A PROJECT REPORT ON THE ORGANISATIONAL STUDY AT

PEEKAY STEELS CALICUT

Submitted to Bangalore University, Bangalore for the partial fulfillment of the
requirement for the award of
MASTER OF BUSINESS ADMINSTRATION
Submitted by
AHMAD UMBIHI AM!!"
#$%&H" I"S#I#U#! &' MA"A(!M!"# A"D SI!"!
)Affiliated to Bangalore University* +,,-
.
DECLARATION
#his is to state that the study titled /An organi0ational study on 1!!2A3 S#!!4S5 is
based on the original wor6 7arried by me under the supervision of Mrs$ 1riya 4e7turer,
Dept$ of management studies towards the partial fulfillment of the requirement for the
MBA 7ourse of Bangalore University during the third semester$
+
ACKNOWLEDGEMENT
#he satisfa7tion and euphoria that a77ompany the su77essful 7ompletion of any tas6
would be in7omplete without the mention of people who made it possible, whose
7onstant en7ouragement 7rowned the efforts with su77ess$
8ith immense pleasure I wish to e9press my sin7ere gratitude to Mr$1$S Abdulla 6oya,
Business Development manager, 1ee6ay :olling Mills for his 6indness and help he
showered upon me$ I also e9press my sin7ere gratitude to Mr$ Monnu %ohn, head of the
department of management studies And Mrs$ 1riya, 4e7turer Management studies for
their guidan7e and support through the organi0ational study$
#his a76nowledgement would be in7omplete without e9pressing my whole hearted
than6s to my parents, relatives and friends who motivated me and for their sin7ere
inspiration and en7ouragement they showed through out the study$
In the a7hievement of an enri7hed e9perien7e, I wish to a76nowledge with heart filled
gratitude to all those who have helped in the 7rystalli0ation of this pro;e7t$
4oo6ing ba76, I see a lot of other en7ouraging fa7es and helping hands whi7h guided me
through the pro;e7t$ I than6 them all of the su77essful 7ompletion of this study$
Above all I than6 almighty god for giving me wisdom and 6nowledge to the 7omplete the
study in time and to the best of my abilities
<
CONTENTS
hapter=.
.$ Introdu7tion
+$ Steel Distribution= Industry 1rofile
<$ Indian Steel Industry
>$ Steel 1ro7essors = Business :atio :eport
?$ &rgin of steel
@$ Strategi7 :estru7turing for the Indian Steel Industry
hapter=+
.$ ompany 1rofile
+$ &rgani0ational Stru7ture
<$ #he #emp7ore 1ro7ess
>$ Auality 1oli7y
?$ Bision
@$ Mission
-$ 4o7ation Map
C$ orporate So7ial :esponsibility
D$ !nvironment Safety
.,$ #e7hni7al S6ill #raining 1rogrammes
..$ Awards E :e7ognitions
hapter=<
.$ Mar6eting E 1rodu7t Details
+$ Sales
<$ Dealers
>$ ustomers
hapter=>
.$ Human :esour7e department
+$ 'inan7e Department
<$ 1rodu7tion Department
>
hapter=?
.$ #he 1ee6ay Advantage
+$ S8&# Analysis
<$ 'indings, Suggestion and on7lusion
>$ Bibliography
?
INTRODUCTION
Man has been using steel sin7e periods$ An7ient utili0ation of Mesopotamia,India,hina,
(ree7e and :ome all had some 6nowledge of the produ7tion of iron and some of them
also had 7rude steel$Assysilians used iron weapons to 7onquer neighboring
Mesopotamian 7ountries$
#he first iron produ7ed was wrought iron by ?,, B$ #he 7ementation pro7ess of ma6ing
steel was dis7overed$ ast iron was developed in hina in +,,B$Hen7e, from ma6ing
weapons and through dis7overy of 7ementation pro7ess, ru7ible pro7ess, Benemer
pro7ess, &pen hearth pro7ess, Blast furna7e, !le7tri7 Ar7 pro7ess, and Indu7tion pro7ess
et7 dis7overed till today the 7onsumption of steel has risen to very large amount$
Iron and steel industry in the group of 7ompanies that mine and pro7ess iron=ors, indire7t
the iron and 7onvert mort into steel$ #he remaining iron is pro7essed for use in iron
produ7ts$ Steel is produ7ed in many fasi7 shape and si0e$ &ther industries are these basi7
forms to manufa7ture automobiles, refrigerators, 7asting and many other produ7ts$
#he fasi7 si0es and shapes are mainly Blooms, Billets, Ingots and slabs whi7h are also
7alled semi finished produ7ts$ the finishing mills use these to give rise to final produ7ts
mainly steel and strip,fars plates pipes and tubes in 7otton steels, stru7tural shapes, wire
rails and ma7hines$
Steel is su7h an important material that a nationFs industrial strength and standard of
timing are often measured by the amount of steel it 7an produ7e$ #he worldFs ma;or steel
produ7ers are US, :ussia, (ermany, %apan and United 2ingdom$ It is a part and par7el
of the e7onomy almost all 7ountries developed$ #otal world produ7tion of steel is
estimated of steel is estimated at D,, million tones per year an the Us 7ontributes to the
.G@ th of the worlds produ7tion$
@
Origin of st!
Steel is a rather spe7ial form of ironH an appropriate definition for this a77ount would be
iron alloyed with ,$?I to .$?I 7arbon, so distinguishing it from wrought iron, whi7h has
mu7h less 7arbon, and from 7ast iron, whi7h has more 7arbon$
#he an7ients re7ogni0ed the value of steel, and also 6new the arts of hardening and
tempering, is 7learJ what they did not 6now was the a7tual 7ause of the differen7e
between iron and steel$ Indeed, it was only at the end of the eighteenth 7entury that the
role played by 7arbon was finally elu7idated$ It was in .-C. that Bergman, in Sweden,
reported he had found that 7ast iron 7ontained up to <$<I of what he termed KplumbagoK,
steel 7ontaining up to ,$CI and wrought iron, less than ,$+I$ In .-C@, a group of 'ren7h
savants published a paper whi7h, essentially substituting K7harbonKfor BergmanKs
KplumbagoK, established 7arbon as the essential 7onstituent that distinguished soft iron
from hardenable steel$
1rior to this date, throughout the early part of what we now term the Industrial revolution,
steel e9hibiting a fitness for purpose had been produ7ed on what was 7learly a
7ommer7ial basisH repeatedly and reliably$ Admittedly, this was only a7hieved by what
have been 7alled Krule of thumbK pro7eduresJ on7e a method had been shown to wor6, then
none of the parameters must be 7hanged$ It 7ould, however, be 7ommented that modern
quality 7ontrol systems also 7all for adheren7e to standard methods of produ7tion$
#he earliest steel was provided by a modifi7ation of the bloomery pro7ess for iron
produ7tion, some 7arbon being retained in the metal ta6en out from the hearth$ #his dire7t
produ7tion of steel from the ore was a deliberate a7t on the part of the smith, presumably
by ad;ustment of the ratio of 7har7oal to ore$
8ith the repla7ement of the bloomery by the blast furna7e in the medieval period,
produ7tion of steel from 7ast iron be7ame more 7ompli7ated$ Sin7e the 7arbon 7ontent of
steel falls between that of 7ast iron and wrought iron, it was logi7al to endeavor to refine
7ast iron by partial removal of 7arbon, leaving the 7orre7t amount in the produ7t$
Another approa7h was to refine the 7ast iron by removing virtually all the 7arbon, so
-
produ7ing wrought iron$ #his, in flat re7tangular bars, was then re7arburised in a
7ontrolled manner by embedding in 7rushing 7har7oal and heating to a bright red heat,
whereby 7arbon from the 7har7oal gradually diffused into the body of the iron, 7onverting
it into the produ7t 6nown as Kblister steelK$ #his was the K7ementation pro7essK and, again,
did not involve the produ7tion of molten metalJ although the bars were modified
somewhat in appearan7e, they retained their physi7al identity$ #he pro7edure, first
des7ribed in .@,. and 7ited in a patent of .@.>, was obviously a wor6ing pro7edure
during the seventeenth 7entury and was in operation throughout the whole of the
Industrial :evolution$ #he produ7tion of molten steel 7ame with the wor6 of Huntsman in
the .->,s, utilising a 7o6e=fired furna7e to melt blister steel in a 7ru7ible, so produ7ing a
homogeneous melt, whi7h 7ould then be poured into a suitable mould to produ7e an ingot
of K7ast steelK$ #he 7ombination of the 7ementation furna7e with 7ru7ible furna7es be7ame
the Kintegrated steelwor6sK of the first half of the nineteenth 7entury in Britain$ #he story
of steel 7ontinues even today$
St! Distri"#tion $ In%#str& Profi!
