take two days to one week to complete.

Produce a master pattern: An artist or mold-maker creates an original pattern from wax, clay,
wood, plastic, steel, or another material.[2]

      Moldmaking:

                        A mold, known as the master die, is made of the master pattern. The
master pattern may be made from a low-melting-point metal, steel or wood. If a steel pattern
was created then a low-melting-point metal may be cast directly from the master pattern.
Rubber molds can also be cast directly from the master pattern. The first step may also be
skipped if the master die is machined directly into steel.

    Produce the wax patterns:
                          Although called a wax pattern pattern materials also include plastic and
frozen mercury.[2] Wax patterns may be produced in one of two ways. In one process the
wax is poured into the mold and swished around until an even coating, usually about 3 mm
(0.12 in) thick, covers the inner surface of the mold. This is repeated until the desired
thickness is reached. Another method is filling the entire mold with molten wax, and let it
cool, until a desired thickness has set on the surface of the mold. After this the rest of the wax
is poured out again, the mold is turned upside down and the wax layer is left to cool and
harden. With this method it is more difficult to control the overall thickness of the wax
layer.[citation needed]

                          If a core is required, there are two options: soluble wax or ceramic.
Soluble wax cores are designed to melt out of the investment coating with the rest of the wax
pattern, whereas ceramic cores remain part of the wax pattern and are removed after the
workpiece is cast.

    Assemble the wax patterns:

                          The wax pattern is then removed from the mold. Depending on the
application multiple wax patterns may be created so that they can all be cast at once. In other
applications, multiple different wax patterns may be created and then assembled into one
complex pattern. In the first case the multiple patterns are attached to a wax sprue, with the
result known as a pattern cluster, or tree; as many as several hundred patterns may be
assembled into a tree.[3] Foundries often use registration marks to indicate exactly where
they go.[citation needed] The wax patterns are attached to the sprue or each other by means
of a heated metal tool.[2] The wax pattern may also be chased, which means the parting line
or flashing are rubbed out using the heated metal tool. Finally it is dressed, which means any
other imperfections are addressed so that the wax now looks like the finished piece.
    Investment:

                       The ceramic mold, known as the investment, is produced by three
repeating steps: coating, stuccoing, and hardening. The first step involves dipping the cluster
into a slurry of fine refractory material and then letting any excess drain off, so a uniform
surface is produced. This fine material is used first to give a smooth surface finish and
reproduce fine details. In the second step, the cluster is stuccoed with a coarse ceramic
particle, by dipping it into a fluidised bed, placing it in a rain sander, or by applying by hand.
Finally, the coating is allowed to harden. These steps are repeated until the investment is the
required thickness, which is usually 5 to 15 mm (0.2 to 0.6 in). Note that the first coatings are
known as prime coats. An alternative to multiple dips is to place the cluster upside-down in a
flask and then liquid investment material is poured into the flask. The flask is then vibrated to
allow entrapped air to escape and help the investment material fill in all of the details.

                       Common refractory materials used to create the investments are: silica,
zircon, various aluminium silicates, and alumina. Silica is usually used in the fused silica
form, but sometimes quartz is used because it is less expensive. Aluminium silicates are a
mixture of alumina and silica, where commonly used mixtures have an alumina content from
42 to 72%; at 72% alumina the compound is known as mullite. During the primary coat(s),
zircon-based refractories are commonly used, because zirconium is less likely to react with
the molten metal. Other refractory materials that have been used include molochite and
chamotte.[citation needed] Prior to silica, a mixture of plaster and ground up old molds
(chamotte) was used.

The binders used to hold the refractory material in place include: ethyl silicate (alcohol-based
and chemically set), colloidal silica (water-based, also known as silica sol, set by drying),
sodium silicate, and a hybrid of these controlled for pH and viscosity.
     Dewax:

                      The investment is then allowed to completely dry, which can take 16 to
48 hours. Drying can be enhanced by applying a vacuum or minimizing the environmental
humidity. It is then turned upside-down and placed in a furnace or autoclave to melt out
and/or vaporize the wax. Most shell failures occur at this point because the waxes used have a
thermal expansion coefficient that is much greater than the investment material surrounding
it, so as the wax is heated it expands and induces great stresses. In order to minimize these
stresses the wax is heated as rapidly as possible so that the surface of the wax can melt into
the surface of the investment or run out of the mold, which makes room for the rest of the
wax to expand. In certain situations holes may be drilled into the mold beforehand to help
reduce these stresses. Any wax that runs out of the mold is usually recovered and reused.

