Industry Overview
M M Forgings Limited (MMF) was originally incorporated in 1946 as Madras Motors Ltd., engaged in the trading and retail of motorcycles from Enfield, UK and manufactured by Royal Enfield, India. The company diversified into manufacturing under the vision and commitment of its founder, Late Sri S. E. Krishnan, FCA, commencing its first forging manufacturing facility at Singampunari in Sivagangai District, Tamil Nadu, in 1974 with a capacity of 780 MT.
Built around a commitment to total customer satisfaction through quality, timely delivery and competitive pricing, MMF has developed into a significant exporter of forgings in India, with 60% of its sales being exported. The company has received the Engineering Export Promotion Council (EEPC) award for export excellence for 27 consecutive years and is described as the largest exporter of steel forgings from South India within its product range.
MMF has continuously expanded its operations by adding state-of-the-art forging facilities and machining capabilities to serve international customers. Its operations include manufacturing and machining capabilities relevant to products such as front axle beams and stub axles, supported by inspection, cleaning, deburring, anti-rust treatment and other quality-control processes.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 1120 Nos/Day |
| Land & Building (40000 sq.mt.) | Rs. 46 Cr |
| Plant & Machinery | Rs. 116.40 Cr |
| Working Capital for 2 Months | Rs. 32.83 Cr |
| Total Capital Investment | Rs. 197.24 Cr |
| Rate of Return | 15% |
| Break Even Point | 21% |
Content Index
- INTRODUCTION
- KEY PERFORMANCE HIGHLIGHTS
- MANUFACTURING FACILITIES
- GREEN POWER
- THE COMPANY ALSO HAS SOLAR FARMS IN TAMILNADU AT THE FOLLOWING SITES:
- FACILITIES
- THE FACILITIES INCLUDE
- CREDIT RATING
- THE COMPANY ENJOYS GOOD CREDIT RATING AS BELOW:
- SUBSIDIARY COMPANY IN UTTARAKHAND
- EXPANSION
- COMPANY AND MANAGEMENT
- PARTICULARS OF BOARD OF DIRECTORS:
- INTRODUCTION ABOUT PRODUCT
- FRONT AXLE BEAM AND STUB AXLE
- FRONT AXLE BEAM
- STUB AXLE
- USES AND APPLICATION
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- FOR FRONT AXLE BEAM
- FOR STUB AXLE
- PRODUCTION PROCESS FOR FRONT AXLE BEAM AND STUB AXLE
- MACHINING
- THERE ARE FOLLOWING MACHINING OPERATION ARE GIVEN BELOW:
- (1) MILLING OPERATIONS
- THERE ARE FOLLOWING TYPES OF OPERATIONS IN MILLING PROCESS
- (A) FACE MILLING
- MOUNTING THE WORKPIECE
- DEPTH OF CUT
- (B) GANG MILLING
- (2) DRILLING PROCESS
- ESTABLISHING A CENTERING MARK OR FEATURE BEFORE DRILLING, SUCH AS BY
- SPOT DRILLING
- CENTER DRILLING
- DEEP HOLE DRILLING
- GUN DRILLING
- MICRO DRILLING
- DRILLING IN METAL
- (3) BOARING OPERATIONS
- (4) TURNING OPERATION
- TURNING SPECIFIC OPERATIONS INCLUDE:
- HARD TURNING
- FACING
- PARTING
- GROOVING
- NON-SPECIFIC OPERATIONS INCLUDE:
- BORING
- KNURLING
- (5) DEBURRING OPERATIONS
- WHAT IS BURR AND HOW DOES IT OCCUR?