overing over .-? industries and updated every D, days, the 'irst :esear7h Industry
1rofiles do the heavy lifting for you = saving your sales team valuable resear7h time,
enhan7ing 7lient 7ommuni7ations and giving you the 7ompetitive edge to win more
business$
!asy=to=use and up=to=date, the Industry 1rofiles provide you with the industry resear7h
ne7essary to stay on top of 7onstant 7hanges in sele7t industries$
#he 'irst :esear7h profiles help target your produ7ts and servi7es dire7tly to prospe7ts$
#he Industry 1rofiles provide the information and understanding you need to engage new
prospe7ts during the sales pro7ess, deepen 7ustomer relationships and strengthen your
own bottom line$
C
E'(#ti) S#**+r&
Brief !97erpt from Industry &verview hapterH
In the US, about .,,,,, 7ompanies distribute steel and other metals, with 7ombined
annual revenue of L.., billion$ 4arge 7ompanies in7lude :yerson, #hyssen, Metals USA,
and :elian7e Steel E Aluminum$ #he industry is fragmentedH the ?, largest 7ompanies
only hold about ?, per7ent of the mar6et$ A typi7al large distributor has annual sales of
L?, million and around <? employees$
COMPETITI,E LANDSCAPE
#he health of the manufa7turing and 7onstru7tion industries drives demand for steel$ A
distributorFs sales volume determines profitability be7ause many 7osts are fi9ed$ 4arge
distributors benefit from e7onomies of s7ale in pur7hasing, pro7essing, and distribution$
Small 7ompanies 7an 7ompete by spe7iali0ing in parti7ular produ7ts or offering spe7ial
pro7essing servi7es$
PRODUCTS- OPERATIONS . TECHNOLOGY
Steel produ7ts are made from 7arbon or alloy, stainless or spe7ialty steels, and 7ome in
the form of sheets, plates, bars, rods, tubes, and stru7tural items li6e rails and I=beams$ In
addition to selling steel mill produ7ts, distributors sell various pro7essing servi7es that
7ustomi0e produ7ts for parti7ular 7ustomers$ Be7ause of the large number of steel
produ7ts, most distributors spe7iali0e in the types of steel they 7arry and types of
pro7essing operations they perform$ Different grades of metal and the varying thi76nesses
and si0es of materials result in a large variety of produ7ts$ A large distributor may handle
C?,,,, produ7ts$
Although several large 7ompanies have grown by a7quisition in the past de7ade, most
distributors have ;ust one fa7ility$
D
(lobal steel demand is rising on the ba76 of a77elerated infrastru7ture a7tivity in hina,
IS and India, housing boom in USA, and white goods resurgen7e in !urope$ During the
re7ent re7essionary phase, the industry has 7onsolidated in terms of ownership as well as
mothballing of ineffi7ient 7apa7ities$ Steel pri7es 7ontinue firming up$
'or the first time in last +, years, there is demand growth all over the world for steel$
In US, the demand is led by the booming housing industry$ Additionally the auto
industry is showing signs of re7overy as auto sales hit their strongest levels for the year in
%uly even as US posted a +$>I (D1 growth$
= In !urope, there is demand from a buoyant housing and white goods industry a77ording
to industry sour7es$ In India, hina and other Asian 7ountries the demand is led by
emphati7 investment a7tivities in infrastru7ture$ :ussia and other IS nations are also
witnessing strong internal demand$ = Iraq re7onstru7tion wor6 is e9pe7ted to fuel further
demand for steel over the ne9t three years$ hina is 7onsuming steel li6e never before for
its infrastru7ture with investments su7h as #hree (orges pro;e7t on 3angt0e as well as
part of its build up to the Bei;ing &lympi7s in +,,C and the Shanghai !9po in +,.,$
#he demand supply gap is e9pe7ted to in7rease and this will drive steel pri7es
northwards, even as the global steel industry is not prepared for this demand onslaught$
In%i+n st! in%#str&
In India large s7ale steel ma6ing was only in the government se7tor$ #he only private
se7tors plants were those of #A#A irons and steel 7ompany and Indian iron and steel
7ompany$ Small steel ma6ing units with small 7apa7ity !A'GIndu7tion furna7e and re=
rolling mills were set up in the private se7tor$
#he growth of steel industry in India was restri7ted as the private se7tors were not
allowed to set up large integrated steel plants$ #he pri7ing and distribution were
7ontrolled by the government$ Imports were restri7ted and import tariffs were high,
.,
development was very slow in other se7tors li6e agri7ulture, automobile, engineering and
7onstru7tions$
In the se7ond half of the eightyFs, the government de li7ensed the industry and many
private entrepreneurs showed interest in setting up steel plants$ Some of them already
been 7ommissioned and the rest are in pro7ess$ In the early of ninetyFs , the government
de7ontrolled the pri7ing and distribution and also progressively redu7ed the import
tariffs$ #his brought in 7ompetitiveness in the se7tor and the industry started growing at a
rate of ?I by the mid ninetyFs$ However in .DD@, the growth had flattened out and today
the industry is saddled with large inventory while profit margins have been seriously
eroded$ &ne of the reasons for this is the la76 of demand whi7h is due to the 7ountries
very low steel 7onsumption$ Moreover substantial in7rease in 7ost of inputs and sluggists
mar6et 7onditions prevented the industry from offsetting this by the way of sales
reali0ation$
In short in India, the steel industry has been severely affe7ted by the general e7onomi7s
slow down
St! Pro(ssors $ B#sinss R+tio R/ort
#his Business :atio :eport 7ompares the finan7ial performan7e of the leading players in
this Industry se7tor, offering a qui76 and 7ost=effe7tive 7ompetitor analysis tool for senior
management$
:atios are an invaluable tool for 7omparing the performan7e of 7ompanies on a li6e=for=
li6e basis$ Using ratios, the relative profitability, growth or debt levels, for e9ample, of
differently si0ed 7ompanies 7an be dire7tly measured or 7ompared with ease$ #his
Business :atio :eport fo7uses on the performan7e of 6ey players in the steel pro7essing
industry$ Having 7losely analy0ed the se7tor, our editors and analysts have 7ompiled the
largest 7ompanies, so you donKt have to$ A Business :atio report is, in effe7t, a 7omplete
finan7ial referen7e for the se7tor$
..