     Burnout & preheating:

                      The mold is then subjected to a burnout, which heats the mold between
870 °C and 1095 °C to remove any moisture and residual wax, and to sinter the mold.
Sometimes this heating is also as the preheat, but other times the mold is allowed to cool so
that it can be tested. If any cracks are found they can be repaired with ceramic slurry or
special cements. The mold is preheated to allow the metal to stay liquid longer to fill any
details and to increase dimensional accuracy, because the mold and casting cool together.

     Pouring:

                      The investment mold is then placed cup-upwards into a tub filled with
sand. The metal may be gravity poured, but if there are thin sections in the mold it may be
filled by applying positive air pressure, vacuum cast, tilt cast, pressure assisted pouring, or
centrifugal cast.
    Removal:

                       The shell is hammered, media blasted, vibrated, waterjeted, or
chemically dissolved (sometimes with liquid nitrogen) to release the casting. The sprue is cut
off and recycled. The casting may then be cleaned up to remove signs of the casting process,
usually by grinding.

Valve Parts include Investment Castings for Butterfly Valve, Globe Valve, Gate Valve, Ball
Valve and Valve Actuators in Steel and Stainless Steel. The smooth surface offered by

Investment Casting gives best efficiency.
                               FOOD INDUSTRIES

Food Industries Parts includes Investment Casting Parts for Food Processing Machineries and
Equipments, mostly made of Stainless Steel. The parts are supplied with Vibro Polishing and
Glass Bead Blasting to improve surface finish.
                              MACHINED PARTS

Machined Parts includes fully Precision Machined Components, Machined Investment
Casting, 5-axis machining, 4-axis machining and CNC machining.
     The Company is certified by the following
1. Prevail Casting Pvt. Ltd. approved by ISO 9001 2000 / EN ISO   9001:2000 by
   RWTUV, Germany

2. Prevail Casting Pvt. Ltd. approved by AD 2000-Merkblat WO by RWTUV,

3. PED/97/23/EC certification from RWTUV, Germany

4. N.A.B.L. approval for Chemical and Mechanical Testing

5. I. B.R. Approval
                        Industries Served
 Automotive/Transportation

 Material handling

 Machine tools

 Food processing

 Electronics

 Art

 Toys

 Pumps and valves

 Marine

 Robotics

 Defense

 Medical products

 Hand tools

 scientific instrumentation
                              INVESTMENT CASTING PROCESS


                                       PREVAIL CASTING

                      The investment casting process begins with fabrication of a sacrificial
pattern with the same basic geometrical shape as the finished cast part. Patterns are normally
made of investment casting wax that is injected into a metal wax injection die. Fabricating the
injection die often costs tens of thousands of dollars and can require several months of lead

                      Once a wax pattern is produced, it is assembled with other wax
components to form a metal delivery system, called the gate and runner system. The entire
wax assembly is then dipped in ceramic slurry, covered with a sand stucco, and allowed to
dry. The dipping and stuccoing process is repeated until a shell of ~6-8 mm (1/4-3/8 in) is
                       Once the ceramic has dried, the entire assembly is placed in a steam
autoclave to remove most of the wax. After autoclaving, the remaining amount of wax that
soaked into the ceramic shell is burned out in a furnace. At this point, all of the residual
pattern and gating material is removed, and the ceramic mold remains. The mold is then
preheated to a specific temperature and filled with molten metal, creating the metal casting.

                       Once the casting has cooled sufficiently, the mold shell is chipped
away from the casting. Next, the gates and runners are cut from the casting, and final
postprocessing (sandblasting, machining) is done to finish the casting. It shows the CAD
solid model, the shell, and the pattern produced in the QuickCast process.

