2ISHAAN ENGINEERINGMISSION:-To become a reliable partner in supplying aluminum/zinc castings, keeping high quality standards and performance.VISION:-To manufacture and supply products with ultimate quality, precision and customer satisfaction.
3HISTORYIshaan Engineering was established by late Shri Jitendra M. Shah, Mr. Nimish J. Shah & M/s. Amkay die-casting Industries.M/s. Amkay die-casting industries was established by late Shri Jitendra M. Shah in 1959 in Mumbai. In 1969 it was shifted to Vapi, 160 Kms from Mumbai.In 1976 we started another unit at Daman, U.T. and then in 1990 in Bengaluru.In 1996 M/s. Ishaan Engineering was established at Dadra & Nagar Haveli. Ever since we have been established, we have maintained the company’s reputation and continued the tradition of quality die-casting products and customer service and satisfaction.
4ABOUT US Established in 1997. Holding a past experience of 54 years in die-casting.Presently having 8 PDC machine, 2 GDC machines and 1 Hot chamber machine with output of 1000 metric tons p.a.ISO certified company and also follow SIX SIGMA quality standards in our manufacturing process.Ishaan Engineering is a well know company engaged in manufacturing of non-ferrous aluminium and Zinc metal castings for last 17 years.We have 2 manufacturing units, one located at Dadra & Nagar Haveli, Silvasa and second located in Vapi, (S.Gujrat). Both of our units are just two and half hours from Mumbai.
5COMPANY PROFILE The facilities we have are:- CAD/CAM centers. Tool Designing and manufacturing.Pressure and Gravity Die-casting machines .Filling, fettling, grinding and sanding of machines.Vibro-benz for burr removal.Drilling and tapping of machines.Shot blasting of machines.CNC Turning center.
6Our turn-over grew from ₹4 million to ₹120 million in the following years of establishment. We have CCTV facility, which keeps our plant and other departments updated to our head-quarter.We contribute to environment by changing our initial oil fired furnaces into electric/gas fired furnaces, thereby decreasing the amount of pollution, heat, losses, health hazard and increasing human and plant efficiency.
7OBJECTIVES Dispatch of the job as per-committed schedule. Procurement of the material as per schedule.The products shall be developed as per the committed time.Rejection shall not be more than 3%.To increase sales turn over 25% every year.To reduce customer complaint 50% every year.All suppliers to fall within acceptable range of minimum 80% rating.
8CONCEPTS OF DIE DESIGN 2D / PDF drawings. 3D model of component. 3D model of complete Die.Casting simulations.Die-casting parameter calculations.Die steel selection.Die manufacturing.Heat treatment.Stress reliving.Nitriding.
9MATERIAL SELECTION & DIE MANUFACTRING PROCESS MOULD BASEMATERIALPUNCH CAVITY MATERIALDIE-MANUFACTUR-ING PROCESSHEAT TREAT-MENTNITRIDINGSAMPLEC-45MILD-STEELEN-9HDS-11HDS-13BOHLERASSABTHYSSUN KRUPDIODOPOLDYROUGHINGCNC-MACHINGSPARKINGHEAT TREATMENT (PRIMARY)WIRE CUTSCNC MACHINGGRINGINGPOLISHINGASSEMBLYNORMAL SALT BATHVACCUMH/THARDNERC48/50SALT BATHGAS NITRIDINGSAMPLEAPPROVAL
10OUR DIE CASTING FACILITIES Pressure die castings(8-HMT Buhler)Gravity die casting80 ton120 ton(2)160 ton180 ton250 ton (2)400 tonVerticaldie-castingHorizontal die-casting
11All the furnaces are electronically temperature controlled. In PDC we manufacture aluminium castings ranging from 20gms to 3kgs.In GDC we manufacture aluminium castings ranging from 200gms to 10kgs.Over head cranes for loading and unloading of dies.Independent maintenance department.
13SECONDARY PROCESS Trimming of castings Manual cutting / Bend saw cuttingFiling, fettling, grinding and sanding.Machining CNC / conventionalShot blastingVibro-benz finishingInspection and checking
14WHAT DO WE DELIVERSpecialized in Pressure die-casting (PDC) and Gravity die-casting (GDC).We deliver 3.06 million castings per annum.We manufacture 20 gram to 3.00kgs in pressure die casting and 200 grams to 10.00kgs in gravity die casting.We deliver shot blasted, dully CNC machined castings ready to assemble.
15QUALITY CONTROL INSTRUMENTS We at Ishaan Engineering are very particular about our quality measure and hence consider the following steps for every machine:-Digital vernirBore gaugeDial indicatorFinger dial with magnetic standThickness gaugeThread gaugesGo-No-Go gaugesAir gaugesRing gaugesJigs and fixturesDead center to check ovalityAll the instruments are calibrated at regular time period.
16CPK / GAUGE R&R We maintain 1.66 CPK in end covers bearing bore. Run out between bearing bore to spigot diameter is maintained in 20 microns.In conventional machining bore diameter is maintained with 80 microns.We conduct periodically gauge R&R analysis.
17QUALITY POLICYWe at Ishaan engineering are committed to develop and manufacture consistent quality Aluminium & Zinc castings as per our customer requirements and supply to them in time to their total satisfaction.We are committed to our continual improvement in our products & supply quality castings by maintaining process parameters, technical up-gradation and implementing “Quality Management System” involving all employees.
18FOCUS AREA Setting up an independent Quality-Control (QC)department. Controlling and Monitoring of Parameters during process.Checking of blow holes at regular intervals by various methods.Using Go-No-Go gauges for the final checking.
19MILESTONES Thin wall, less taper castings 85 tons output in a month 1.67 CPK in machining2.67% rejection per month
20FUTURE PROCUREMENT 180 ton die-casting machine CNC machining center Pneumatic power pressHanger type shot blasting machinesMulti spindle drilling and tapping machinesEDM machineHoist