A business ratio report 7an be used to assess trading and finan7ial information onH
#he ompanyH
=Si0e
=Stru7ture
=1erforman7e
#he IndustryH
=Stru7ture
=Ma;or 7ompanies
=1erforman7e
8hat you 7an loo6 for when reading your Business :atio :eportH
= #rends
#he results given in a Business :atio report generally 7over at least the previous three
full a77ounting years, therefore any flu7tuations in any area 7an be easily pinpointed
= Ben7hmar6s
#he average results for ea7h ratio together with the industry profile of the average
7ompany in the se7tor 7an both be used as ben7hmar6s to 7ompare individual 7ompany
performan7e$
Si0e
All the ma;or 7ompanies in the se7tor are ran6ed on the basis of sales, profits, total assets
and employee numbers )1!:'&:MA"! 4!A(U! #AB4!S M Se7tion >*$ #he largest
and smallest of the 6ey players 7an be easily identified, while the relative si0e of any
7ompany 7an be assessed$
(rowth
#he average annual growth of ea7h 7ompanyKs sales, profits, total assets and number of
.+
employees over the three=year period being analy0ed is 7al7ulated and ran6ed
)1erforman7e 4eague #ables M Se7tion >*$ #his 6ey information highlights strong and
wea6 performers, whi7h 7ompanies are e9panding or losing mar6et share, in7reasing or
de7reasing asset investment, or ta6ing on or shedding employees$ #he industry results are
also given for 7omparison purposes$
#his information is perfe7t for all 6inds of planning and de7ision=ma6ing
In7ludingH
ompetitor
Analysis the depth of finan7ial analysis provided on ea7h 7ompany in ea7h report offers
you a 7omprehensive insight into the performan7e of individual businesses over re7ent
years$ #he performan7e ratios let you easily identify the finan7ial strengths and
wea6nesses of 7ompetitors in terms of profitability, liquidity, gearing, effi7ien7y and
employee performan7e
Simple Ben7hmar6ing
A Business :atio :eport is ideal for ben7hmar6ing your own 7ompanyKs performan7e$
3ou 7an 7hoose to ben7hmar6 your 7ompany against a ma;or 7ompetitor, or assess the
overall industry average performan7e$ And you 7an fo7us on the 7riteria that are
important to your business, su7h as profitability, employee performan7e or sales growth$
Setting realisti7 performan7e targets be7omes easier for youJ with Business :atio
:eports, you will 6now that they are based on solid fa7ts about your industry$
#ra76ing 1erforman7e #rends
8ith at least three years of finan7ial data for ea7h 7ompany and the entire industry you
7an identify performan7e trends instantly$
Identifying A7quisition #argets
Business :atio :eports ma6e it simple for you to identify potential a7quisitions$ 3ou 7an
easily find 7ompanies fitting your 7riteria using the 1erforman7e 4eague #ables$
.<
A Business :atio :eport ta6es the hard wor6 out of finan7ial performan7e analysis$ 3ou
are left free to fo7us on using the vital information it imparts to drive your business
forward$
Strategi7 :estru7turing for the Indian Steel Industry
#here have been almost revolutionary 7hanges in the global steel s7ene with fier7e
7ompetitive pressures on performan7e, produ7tivity, pri7e redu7tion and 7ustomer
satisfa7tion$ "ational boundaries have melted to en7ompass an ever in7reasing world
mar6et$ #rade in steel produ7ts has been on the upswing with the produ7tion fa7ilities of
both the developed and the developing 7ountries 7omplementing ea7h other in the ma6ing
of steel of different grades and spe7ialty for the world mar6et$
#he Indian steel industry 7omprises of the produ7ers of finished steel, semi=finished steel,
stainless steel and pig iron$ Indian steel industry, having parti7ipation from both publi7
se7tor and private se7tor enterprises, is one of the fastest growing mar6ets for steel and is
also in7reasingly loo6ing towards e9ports as driving the growth of the industry$
Aruvian :esear7h brings a resear7h report on Strategi7 :estru7turing for the Indian Steel
Industry fo7using on the Indian Steel Industry and analy0ing ea7h and every aspe7t of the
industry, but mainly fo7using on the strategi7 restru7turing the industry requires and is
presently undergoing to meet up to the 7hallenge of the global steel industry$ Starting
from an analysis of the 7ompetitiveness of the industry to the produ7tionG7onsumption
s7enario of the industry, the report analy0es the Indian Steel Industry through a S8&#
framewor6 analysis, a 1!S# framewor6 analysis, and a 1orterFs 'ive 'or7es Strategy
Analysis$ #hen it moves on to the strategi7 restru7turing analysis$
An analysis of the ma;or players in the Indian Steel Se7tor and the (lobal Steel Industry
7ompletes this 7omprehensive resear7h report$
.>
HA1#!:=+
COMPANY PROFILE
COMPANY PROFILE
1ee6ay :olling Mills )1* 4td$ Is an IS& D,,.H+,,, 7ertified 7ompany, a77redited by the
bureau of Indian standards )BIS*H ISI li7ense holder ISH .-C@=.DC?$ 1ee6ay has now
adopted #emp7ore te7hnology under li7ense from :M Belgium for the produ7tion of
#M# :e=bars$
GROWTH
'ounded in .D>+ by the visionary Ha;i 1$6 Moidu, ours is a story unstinting dedi7ation to
quality, the strong foundation laid down by his e9traordinary business a7umen and
un7ompromising integrity has forged a 7ompany that remains 7ommitted to providing the
7onsumer the very best$ &ver the past ?, years, the group has 7herished these values and
fo7used on new ob;e7tives$ "ew ventured in whi7h it 7ontinues to set ben7hmar6s$ #oday,
the 1ee6ay (roup has a turn over of USD -? million$
1ee6ay :olling Mills )1* 4td$ Is South IndiaFs only produ7er of 'e ?,, grade #M# bars,
1ee6ay steel is trusted by many of the leading builders a7ross states, be7ause we offer
premium quality, at pri7es that are signifi7antly lower than those of premium brands$
#he groupFs strong vision has given it the right dire7tion and ever=in7reasing urge to
grow$ It is this vision that is leading 1!!2A3 group to new hori0ons, e9panding and
diversifying to new industries and 7utting edge te7hnologies$ At present, the groupFs
.?