                   Investment casting process description (cont'd.)
              Investment casting process description

CAD solid model (top), ceramic shell with Quick Cast pattern (left),

                    Quick Cast pattern (right).
                                The major impact rapid prototyping processes have had on
investment casting is their ability to make high-quality patterns without the cost and lead
times associated with fabricating injection mold dies. In addition, a pattern can be fabricated
directly from a design engineer's computer-aided design (CAD) solid model. Now it is
possible to fabricate a complex pattern in a matter of hours and provide a casting in a matter
of days. Investment casting is usually required for fabricating complex shapes where other
manufacturing processes are too costly and time-consuming.

             CAD solid model (top), SLS polycarbonate pattern (left),

                               A356 aluminum casting (right).

            Stainless Steel    Steel Investment   Aluminum Investment   Nickel and Cobalt
         Investment Castings       Castings             Castings        Alloy Investment

This detailed explanation of the investment casting process is intended to help our customers
learn about investment casting to be able to make better purchasing decisions.


Replicas of the desired investment casting are produced by injection molding or for smaller
volumes using rapid prototyping (SLA or SLS). These replicas are referred to as patterns.


Patterns are then attached to a central wax stick, called a sprue, to form a casting. This is called a
wax tree.


The shell is built by immersing the wax tree assembly in liquid ceramic slurry and then into a bed
of fluidized fine sands. Up to eight layers may be applied in this manner depending on the shape
and weight of the part.


Once the ceramic is dry, the wax is then melted out, creating a negative impression of the
assembly within the ceramic and sand shell. This process uses autoclaves to maintain shell

In the conventional lost wax casting process, the preheated shell (up
to 1800 deg F) is filled with molten metal by gravity pouring the
metal into the ceramic shell. As the metal cools, the parts, gates,
sprue and pouring cup become one solid casting. Shell temperature
and melt temperature will vary depending on the alloy.                       Transfer Ladel


Once the metal is cooled and solid, the ceramic shell is broken off by
vibration or water blasting.


The parts are then cut away from the central sprue using a high speed saw.

After minor finishing operations, or possible required machining operations, the metal
investment castings--identical to the original wax patterns--are ready for shipment to the
customer from our metal investment casting China foundry. We are able to provide finished
stainless steel investment casting, steel investment casting, aluminum investment casting, cobalt
alloy investment casting, nickel alloy investment casting and precision investment castings.


Please call for tolerance specifications for wall thickness or any tolerances in general. Depending
on the metal or alloy, minimum wall thickness can range from 0.04 inches to 0.08 inches.

“Best accurate tools ensure best accurate patterns.”

Prevail Casting supports in-house Tool Room to make dies with the shortest lead time for
sample production. We have CAD/CAM facility for die designing and manufacturing by
using 5-axis and 4-axis VMC from DMG, Germany.

Details Of Testing Procedure:

Chemical Testing:

Chemical testing using Spectrometer ARL-3460
(made in Switzerland), which is well calibrated
using setting up samples and certified reference
We have ability to check seventeen elements in our spectrometer. (C, Si, S, P, Mn, Ni, Cr,
Mo, Cu, V, Ti, W, Co, Nb, N, Al and Fe)
Mechanical Testing:

Tensile Testing

Tensile testing using Universal Testing Machine of 10 ton
capacity, which is well calibrated.

It is equipped with Computerized Extensometer System to
calculate Yield Stress 0.2% and 1% Proof Stress.

Hardness Testing:

Hardness testing in HRC and HRB is done using Brinell
Hardness Testing Machine, which is well calibrated by
Micro Analysis:

Micro analysis using Olympus Microscope (made in Japan) with attached
Digital Camera up to 1000X magnification and Automatic Computerized Micro
Characterize Software. We can check following parameters.

1. ASTM Grain Size measurement

2. Linear Measurement/Angular Measurement

3. Inclusion Rating

4. Nodularity Of Cast Iron

5. Volume Fraction

6. Powder Particle Size Distribution

7. Hardness Indentation Mearsurement


                     NO.: 3460 WITH Ni,     LABORATORY-
                      Fe & Co BASE, 23      SWITZERLAND

2     MICRO SCOPE      MODEL NO.:          OLYMPUS-JAPAN       1

3         U.T.M.          10 TONNES        FIE-ICHALKARNJI,    1

                        CAPACITY            MAHARASTRA

4      ROCKWELL       RAS/RABI/RASM            SAROJ           1
        HARDNESS                            ENGINEERING
                       RAB 250/TWIN
         TESTING                           UDYOG PVT. LTD.