a7tivities in7lude steel produ7tion, food pro7essing, rubber plantation, health 7are,
edu7ation 7haritable institutions et7$
1ee6ay :olling Mills )1* 4td, established in .DD<, manufa7ture #M# :e=bars in various
si0es ranging from Cmm to +?mm$#he #M# :e=Bars are manufa7tured using
#!M1&:! #e7hnology under li7ense from 7entre de :es7her7hes Metallurgiques
):M*, Belgium, the inventors of the pro7ess$ #!M1&:! is a brand whi7h is very
popular and a77epted with 7onfiden7e throughout !urope and other developed
7ountries$#M# :!=Bars are produ7ed in two grades vi0$ '!=>.? and '!=?,,
#he 7ompany employs advan7ed te7hnology with modern ma7hinery and equipment$ It
has well equipped quality 7ontrol laboratory 7onsisting of sophisti7ated testing
!quipments$ #he ompany has installed a high speed Bar Delivery System with
automated
:a6e type 7ooling bed at huge investment$ this addition in plant ad ma7hinery will
7onsiderably improve the quality of out #M# steel and produ7tion$1ee6ay :olling Mills
is the only rolling mill to have highly sophisti7ated automati7 7ooling bed system in the
se7ondary steel se7tor in south India$
EDGE
8e are proud to have a77ess to #emp7ore #e7hnology under the li7ense from :M
Belgium$ #his allows us to 7reate a superior produ7t$
THE TEMPCORE PROCESS
#he re=bar leaving the last stand of hot rolling passes through a spe7ial water 7ooling
se7tion$ #he 7ooling is su7h that a surfa7e layer of the bar is quen7hed in to marten site,
the 7ore remaining austeniti7$ #he quen7hing treatment is stopped when a determined
thi76ness of marten site has been formed under the s6in$ #he :e=bar leaves the drasti7
7ooling se7tion, the temperature gradient established in its 7ross se7tion 7auses heat to
flow from the 7entre to the surfa7e$ #his results in self tempering of v marten site$ 'inally,
.@
during the slow 7ooling of the re=bar on the 7ooling bed, austeniti7 7ore transforms into
ferrite and pearlite$
1ee6ay #M# is produ7es by the worlds most advan7ed te7hnology li7ensed from entre
de :e7her7hes Metallurgriques ):M* , Belgium, inventors of this pro7ess$ #emp7ore
bars are being su77essfully used in most parts of the developed world$#M# are produ7ed
in two grades5 #M# >.? and #M# ?,,$ #he numbers indi7ate the proof stress$
Auality 1oli7yH
&ur 7onstant endeavor is to satisfy and 7ontinually improve our 7ustomer satisfa7tion
regularly and improve our quality management systems, people and pro7esses to remain
as a mar6et leader in our industry$
1ee6ay :olling Mills )1* 4td$, is an IS& D,,. M +,,, 7ertified 7ompany, a77redited by
Bureau of Indian Standards )BIS*H ISI 4i7ense holder ISH .-C@=.DC?$ It was
established in .DD<$
1ee6ay has now adopted #emp7ore te7hnology under 4i7ense from :M Belgium for the
produ7tion of 1ee6ay #M# :ebars$
:M is a Belgium (overnment owned :esear7h Institution
Auality to 1SI means not only produ7t quality or servi7e quality but also 7ost, delivery
and after sales servi7e whi7h goes with it$ :esponding to this 7on7ept of quality 1SI has
adopted quality systems appropriate to itKs 7lients$
1SIKs 7ommitment to produ7t quality is refle7ted through quality systems adhered to from
sele7tion of raw material to dispat7h of finished goods$ !97ellent tra7eability and
identifi7ation are fa7tors for our produ7t and are maintained from re7eiving stage till
dispat7h$
.-
1SI is 7ommitted to total quality whi7h shall be a7hieved by timely delivery of quality
produ7ts to the entire satisfa7tion of the 7ustomer and by 7ontinually improving its
quality management system pro7esses$
#he Bright Steel Bars of 1SI are 7hara7teri0ed by a smooth surfa7e, free from s7ale and
harmful imperfe7tions, tight dimensional toleran7es, superior straightness and higher
strength than hot=rolled produ7ts$ #hey are ideally suited to ma7hining and shafting
appli7ations$
#he 7ompanyFs produ7ts are well a77epted in the mar6et$ #he 7ompany has paid 7entral
e97ise duty to the tune of :s$+@ 7rore during last year$ we are pleased to iformthat the
7ompany is re7ipient of the #op duty 1ayer Award and the highest growth rate award in
the organi0ed private se7tor in the ali7ut entral !97ise ommissionerate fir the last
three years$
.C
,ISION
#o be an engineering 7onglomerate and lead 1ee6ay to new horiaons , e9panding and
diversifying to new industries and 7utting edge te7hnologies$ A one stop supplier to all
the ma;or &!MFS globally in terms of ready to assemble ma7hine 7astings forging and
fabri7ation requirements globally$
MISSION
#o produ7e .<,+,, tons of steel 7astings in finan7ial year +,,C=+,,D$#o serve the
7ustomer with wide range of requirements starting from ,$?6g to .+ tons single 7asting
from our different lo7ations emerge as one of the top five manufa7turers
Lo(+tion M+/
2erala, 6nown as (odFs own 7ountry is a land of your dream$ It is a reservoir of ri7h and
varied 7ulture$ #he e9oti7 ba76 waters and gorgeous wild life ma6e it one of the best
tourist 7enters of India$ It has fol6lores, festivals, lush green forest and many other things
thatFs uniquely its own$ &ur 7ompany 1!!2A3 :&44I"( MI44S )1* 4#D is privileged
to be situated in the paradise, in a 7ity 6nown as the 7ity of hospitality=2o0hi6ode
)ali7ut*
ali7ut has an international airport$ #he nearest seaport is o7hin, whi7h is about +., 6m
south of ali7ut$ o7hin is also a busy international airport$
&ur 7ompany has dire7t a77ess to "ational Highway .-, whi7h stret7hes through the
heart of 2erala from o7hin to Mangalore$ &ne of the busiest railway stations of 2erala M
ali7ut is mere ? 2ms from our fa7tory$
.D
"earest Airports ali7ut international airport +@ 2ms
o7hin "edumbasseri international airport .C? 2ms
"earest Seaports o7hin about +., 2ms
Mangalore about +>, 2ms
By :oad @ 2ms from ali7ut town towards south by "H .-
+., 2ms from 2o7hi )o7hin* towards north
COROPORATE SOCIAL RESPONSIBILITY
1ee6ay group is aware of its 7orporate responsibility$ #he group espe7ially the steel
7ompany is 7ommitted to 7ontribute to the e7onomi7 development and improving to
quality of life of the wor6 for7e and their families and the so7iety at large$ #he group
liberally supports orphanages s7hools for the blind and dumb and mentally handi7apped
7hildren$ It also provide in plant training 1rogramme to students re7eiving edu7ation in
engineering , te7hnology , management and other related sub;e7ts in south India$
In addition steel 7asting private )4#D* is 7ondu7ting a te7hni7al s6ill 1rogramme, the first
of it 6ind by an industry in 2erala whi7h is designed e97lusively fir these equipped with
relevant te7hni7al 6nowledge and having a 7areer goal in the spe7ified areas$ #he
1rogramme attempts to fulfill highly s6illed training relevant to foungry and hot rolling
industry and fire safety$ It is a si9 month 1rogramme imparting on the ;ob te7hni7al s6ills
to graduates, diploma and I#I 7ertifi7ate holders in engineering and physi7s$ At the end of
training the 7andidate are provided with 7ertifi7ate$
+,
EN,IRONMENT SAFETY
8e are 7ons7ious of our responsibility for the environment safety$ 8e abide by the
various statutory rules and regulations for the environment prote7tion and pollution
7ontrol$ 8e have started ta6ing steps for a totally dust free atmosphere in the foundry
whi7h will ensure health and safety of employees and smooth and safe fun7tioning of
foundry$ &ur aim is to obtain IS& .>,,. relating to environment management by +,,D=
+,.,$#his will help to improve produ7tivity level of our employee whi7h will ultimately
ensure better quality and delivery of our produ7ts At lower 7ost,
T(0ni(+! S1i!! Tr+ining Progr+**s
1ee6ay (roup of 7ompanies, being a su77essful business group in 2erala for the past ?
de7ades, and have proven their su77ess in Manufa7turing, #rading, 'ood 1ro7essing,
:ubber 1lantations, Health are, !du7ation and harity$
1ee6ay Steel astings )1* 4td and 1ee6ay :olling Mills )1* 4td are the two ma;or
divisions of 1ee6ay group of 7ompanies$ 1ee6ay Steel astings )1* 4td, has two state=of=
the=art foundries lo7ated at ali7ut ) 2erala * and oimbatore ) #amil "adu*, whi7h
produ7es high quality steel 7astings, 7atering to the needs of the ma;or industries in India
)(! and 4E# *and abroad$
8e are offering #e7hni7al S6ill #raining 1rogramme )#S#1*, to impart on=the=;ob
te7hni7al s6ills to diploma and I#I 7ertifi7ate holdersG graduates in 1hysi7s and
me7hani7al engineering, in spe7ifi7 areas of foundry te7hnology, so as to help s6ill
advan7ement to ta6e up high s6ill ;obs$
#his 1rogramme is designed e97lusively for those equipped with relevant te7hni7al
6nowledge and has a 7areer goal in the areas li6e 'ettling and Heat #reatment, Melting,
Moulding, 8elding, and "D#$ #he program attempts to fulfill the demands of the Indian
7asting and rolling industry by offering highly s6illed training dire7tly relevant to foundry
and hot rolling industry
+.