                      We have completely developed Conventional and CNC machine shop
with endowed and proficient staff to deliver castings in fully machined condition.

                      Our DMG, Germany makes VMC's with 5-axis and 4-axis machining
ability and Gildemeister; Germany creates CNC-Turning Machines. We have domestic
Fixture design and manufacturing facility as well and provide ―5-axis machining‖ and ―4-axis

                      Prevail Castings support standard and well calibrated instruments for
accurate inspection. The practice of in-process inspection of critical dimensions in our
company is distinctive.

                      CNC machine shop combined with Conventional Machining facility
ensures paramount accuracy and quality at unsurpassed competitive rates.
Investment castings, from India, China, and other parts of the Pacific Rim are making inroads
into the American market. Why? They are lower in cost and of high quality. Fine quality
products are now available in investment cast steel, aluminum, brass, bronze, high-nickel
alloys, and manganese steel. As with domestic sources, these "near net shape" parts often
need no machining and tooling cost is low, or even zero.
    Note the difference in finish between the sand cast product and the investment cast part on
    the left. While sand cast steel parts are lower in cost, for a slightly more, you can have a
    smooth finish that may help you avoid machining. These particular pieces were made both
    ways. Machined castings are especially good candidates for investment casting.

      These two different types of product like; sand casting & investment casting. Their
      product are totally different each other in sand casting there are heavy weighted and
      widest out look prouct and other side investment casting means wax product is also
      very heavy weight but out look is small size product.

Company has large capacity to store raw material of production process. They maintain
goods input as well as output register.

                      The Company has only one segment as its total investment is in
Investment Casting only. Company has undertaken employees‘ development initiatives,
which have very positive impact on the morale and team spirit of the employees.

                      The company has continued to give special attention to HUMAN

                      Company       has    also    adopted     APPRAISAL          SYSEM   &
PERFORMANCE REVIEW SYSTEM in some key area. Industrial relations remained
cordial throughout the year and there was no incidence of strike, lock-out etc.
                       The company has adequate system of internal control commensurate
with its operations to ensure orderly and efficient conduct of business. Company has an
adequate internal system to ensure that.

     All asset and resource are acquired economically, used efficiently and are adequately
  Significant financial, managerial and operating information is accurate, reliable and is
     provided timely; and
  All internal policies and statutory guidelines are with complied.
  The company has an Audit Committee which regularly reviews the report submitted by
     internal Audit team. Company has an internal control system towards achieving

                       In operation optimum utilization of resource, effective monitoring,
and compliance with applicable laws and regulations.

                       Company has established internal Audit Panel by in-house team, to
ensure reliability to financial and records, and to prepare financial statement and other data
and to maintain accountability. Committee of the Board reviews the findings and
recommendation of the internal audit panel.

                      In this part company has selected one manager, who is work for
company‘s all employees including managers and workers. A manager of personnel
department is timely visit to all members of the organization for their work condition and
work environment. They always guide about create healthy working environment, make good
relationship with all other members.

                      A personnel manager is also involve in conflict situation when it may
be arise and solved the entire problem with best solution. They always try that no one can feel

        Create Good working environment.

        Maintain Long Term Relationship

        Solve Entire Problem.

        Provide Strong Link Between Two Hierarchies.

                         LIST OF MACHINERIES

SR           NAME OF               SPECIFICATION              MANUFECTURER NO.

 1          INDUCTION                        300 Kg.                                        1
          FURNACE WITH                       150 Kg.