A8A:DS A"D :!&("I#I&"S
4argest private engineering entity in 2erala
4argest e9porter of engineering goods from 2erala
Ma;or 7ontributor to the national e97hequer from this part pf the 7ountry$
#op duty payer and the highest growth rate award in the organi0ed private se7tor
in ali7ut$
M+r1ting .Pro%#(t %t+i!s
#he mar6eting a7tivities of 1SI is supported by itKs sto76holding at @ warehouses 7um
distribution 7enters and also through dealers and dire7t mar6eting$ #he 7ompany has its
approved transporters, freight forwarders and 7learing agents to handle the logisti7s of
7ost effe7tive materials movement of raw materials and finished produ7ts$ Materials are
delivered within the agreed time to our 7lients in India and overseas$
#ogether with a team of dedi7ated staff and 7ommitment to sto76 holding, 1SI is
supplying dire7tly to the following se7torsH
.$ Automotive
+$ (eneral !ngineering Agri7ulture and ma7hine building$
<$ Mining
>$ :epetition !ngineering$
?$ 'orging
Brig0t st! "+rs +r 'tnsi)!& #s% in t0 fo!!o2ing3
.$ Automotive = )Sho76 Absorber 1iston :ods, :a76 Bars, Head :ests and (eneral
Automotive 1arts*$
+$ (eneral !ngineering Agri7ulture and ma7hine building$
<$ Mining
>$ :epetition !ngineering$
++

BRIGHT LEADED
FREECUTTING STEEL
.+4.> is low 7arbon leaded free 7utting steel supplied bright drawn or smooth turned,
offering a high and 7onsistent level of ma7hinability with no adverse effe7t on the
me7hani7al properties$
#ypi7al Appli7ationsH
1arts and 7omponents sub;e7t to moderate strength levels and relatively low sho76
loading, with ma7hinability a ma;or 7onsideration$
BRIGHT NON $ LEADED FREECUTTING STEEL
.+.> is a low 7arbon free 7utting steel supplied bright drawn or smooth turned, offering a
high and 7onsistent level of ma7hinability$
T&/i(+! A//!i(+tions3 1arts and 7omponents sub;e7t to moderate strength levels and
relatively low sho76 loading, with ma7hinability an important 7onsideration$
BRIGHT COMMERCIAL 4UALITY MILD STEEL$
Is 7ommer7ial quality low 7arbon mild steel, supplied bright drawn or smooth turned,
+<
offering a good balan7e of strength, du7tility and toughness with e97ellent weldability
and fairly good ma7hinability
$
T&/i(+! A//!i(+tions
A9les, bolts, 7onne7ting rods, motor shafts, hydrauli7 shafts, pins, pump shafts,
ma7hinery parts et7$ &r when 7arburi0ed for 7amshafts, light duty gears, spindles and
rat7hets et7$
MEDIUM TENSILE STEEL
#his is a medium 7arbon, medium tensile steel, supplied bla76 as rolled, bla76 as forged
or normali0ed and bright drawn or smooth turned, offering good strength, toughness and
wear resistan7e$ an be hardened and tempered$
T&/i(+! +//!i(+tion
A9les, bolts, 7onne7ting rods, hydrauli7 rams, pins, rolls, spindles, shafts, studset7,
requiring higher strength or similar grades 7an provide$
B#sinss +(ti)it&3
#rading of bright steel bars produ7ed by 1ee6ay Steel Industries
Independent trading of rolled long and flat steel produ7ts$
+>
Imports and !9ports of rolled and finished steels$
:epresentatives of overseas steel produ7ers and traders in India
:epresentatives of Indian steel produ7ers for overseas 7ountries
M+tri+!s3
AA5 F!+t St! Pro%#(ts
.$ Hot :olled 1lates G Sheets and oils
+$ : G (1 oils and Sheets
<$ !le7trolyti7 #in 1lates
>$ SS oils and Sheets
BB5 Long Pro%#(ts
.$ Se7tions li6e angles, 7hannels, beams, ;oists et7$
+$ :ound Bars )Bla76 and Bright*, Deformed bars and 8ire :ods
<$ Steel 1ipes = !:8 G H'I8 G Seamless G Saw Auality
>$ Billets and Blooms
BHARAT MERCANTILE CORPORATION
4argest trader, distributor and importers in !astern India for 7hemi7als and bul6
7hemi7als$
+?
BRIGHT STEEL BARS
Bright Steel Bars are manufa7tured from Hot :olled BarsG8ire :ods through the pro7ess
of 7old drawing, 7entreless grinding, turning or a 7ombination of these to produ7e steel
with greater dimensional a77ura7y, straightness, smooth surfa7e, free from harmful
defe7ts and enhan7ed me7hani7al properties$
old finished steel offers many benefits, in7luding 7lose si0e toleran7e and 7on7entri7ity,
straightness, strength, a smooth finish, pre7ise me7hani7al properties, and greater
ma7hinability$ #he finished produ7t has a shiny appearan7e that e9plains the 7ommon use
of the term Nbright bar$N old finished produ7ts are used to manufa7ture pre7ise
7omponents in almost every industry
+@
Gr+%s3
Mi!% st!- C+r"on St! . Fr$C#tting St!
!n<B
!n<+B
!nC
!nCA
!nCD
!nD
2=>?
!n.A="4
!nCM
!n.?AM
!n.A=4
et7
WEIGHTS OF STEEL BARS
ROUNDS- S4UARES- HE6AGONS- 7 S/(ifi( Gr+)it& 859: ;
Si0e MM :ound 2gsGM Square 2gsGM He9agon 2gsGM
C ,$<D? ,$?,+
D ,$>DD ,$@<@
+-
., ,$@.- ,$-C?
.+ ,$CCC .$.< .$.>D
.? .$<C- .$-@@ .$->
+, +$>@@ <$.> +$DDC
+? <$C?< >$D,@ >$+>D
<, ?$?>D -$,@? @$..C
<, ?$D+? -$?>> @$?<<
<+ @$<.< C$,<C @$D@.
<? -$??< ?$,-? C$<+C
<C C$D,< ..$<<? D$C.-
>, D$C@ .+$@? .,$C--
>? .+$>C? .?$.+. .<$-@-
?, .?$>.< .D$@+? .@$DD@
?? .C$@? ++$DD. +,$.+.
?@ .D$<<? +>$@.C +.$<.D
@, ++$.D? +C$+@ +>$>->
@? +@$<<C <<$.@@ +C$-+<
-, <,$+. <C$>?@ <<$<.+
-? <?$,@? >>$.?@ <C$+>
C, <D$>?C ?,$+> ><$?,D
C? >>$?>? ?@$-. ?<$<??
D, >D$D<D -,$C>? @.$<??
D? ?@$+>D ??$D<@ @>$.+.