 2                                            -
          SEMI AUTOMATIC                                               MAYUR
               WAX                                                  ENGINEERIG             13
       HEAT TREAMENT              COMPUTERISED             PATEL FURNACE              2
                                75 Kg. OF 30 KW &        AND SHOT BLASTIG
                                 150 Kg. OF 75 KW
 4                                MODEL NO. 649.               GALA
         SHOT BLASTING                                                               1
                                    (80 Kg.)               MANUFACTURER

 5                                    VB 625 R/D
                                                             MEC SHOT
       VIBRO POLISHING                                                               2
                                                          BLASTING EQUIP

 6                                        -                 DECKEL MAHO
           GLASS BEAD                                         (GERMANY)              1

 7          VERTICAL
                                  WORKING AREA
                                                            DECKEL MAHO
                                 (X/Y/Z:630/560/560)                                 1
           MACHINING                                          (GERMANY)
             CENTRE (5-

 8          VERTICAL
                                                            DECKEL MAHO
                                  WORKING AREA                (GERMANY)              1
          MACHINING              (X/Y/Z:730/560/560)
         CENTRE (4-AXIS)

 9         HORIZONTAL                                       DECKEL MAHO
                                 WORKING AREA                 (GERMANY)              1
            TURNING                (X/Z:260/500)
                            TECHNICAL DATA

Alloy Handled

                    We can produce Any Special metals as per Customer‘s Specification or
International Standard Specifications like IS, ASTM, AISI, SAE, UNI, UNE, AFNOR, DIN,
    Some of the general alloys that we handle regularly are listed below in table below.

       Carbon Steel:                SAE - 1020, 1030, 1040, 4140, WCA, WCB, WCC,
                                              LCA, LCB,EN-8, EN-9, EN-36,

Austenitic Stainless Steel:           CF8 , CF8M , CF3 , CF3M, CF8C, CF8 (NM),
                                         CF3M (NM), CK-20, CN-7M (Alloy 20)

Martensitic Stainless Steel:              410 (CA-15) , 420 (CA-40), 431, 440C

  Duplex Stainless Steel:             CD-4MCu, CD-4MCuN, CD3MCuN, CE3MN,

    PH Stainless Steel:                   CB7Cu-1(17-4PH), CB7Cu-2(15-5PH)

       Super Alloys:                  HAST- B, HAST- C,HAST-B3, STELLITE-6,
                                               STELLITE-3, CZ-100, Monel

   Non Ferrous Alloys:                    Brass, Bronze and Other Cu-Base alloys

                  Applicable Reference Tolerance standards are IS 11166, ISO 2768,
VDG-P690.DIN1680, and Class 2.

                         DIMENSIONAL TOLERANCE:
                   Dimension (mm)                   Tolerance (mm)
                         Up to 25                        ± 0.125
                             25-50                            ± 0.25
                             50-75                           ± 0.375
                            75-100                            ± 0.5
                            100-150                           ± 0.75
                            150-200                            ±1
                            200-250                           ± 1.25
                            250-300                           ± 1.5
                   Dim         As CAST          Mechanical Straightened
                  Range          (mm)                         (mm)
                 Upto 25          0.15                        0.1
                    50               0.2                      0.15
                    75               0.3                      0.2
                    100              0.4                      0.25
                    150           0.55                        0.4
                    200              0.9                      0.7

                Diameter (mm)                   Tolerance (mm)
                       25                              0.15
                       50                              0.4
                       75                              0.5
                      100                              0.75

                          Computer-Aided Approach
                      The modern approach to investment casting development is a result of
two major factors. The first is the customer demand in terms of quality consistency (mainly
conformance to geometry and property specifications), shorter lead-time (for sample part as
well as regular production) and continuous reduction in cost (essentially tooling development
and manufacturing costs, since material costs are usually fixed). These cannot be satisfied by
conventional approaches alone.

                       The second major factor is the decreasing availability of technically
skilled and experienced manpower for processes that have a large number of human-
controlled parameters, and therefore involve many changes in tooling and process parameters
before producing satisfactory parts.

                       Casting in general, and investment casting in particular, fall in this
category, and require at least a decade of dedicated learning through trial and error or
preferably under the able guidance of a senior engineer. With a sharp reduction in the number
of qualified engineers taking up long-term careers in manufacturing, there is a serious
problem indeed, and therefore industries are turning towards modern technologies to capture
the domain knowledge and automate the processes.

                        Here we describe a computer-based approach to rapidly develop an
investment casting, focusing on pattern design and methoding optimization, which is the most
critical and time-consuming activity (see Figure 2). The first step in computer-aided approach
to casting development is the creation of a solid model using a 3D CAD software (like Pro-
Engineer, SolidWorks or Unigraphics). These provide functions such as extrusion, revolution
and Boolean operations starting from a 2D sketch or standard primitives (cube, cylinder,
sphere, etc.), followed by modifiers (like draft and fillets).