+C
.,, @.$@?> -C$? @-$DC<
.,? @-$D-< C@$>@ ->$D?.
.., ->$@,. D>$DC? C.$+?D
..? C.$?<- .,<$C.@ CD$D,-
.+, CC$-C. ..<$,> D-$CD?
.+? D@$<<- .+.$@?@ .,@$++<
.<, .,>$.D? .<+$@@? ..>$CD.
.<? ..+$<@> .><$,@@ .+<$CDD
.>, .+,$C>. .?<$C@ .<<$+>-
.>? .+D$@+- .C?$,>@ .>+$D<>
.?, .<C$-+. .-@$@+? .?+$D@+
.@, .?-$C<< +,,$D@ .->$,<@
.-, .-C$.-D ++C$C@? .D@$>-.
.-? .CC$C.> +>,$>,@ +,C$.DC
.C, .DC$-?- +?>$<> ++,$+@?
+,, +>@$@.> <.>$$,,, +-.$D<+
+., +-.$CD< <>@$.C? +DD$C,?
++, +DD$>,< <<-$<> <+D$,<C
+?, <?C$<?@ >D,$@+? >+>$CD>
+C, >C<$<@? @.?$>> ?<+$DC@
+C? ?,,$-C+ @?-$@.@ ??+$.D+
+D, ?.C$?,C @@,$.C? ?-.$-<-
+D? ??@$?>. -@.$.>@ ?D.$@++
+D
<,, ?@.$,?. -D-$+C< @-D$.@-
S+!s3
3ear Sales )tonnes* amount )7rores*
.$ +,,<=,> <,D--$-. ?<$?D
+$ +,,>=,? <-,C?$@. @?$-@
<$ +,,?=,@ ?+,??. .<?$?<
<,
>$ +,,@=,- >+><,$<+ .++$?<
?$ +,,-=,C <D,+?. ..?$,,
#he produ7ts are produ7ed only after the order is made by the 7ustomer$ #he 7urrent
situation is that the 7ompany is not able to supply the in7reasing demand for its produ7ts$
Ma;or sales of the produ7ts are from e9ports to foreign 7ountries$ 1rodu7ts are e9ported
to !uropean Union namely 'ran7e, Italy, U2, (ermany, "etherlands, %apan and the
Middle !ast$ #he steel 7astings are also sold to publi7 se7tor underta6ings, defense
establishments, .,,I e9port oriented units and large value manufa7turers in India$ #he
steel 7astings are well a77epted by the 7ustomers in India and Abroad
O#r D+!rs3
O ANRANJU STEELS, 2uttipuram$
O ASIAN STEELS, 1uthiyangdi$
O B5M5STEEL, 2allai :oad, ali7ut$
<.
O C5S5A5 ASSOCIATES, ali7ut$
O CI,IC STEEL . CEMENT, 2araparamba, ali7ut$
O ELITE STEEL, heruvannur$
O FERROUS ENTERPRISES, 2alla7hi$
O HADEED METALS, Badagara$
O KAMBIL ENTERPRISES, 2ambil$
O KA,ALAKKAT AGENCIES, #hrissur$
O MELIT METAL AGENCIES, Sulthan Bathery$
O METRO STEEL CORPORATIONS, South 2anhangad$
O METRO STEELS, Modern Ba0ar$
O MOGUL STEEL AGENCIES, heruvathoor$
O OMEGA STEELS, ali7ut$
O 4UEENS STEEL- Badagara$
O RAJA AGENCIES, Badagara$
O SAFA STEEL LINES, hira66al$
O SEENA STEEL, ali7ut$
O SOUTHERN STEEL, 2annur$
O ST5MARY<S CEMENT CENTRE P,T5LTD, !ttumanoor$
O STEEL HOUSE, #hana$
O STEEL INDIA, 2oyilandy$
O STEEL WORLD, (ovindapuram$
O SUPER STEELS, Mowan7hery 1$&$ 2annur Dist$
O T5M5 STEEL AGENCIES, ali7ut$
O THARAYIL STEEL INDUSTRIES, 1erintalmanna$
O THE STEEL.CEMENT ASSOCIATES, Meethottutha0ham$
O ,5K5ENTERPRISES, Iringanoor$
<+
O YEM ,EE TRADERS, :amanattu6ara$
O =ENITH STEEL, heruvannur
List of I*/ort+nt B#i!%rs +n% Instit#tions #sing P1+& St!s
LARSEN . TOUBRO ECC5- C0nn+i- +n% BHEL, for 2uttiyadi
Hydro !le7tri7 1ower Station$
<<
LARSEN . TOUBRO 8ater supply 1ro;e7t$ %apanese 28A 1ro;e7t$
#o6yo !ngineering onsortium approved our Steel$
ITD CEMENTATION, Mumbai using '! ?,, and '! >.? for 1!!B!!S
1antaloon Shopping Mall$
M5E5S5M%i(+! Co!!g, 1erintalmanna, onstru7tion by 4A:S!" E
#&UB:& !$, hennai$
HOSMAC Cons#!t+nt, Mumbai$
ABAD BUILDERS, o7hin$
HEERA CONSTRUCTION, o7hin$
M+t+ A*rit0+*+&i Instit#t of M%i(+! S(in(, o7hin$
Jo**r Pro/rtis . In)st*nts Lt%, o7hin$
G+!+'& B#i!%rs, ali7ut$
Crs(nt B#i!%rs, ali7ut$
E'/rss Ho#sing P)t5 Lt%$, ali7ut$
Hi$Lit B#i!%rs, ali7ut$
P,S A/+rt*nts, ali7ut$
A( Str#(t#rs +n% B#i!%rs, ali7ut$
M+!+"+r R+!tors, ali7ut$
Sros0 Constr#(tions, hennai$
Prstig M%i(+! Co!!g, 2annur$
N+tion+! Instit#t of T(0no!og&, hathamangalam, ali7ut$
T!/0on E'(0+ngs of BSNL, 2asargod$
<>
S+fi !du7ational Institutions$
KMTC Enginring +n% M%i(+! Co!!gs, Mu66am, ali7ut$
C5T5R+*+n+t0+n . Co5S+!* for t0ir Pro>(ts of CPWD, ali7ut$
LULU INTERNATIONAL CON,ERSION CENTRE, #hrissur$
A!!i+n( D2! W!! Pro>(ts, o7hin$
St5 Jos/0<s D)+giri Co!!g, ali7ut$
Asst Ho*s, o7hin$
Rg+! Pro>(ts, o7hin$
Infr+ Ho#sing Pro>(ts, o7hin$
S0+nt0i Ho* B#i!%rs, o7hin$
SOUTHERN IN,ESTMENTS Pro/rtis 7S5I;, ali7ut$
H#*+n Rso#r( D/+rt*nt
<?