                       However, when intricate freeform shapes are involved (such as in art
castings) the conventional CAD systems are inadequate. One answer is in haptic or touch4
based modeling systems (such as the Phantom from Sensable Technologies, USA), which
literally allow a user to sculpt by holding a robotic arm and thus create a complex model in
virtual space.
                      The second approach, suitable when a physical model already exists, is
to reverse engineer the solid model using one of the contact or non-contact systems. The
systems give a cloud of points, over which a surface can be fitted and then converted into a
solid model. Using specialized modules in the CAD software (such as Pro/Casting) or
specialized software (such as Delcam DUCT), the part model is converted to pattern model
by applying draft, shrinkage, machining and other allowances.

                      The parting plane may be identified interactively by the user by
specifying the points along the parting line, or assisted by the software. Application of
allowances is at best a semi-automatic task and at worst an interactive task (for example, the
user identifying each face to which draft has to be applied and specifying the appropriate
draft angle).

                       The next step is to decide the best design and layout of feeders and
gating system. The feeder design involves identifying the last solidifying region (hot spot)
inside the casting and placing a top or side feeder with appropriate shape and dimensions. The
modulus principle may be used for the first approximation, but it has to be verified and
optimized by casting solidification simulation.

                      Pump Parts include Investment Castings used in Chemical & Oil
Industries, made of Stainless Steel or Super alloys. E.g. Castings for Pump Impeller, Pump
Casing, and Pump Cover, Diffuser, Mechanical Seals etc. The smooth surface finish with
Investment Casting offers highest efficiency.

Several definitions have been proposed for the term marketing. Each tends to emphasize
different issues. Memorizing a definition is unlikely to be useful; ultimately, it makes more
sense to thinking of ways to benefit from creating customer value in the most effective way,
subject to ethical and other constraints that one may have. The 2006 and 2007 definitions
offered by the American Marketing Association are relatively similar, with the 2007
appearing a bit more concise. Note that the definitions make several points:

                              •      A main objective of marketing is to create customer

                                          •          Marketing usually involves an exchange
                                          between buyers and sellers or between other

                                          •          Marketing has an impact on the firm, its
                                          suppliers, its customers, and others affected by the
                                          firm‘s choices.

                                          •          Marketing frequently involves enduring
                                          relationships between buyers, sellers, and other

•      Processes involved include ―creating, communicating, delivering, and exchanging

                              Marketing is a dynamic exciting and challenging activity. If
efforts ample of employment opportunity in the modern business world.
                       DEFINITION OF MARKETING:


     “Marketing is the activity, set of institutions, and processes for creating,
communicating, delivering, and exchanging offerings that have value for
customers, clients, partners, and society at large”

        According to Philip Kotler, " Marketing is analysis, Planning, Organizing, and
Controlling of the firm and customers, implying resources, facilities, activities with a view to
satisfy the needs and wants of customer group at a reasonable level of profit. "

        The directors of this company are engaged in business over 11years in this district.
The market is tremendous and the said is globalizing all over India.

        Therefore the marketing at any level or at any production capacity and management
is very much hopeful to achieve the same without any difficulties and shall be able to face the
competitions easily.

        Market segmentation is the art of diving a market in to distinct groups for buyers who
might require separate products and marketing mixes is called on.

        Since, the company have only one product, the market cannot be segmented either of
demographic of physiographic bases. So the company has segmented its market has been
divided in to two zones.

          In the local markets company deals with much local company at
            industrial area of Shaper (Veraval), Metoda, etc
          In National market the company deals with many companies like
            INVESTA PUMPS PVT. LTD, Mumbai & many more companies.


          Prevail Casting Pvt. Ltd. Undertakes manufacturing and supplying
            wide range of unmachined (raw casting) and machined Investment
            casting to the domestic and foreign market.

          A company not only deals with local or national market but also as
            well as International Market like Tyco valves & controls, USA.
                                   Market Research

           Marketing research is the function that links the consumer, customer, and public to
the marketer through information--information used to identify and define marketing
opportunities and problems; generate, refine, and evaluate marketing actions; monitor
marketing performance; and improve understanding of marketing as a process. Marketing
research specifies the information required to address these issues, designs the method for
collecting information, manages and implements the data collection process, analyzes the
results, and communicates the findings and their implications.

Why Market Research is Important?

                      Market research is an essential part of any business that wants to offer
products or services that are focused and well-targeted.

                      Business decisions that are based on good intelligence and good
market research can minimize risk and pay dividends and by making market research part and
parcel of the business process and conducting market research throughout the lifecycle of a
product or service market research will bring the following benefits:-

                      Market research will help you better communicate - Your current
customers experiences are a valuable information source, not only will they allow you to
gauge how well you currently meet their expectations they can also tell you where you are
getting things right and more importantly where you are getting things wrong by asking the
customer you not only show them that you care but you also take the guess work out of
customer services.
                      Market research helps you identify opportunities - If you are planning
to operate a new service and want to know the preconceived attitudes people have then
market research can help, not only in evaluating the potential for a new idea, but also by
identify the areas where a marketing message needs to honed.

                      Market research will minimize risk - Market research can help shape a
new product or service, identifying what is needed and ensure that the development of a
product is highly focused towards demand.

                      Market research creates benchmarks and helps you measure your
progress - Unless you measure you may not be able to gauge how well your business is
performing. Early research may highlight glaring holes in your service or short falls in your
product, regular market research will show if improvements are being made and, if positive,
will help motivate a team.

―Set of procedures and practices employed in analyzing and assessing marketing information,
gathered continuously from sources inside and outside of a firm. Timely marketing
information provides basis for decisions such as product development or improvement,
pricing, packaging, distribution, media selection, and promotion‖

       Managing Director

       General Manager

       Marketing Manger



                      Selection and recruitment of the employees is on the hand of marketing
director. In the company on job training are given to the employees so that they apply it well
at their work. And for the development of the company can make yearly performance review
and give gradation and as per that grade company give promotion to the employs. Transfer of
the company is done whenever there is any requirement to the sisters company otherwise
there is no any system of transfer of employee in the company.

                      Prevail Casting Pvt. Ltd. has get permission to sale their product in
INTERNATIONAL or FOREIGN MARKET. A company is export their product in many
country like USA, EUROPE and other country.

                      Company Export its product to U.K., Germany, U.S.A., And China.
The company has achieved remarkable growth in the export sale compare to last year.
Company marketing team is still making efforts to capturing more export market.

                              In this modern age, it is very easy to understand the important
of finance in business. As current position is totally different from the ancient years where to
get finance was so easy. But to it is very difficult to raise fund without proper planning. As
we know that finance is the life blood of modern business world considering the importance
of finance each and every company should manage to get sufficient finance. Finance
management can be defined as a task of acquiring and utilizing funds needed in business in
terms of the objectives of business.

                              In modern business society finance are drawing more and more
attention of all those who are responsible for running financial administration financial
management is a subject associated with problems , challenges , risk and uncertainty related
with finance. The subject also analyses performance of the firm with it or other units.
Financial management as a subject found since 19th century, scope of financing management
has change a lot.
                         ACQUISITION OF FUNDS:

In our present day economy, finance is defined as the provision of money at the time when it
is refer to every enterprise, whether big, medium of small, needs finance to carry on its
operations and to ach targets. In fact, finance is so indispensable today that it is rightly said to
be the lifeblood of an enterprise. The adequate finance, no enterprise can possibly accomplish
its objectives.

Acquiring Sufficient Funds:

The main aim of finance function is to assess the financial needs of an enterprise and then
finding out suitable sources for raising them. The sources should be commensurate with the
fields of the business. If funds are needed for longer periods then long-term sources like share
capital ventures term loans may be explored. A concern with longer gestation period should
rely more on owner instead of interest-bearing securities because profits may not be there for
some years.

    Managing Director

    General Manager



                             FINANCIAL PLANNING

It is the process of estimating the firm‘s future financial requirement. It also refers to the
source by which requirement can be fulfilled. It also speaks the fund flows, when we get and
how to utilize and thus it covers the following activities.