Human resour7e management is a spe7iali0ed bran7h of management of an organi0ation,
spe7ifi7ally 7on7erned with the management of human resour7es in respe7t of their
pro7urement, training and development and motivation towards the attainment of
ob;e7tives of the organi0ation$ In other words Human resour7e management deals with
planning, organi0ing, dire7ting and 7ontrolling and utili0ing the wor6 for7e in the
enterprise for a7hieving the ob;e7tive of the organi0ation$
M+n /o2r
Man power is the pro7ess in7luding fore7asting, implementing and 7ontrolling by
whi7h a firm ensure that it has the right people, at the right pla7e, at the right time doing
the right things for whi7h they are suited for the good of the organi0ation$ #his group has
well e9perien7ed and quality wor6ers in ea7h unit$ #he produ7tion department is +> hours
wor6ing in shifts$ #he rolling starts at ., in the night and will be over by > in the
evening$
R(r#it*nt
#here are various sour7es of re7ruitment$ #hey are
.$ ontra7tor
+$ Advertisements
#he laborers are re7ruited on 7ontra7t basis$ It helps the firm to get wor6ers to meet
sudden shortage$ #he offi7e staff and supervisors are salaried and re7ruited through
advertisement in news papers and by "au6ri$7om
8or6ers are also re7ruited from another sour7e i$e$ the e9isting employees and their
referrals$
R*#nr+tion
<@
#he group is able to pay a reasonable salary to all its employees, differen7e in salary
depends on the position, s6ill required, ris6 involved, responsibility ta6en up and
e9perien7e$
Apart from salary employees get the usual allowan7es$ Housing fa7ilities are provided for
the wor6ers in the produ7tion department$ Bonus is given twi7e a year$#here is also .,I
rise in the salary to ea7h employee every year$ #he wor6er to allowed to ta6e a ma9imum
of .+ holidays apart from national holidays$
'a7ilities 1rovided
Salary and allowan7e stru7ture M Best in the industry, 7ommensurate with qualifi7ation
and relevant e9perien7e$
anteen fa7ility with healthy wholesome food and beverages$
A77ommodation and transportation fa7ility for those who need it$
A77ident and medi7al 7laim insuran7e, so7ial se7urity through !1' and !SI S7hemes$
Annual Bonus, e9=gratia, loyalty bonus and in7entives$
ompany support and help to set up residen7e, s7hooling and other fa7ility for those
who need it$
Modern safety, Health and !nvironment wor6ing 7onditions$
Po/!
<-
1ee6ay family has more than .?,, members$ #he su77ess of the 7ompany is attributed to
the strength and unity if the members of the family$ #he group is 7ons7ious of their s6ills,
passion, strength and strong values$ #he group has a value based approa7h$ #heir groupFs
indomitable spirit, 7ommitment and hard wor6 have won the appre7iation of their
7ustomers$
4oyalty and values are the fabri7 of the groups wor6 philosophyJ every employee is a
partner in our progress and benefits from our profits$ He is proud of his 7ontribution to
the su77ess of the 7ompany$ 8e have regular in plant training 1rogramme for upgrading
the s6ills of the employees and familiari0ing them with the latest te7hnology and
manufa7turing pro7ess$ Bery often the employees are deputed for short term 7ourse
7ondu7ted by spe7iali0ed agen7ies$ #he 7ompany is 7ommittees to safety and health of all
members$
1ee6ay group of ompanies, believe in /1eople='irst5 poli7y in all its ventures,
and strongly believe that the 1eople are the most valued asset of the ompany$ In this
dire7tion, the ompany will strive to ma6e it as the most preferred employment
P1+& H#*+n Rso#r( M+n+g*nt ,+!#s
#he aspirations of its people$
#imely dis7harge of its entire monetary and other obligation$
omplete empathy and patien7e with peopleFs views$
A77essibility to all levels of H: department at all times
P1+& H#*+n Rso#r(s Co**it*nts
<C
Merit as the sole 7onsideration for re7ruitment and development$
omply all statutory requirements in the matter of 7ompensation, so7ial se7urity, safety
and welfare and go beyond statutory requirement to ensure welfare, well being and
7ontinued loyalty to the 7ompany till normal retirement$
Ben7h mar6 best H:M pra7ti7e and develop the full potential of every individual and
provide growth, and wor6 pla7e advan7ement$
'ollow ethi7al people poli7ies and pra7ti7es$
Build effe7tive and seamless 7ommuni7ation 7hannel to ensure highest standard in
quality, produ7tion and delivery to 7ustomers and towards employee growth, welfare and
well being$
'airness, trust, equal opportunities, wor6 pla7e dignity and 7omplete non=
dis7rimination in all matters$
!ffe7tive me7hanism to avoid grievan7e and redress, in 7ase of any grievan7e at the
earliest$
#o build long term partnership between owners, management and employees, in
su77ess of the ompany$
Fin+n( D/+rt*nt
<D
'inan7e is s7ar7e$ It is also the most important aspe7t of business$ 'inan7e requires proper
planning and 7ontrol to a7hieve the ob;e7tives of business$ 'inan7e fun7tion is 7on7erned
with pro7urement of funds from various sour7es to utili0e them effe7tively$ 'inan7e
fun7tions are the provision of money at the time when it sis needed
1rofit 1oli7y
Ma;or portion is reinvested is followed$ #he reinvestment profit poli7y of the 7ompany
helped in the e9pansion$ !ven though the profit of the 7ompany helped in the e9pansion$
!ven though the profit is the rolling industry dropped in small ratio$ It has been
effi7iently made up by the high in7rease in the profit made in the foundry units$ A 7ertain
per7entage of profit is treated as 7apital reserve$
Assts- In)st*nts +n% s0+r C+/it+!
>,
1$2 steel industry with an investment of :s$>? la6h equally 7ontributed by all of the
partners$ #he intial share 7apital was :s$ ,$? rores$#he ompany turned to deemed
publi7 limited in .DD@$1ee6ay rolling Mill Industry started with an intial share 7apital of
:s ,$? 7rores in .DD? $SB# )State Ban6 of #ravan7ore* is the offi7ial ban6ers of the
7ompany$
>.
PRODUCTION DEPARTMENT
P5K STEEL CASTING UNIT
MELTING . ROLLING UNIT
>+
PEEKAY STEEL CASTING 7P; LTD3$
1ee6ay steel asting )1* ltd is modern state of the art foundry lo7ated at ali7ut on 6erala
on the west 7oast of India$ It was established in .DD.$
#hey manufa7ture high quality steel 7astings made of 7arbon steel$ Alloy steel$ Stainless
Steel, "i76el bared steel, duple9 steel et7 in various si0e E weight, up to ..?,, 2g per
pie7e for petro 7hemi7al industry, water supply, earth moving, mining, and automobile
and other engineering industries$ #he annual produ7tion 7apa7ity is ?>,,M#$#he
astings are produ7ed to international spe7ifi7ations$
#hey are members of
asting #e7hnology International )#I=U2*
Ameri7an foundry So7iety )A'S*
Institute &f Indian 'oundry Men )II'*
><
CASTING UNITS
Here the melted steel is used to produ7e different si0es of 7astings valves et7$#he 7astings
produ7es over here are of eyesirt quality$ #he melted steel undergoes 7ompli7ated
appli7ations$ Stand mould yes or s6eletons of different 7apa7ity are produ7ed in a
7omparatively small furna7e$1$2 steel 7asting foundries are mainly divided in to three
units based on their 7apa7ity$
.$ 4ight steel foundry
+$ Medium steel foundry
<$ Heavy steel foundry
4I(H# S#!!4 '&U"D:3
Steel astings of ?,,gm=.- 6g are produ7ed over here$ #he s7rap raw materials are put in
to the furna7e and melts in to liquid steel at .?<? deg elsius$ #he melted steel is poured
over in desired patterns$ #his steel hardens forming designs and is trimmed through
grinding pro7ess$ Steel valves are produ7ed in the light steel foundary #hese steel valves
undergo dimensional tests to 7he76 the e9ternal fitness$ #he internal defe7ts are identified
using the radiography tests and the defe7ts are repaired$ #he final produ7t will be ready
for dispat7h$
M!DIUM E H!AB3 S#!!4 '&U"D:3
Medium as well as heavy steel foundry produ7es 7astings of .,,6g= ., tonnes$ #he
ma7hine 7apa7ity is ++ metri7 tonne per month$ astings are 7lassified and Pprodu7ed on
the basis of 7odes E grades$
Heavy steel foundary underta6es the produ7ing heavy steel arti7le$ Heavy steel 7astings
are produ7ed in the request of the 7ustomer$ &n the basis an estimate 7ost on the basis of
the weight and manufa7turing 7ost is quoted$ It in7ludes only the pro7ess 7ost$
>>
8hen the manufa7tures approve these estimated requirements the unit underta6es the
heavy 7asting produ7tion pro7ess$ #he details of a7tivities to be performed are sent to
ea7h 7on7erned department$
#he steel is melted to .?<? degree elsius$ #his melted ore is 7arried by the ladle to be
poured in to the mould$ #he mould will be made out of stand, whi7h is mi9ed with 7ertain
hardening materials$ A 7oating is put to the mould for the mould to remain in shape$
#he melted ore will be poured to the mould, whi7h is shaped a77ording to the design
required by the 7ustomer$ #his mould is then set and left to 7ool down$ After the 7ooling
pro7ess the mould is ta6en off and the steel moulded is ta6en out$ #he steel 7asting may
not be of perfe7t shape$ #he unwanted e9tensions are to be 7leaned and removed$ #he
heavy steel 7asting is now in a final produ7t stage and it is ready for dispat7h$
>?