            Estimating the firm‘s financial requirement

            Determining the source from which the funds are to be collected

            Determining the use of the funds

                       The planning problems are the most crucial point for financial manager
and top executives. Here, Prevail Casting Pvt. Ltd. adopts long term as well as short term
plans as per financial requirement.
                        ADMINISTRATION DEPARTMENT


In this area when any person feel can not well about their health, so company provides
primary healthcare treatment to the person.

              Provide Health Insurance for all Employees.
              Provide Health Allowances.
              Health Insurance for Family Members.
              Provide Advice for Critical Dieses; Like AIDS, Diabetes, Blood Pressure, Heart
               Problem all guided by some expert person.


                         In company provide some type of training for their employees, who
employ has require which type of training for betterment of their knowledge as well as their

          Off Job Training.
          On Job Training.
This department is arranging some cultural activity for all organization members like;

       Celebrate Diwali festival.
       Celebrate Janmastmy.
       Rangoli Competition.

                      PREVAIL CASTING PVT. LTD. has also provide some extra facility
to their employees like; Transportation Facility

                       Above All Reason Company treated their employees like their
FAMILY MEMBERS. Company also cares about employees other family members, their
                                SWOT ANALYSIS

                      Every company does SWOT Analysis for monitoring their current
position in the market. They do this analysis for the purpose of identifying their strengths,
weakness, opportunities and threats. ―After gaining an enjoy in the customer home, smart
markets aim for space in the customers hear too‖.

                       To rich at customers here Prevail Casting Pvt. Ltd. is doing SWOT
analysis so that they can add value to the customer‘s feedback is the breakfast of any firm or

SWOT means:

             S    : - Strength.

             W   : - Weakness.

             O    : - Opportunity.

             T   :-   Threat.

      Well-maintained infrastructure.
      Dedicated, Intelligent and Loyal
      This Company has nationally as well as internationally
         Market for their products.
      They have very different and monopoly type product line.
      Wide product range to enable the clients to choose the best alternative.


      The major weakness of ―PREVAIL CASTING PVT. LTD.‖ can be said Raw
        Materials‘ used to produce the product is very high fluctuate items because of
        Company never compromise in any types of Raw material to produce any

        Large potential market for delivery and more opportunity in national market as
          well as international market.
        Today day by day the demand of product of the company increases
          tremendously. This affects the demand for auto parts.
        The Foundry industries depend upon how the raw material prices fluctuates
          and respective hike in the sales price of finished products, they further depend
          upon competition among various segments of manufactures within country
          and from manufacturers of outside the country.


     Threats are always at your doorstep wherever you are going to do something. The
       major threats that can be categories as natural calamity as well as the action taken
       by the competitors.

     The Threat of competition is comparatively less in the products which your
       company is manufacturing viz. Investment Casting.

     Awareness towards quality product and potentially of India casting in foreign
       market will provide opportunity to your increase its sale and capture more market

     Company‘s Basic raw material is SCRAP & WAX SILICON SOL, MAGNESIA
       SCRAP & all the mixtures are fluctuating, in furtherance cost of electricity and
       cost of labor through under watch they are also matter of concern.
 Fluctuating trend in the price of fuel (Diesel, L.P.G.) is always matter of concern
   for every industry as to outs.

 Above this competition in the industry has increased, which has made it hard to
   raise the price of product through cost of the final product is higher.

 Change in Government Policy, Foreign Exchange rate may affect the company.
   However company is trying to minimize certain risk by taking the steps, which are
   in the hand of company.


       The company is using latest technology in production.

       They are appointing only technical persons who operate a CNC machine for
        production process.

       The company is continuous focusing on the quality improvement.


     According to my opinion, if company provides one DRESS COAT for different
        level to different employees, so they create more impressive personality to their
        customers or out side‘s people.
     company provide CANTEEN FACILITY for their employee‘s as well as their
        visitors so, any person can spent their more time in the organization or also there
        is useful for food arrangement peoples.

    Kotler Phillip, ―Marketing Management: Analysis Planning Implementation &

     Control ‖

 C. R. Kothari, ―Research methodology, methods    and techniques‖, Second Edition,

     New age international publisher, New Delhi.







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