M!ting Unit
Under this unit, produ7tion of metal bars and rods of a metri7 tone is underta6en$ :aw
materials are either obtained from the ore or are automobile s7raps or 7onstru7tion
material s7rap$ #hese s7raps are melted in this unit by passing it through the indu7tion
7urrent$ #he furna7e is made out of 7opper in the form of a s6ull whi7h is 7ooled by
passing water at the bolt of the s6ull$
#he raw materials s7arps are mainly imported from U$S and !urope$ Shredded s7raps are
also used be7ause of easiness in melting$ Heavy magnets are used to dump the s7rap in
the furna7e$ S7raps are mi9ed in 7ertain proportion to get different properties$ &n7e the
s7rap is melted the heavy density steel settles down and the impurities 7an be removed
through this refining pro7ess$
arbon, sili7on phosphorous et7 are mi9ed up, in 7ertain per7entages whi7h would give
different properties to steel$ 1ri7e of the steel differs on the basis of the quality, i$e$ high
pri7es are quoted to improve quality$
Material Handling apa7ity= #wo 7ranes of + tone 7apa7ity
#o identify the 7hemi7als /added their proportion, 0ero alters are added to the melted
steel$ &n7e the melting pro7ess is over the temperature is measured usingQg a devi7e,
!merson 1yrometer$ #he thermo 7up in the pyrometer when dipped into steel leaves a
holeJ the si0e and voltage determines the temperature$ #he melted steel is poured into
dyes and square moulds whi7h has a hollow spa7e inside$ #hese dyes are pla7ed in
refle7tion 7hannels whi7h have a ladle holding devi7e at the bottom whi7h has a 7losing
and opening system$ ranes are used to the move the materials over$
>@
#he melted steel is poured into dyes and in five minutes it gets 7ooled and the impurities
gets 7ooled and the impurities are removed$ #hese bars rods are sta76ed and get ready for
dispat7h$
>-
Ro!!ing #nit
#he bars are produ7ed in the melting unit s are 7arried to the rolling unit$ #he bars are
produ7ed in the melting init are 7ooled and these bars are re=heated up to .+?, degree
elsius$ #he bars are heated up in a re=heating furna7e$ #his furna7e wor6 by the use of
oil$ #hese heated bars are rolled between two rollers$ #he bars are elongated by drawing
them$
#hese bars will be paned through a quen7hing bo9 for 7ooling it down$ 8hen passing
through quen7hing bo9J the outer surfa7e will get 7ooled$ #hese bars are then twisted to
ma6e twisted D# bars$
#hese twisted bars are then passed to the 7ooling bed, where it gets 7ooled down and the
D# bars are now ready for dispat7h$
>C
MANUFACTURING PROCESS OF STEEL ROLLI NG
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DIS1A#H
>D
MATERIALS HANDLING
Starting from the time, the raw material enters the fa7tory gate and goes out of the fa7tory
in the form of finished produ7ts, it is handled at all stages in between no matter it is in the
stores or on the shop floor$ A 7omponent may be handled even ?,times or more before it
7hanges to finished produ7t$
Material handling involves the movements of materials, manually or me7hani7ally in
bat7hes or one at a time within the plant$ #he movement may be hori0ontal, verti7al or
the 7ombination if hori0ontal and verti7al$
MATERIAL HANDLING E4UIPEMENTSH=
.$ Sigma rane
+$ Bridge rane
?,
MANUFACTURING PLANT FOR CASTING
Pro(ss
8or6 order
R
Monthly wee6ly or daily planning
R Issue pattern oreTBerfying suitability for produ7tion
R
1ouringTHeat no strip
R
2no76 &ut
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Shot blastingT#est stage inspe7tion
R
Ar7 7utting
R
'illing
R
Shot blasting
R
8elding
R
R
(rinding
R
Heat #reatmentTverfying the H$#
R
Shot BlastingT third stage inspe7tion
R
Dispat7hT Inspe7tion E test 7ertifi7ate
?.
A%)+nt+gs of P1+& st!3
&ptimum 7ombination of high yield strength and e97ellent bendability$
!nables designer to redu7e steel 7onsumption, and yet obtain e9tremely safe steel
stru7ture$
!97ellent weldability
Superior 7orrosion resistan7e
"o tenden7y of aging and embrittlement
#M# bars 7an be heated up to ?,, 7 at room temperature without loss of strength$
Uniform properties throught the length, as the entire pro7ess is 7omputer
7ontrolled$
Mill s7ales per unit of surfa7e area less than ?,I in normal hot rolled bars$
!97ellent fatigue properties
an be galvanised with no loss of strength and du7tility
Saving in steel 7onsumption as mu7h as .CI while using 'e ?,,
Best 7hoi7e for earthqua6e resistant 7onstru7tion
?+
FINDINGS3
1ee6ay group fun7tions, imbibing the values of integrity, transparen7y, hard wor6
and 7ommitment$
#he (roup believes in pra7ti7ing ethi7al business
#he group believes in growth and diversifi7ation in to different areas of
manufa7turing$
Any tas6 underta6en is delivered with utmost responsibility and sin7erely meeting
the standards$
1ee6ay fun7tions with the most modern te7hnology in produ7tion and safety$
#he employees perform under the best H: management$
#he group 6nows its so7ial responsibilities to the so7iety and does best for the
needs$
#he raw materials pur7hased are re7orded at 'I'& rates whi7h help in regulating
the 7ost of produ7tion as the pri7e of raw materials 6eeps flu7tuating$
#he 7astings and other produ7ts are dispat7hed after several grounds of quality
7he76 whi7h helps in maintaining the produ7t quality and the goodwill of the firm$
#he s7rap used in produ7tion is imported$ #his is be7ause s7rap is 7heaper and i;
better in quality$
?<
S#ggstions3
.$ Safe wor6 environment need to be provided to the uns6illed wor6ers$
+$ !mployment opportunities should be opened to the lo7al people$
<$ Indian mar6ets 7an be 7on7entrated more rather than foreign mar6ets $#his
would help in in7reasing sales
?>
Bi"!iogr+/0&
.$ Aruvian :esear7h, Mar7h +,,C, 1agesH C,
+$ www$1ee6aysteel$7om
<$ www$1ee6ayrm$7om
>$ www$1ee6ay7be$7o$in
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