- (6) CLEANING PROCESS
- (7) MAGNETIC PARTICLE INSPECTION
- PROCEDURE
- 1.0 MAGNETIC PARTICLE INSPECTION - SCOPE
- 2.0 MAGNETIC PARTICLE INSPECTION -DESCRIPTION OF METHOD
- 3.0 MAGNETIC PARTICLE INSPECTION - EAUIPMENT AND MATERIALS
- 4.0 MAGNETIC PARTICLE INSPECTION - PARTS TO BE EXAMINED
- 5.0 MAGNETIC PARTICLE INSPECTION - SURFACE PREPARATION
- 6.0 MAGNETIC PARTICLE INSPECTION - EQUIPMENT AND CONSUMABLE CONTROL
- 7.0 MAGNETIC PARTICLE INSPECTION - LIGHTING CONDITIONS
- 8.0 MAGNETIC PARTICLE INSPECTION - DIRECTION OF MAGNETISING FIELD
- 9.0 MAGNETIC PARTICLE INSPECTION - SEQUENCE OF OPERATIONS
- 10.0 MAGNETIC PARTICLE INSPECTION - EVALUATION OF INDICATIONS
- 11.0 MAGNETIC PARTICLE INSPECTION - ACCEPTANCE CRITERIA
- 12.0 MAGNETIC PARTICLE INSPECTION - PERSONNEL QUALIFICATION
- 16.0 MAGNETIC PARTICLE INSPECTION - REFERENCED DOCUMENTS
- (8) INSPECTION PROCESS
- FUNDAMENTALS OF INSPECTION
- TYPES OF INSPECTION
- INSPECTION PROCEDURE
- EXAMINATION
- DECISION
- ACTION
- INSPECTION ACCURACY
- INSPECTION VS. TESTING
- AUTOMATED INSPECTION
- FEEDBACK PROCESS CONTROL
- TIMING OF INSPECTION
- OFF-LINE INSPECTION METHODS
- ON-LINE/IN-PROCESS AND ON-LINE/POST-PROCESS INSPECTION METHODS
- (9) ANTI RUST OILING PROCESS
- UNDERSTANDING THE RUSTING PROCEDURE
- INCONSISTENT ATOMS
- CORROSION ON A BUSINESS SCALE
- OILING PREVENT RUSTING: RUST REMOVER OILS
- AUTOMOTIVE RUST REMOVAL TREATMENT
- RUST REMOVING CHEMICALS
- DEBURRING MACHINE
- LINEAR DEBURRING MACHINES
- DOUBLE-SIDED DEBURRING MACHINES
- DISC BRUSHES
- MOST USED MATERIALS:
- MARKET OVERVIEW
- MARKET SIZE
- INVESTMENTS
- GOVERNMENT INITIATIVES
- ACHIEVEMENTS
- ACHIEVEMENTS
- ROAD AHEAD
- INTRODUCTION
- MARKET SIZE
- INVESTMENTS
- ACHIEVEMENTS
- GOVERNMENT INITIATIVES
- ROAD AHEAD
- AUTOMOTIVE AXLE & PROPELLER SHAFT MARKET DYNAMICS
- DRIVERS
- RESTRAINTS
- OPPORTUNITIES
- CHALLENGES
- OBJECTIVES OF THE AUTOMOTIVE AXLE & PROPELLER SHAFT MARKET STUDY
- RESEARCH METHODOLOGY OF AUTOMOTIVE AXLE & PROPELLER SHAFT MARKET
- TO KNOW ABOUT THE ASSUMPTIONS CONSIDERED FOR THE STUDY
- PASSENGER CARS
- LIGHT COMMERCIAL VEHICLES
- HEAVY COMMERCIAL VEHICLES
- FRONT AXLE
- REAR AXLE
- DEAD AXLE
- LIVE AXLE
- TANDEM AXLE
- FRONT PROPELLER SHAFT
- REAR PROPELLER SHAFT
- INTER-AXLE PROPELLER SHAFT
- DETAILED EXPORT DATA OF FRONT AXLE BEAM
- EXPORT DATA OF RIGHT STUB AXLE
- IMPORT DATA OF FRONT AXLE BEAM
- IMPORT DATA OF RIGHT STUB AXLE
- PLANT LAYOUT
- SUPPLIERS OF FRONT AXLE BEAM
- SUPPLIERS OF STUB AXLE
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF STEEL FORGING
- SUPPLIERS OF CUTTING FLUID
- SUPPLIERS OF PACKING MATERIALS
- SUPPLIERS OF DEGREASING CHEMICAL
- SUPPLIERS OF PICKLING CHEMICALS
- SUPPLIERS OF OIL AND GREASE
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF MILLING MACHINE
- SUPPLIERS OF CNC LATHE MACHINE
- SUPPLIERS OF BOARING MACHINE
- SUPPLIERS OF POWER HACKSAW
- SUPPLIERS OF GRINDING MACHINE
- SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES
- SUPPLIERS OF DG SETS
- SUPPLIERS OF EOT CRANE
- SUPPLIERS OF POWER TRANSFORMERS
- SUPPLIERS OF ELECTRICAL PANEL
- SUPPLIERS OF ELECTRIC MOTOR
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSORS
- SUPPLIERS OF PLATFORM WEIGHING MACHINE
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF SHOT BLASTING MACHINE
- SUPPLIERS OF JIGS AND FIXTURE
- SUPPLIERS OF SUBMERSIBLE WATER PUMP
Appendix
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
An automotive forging manufacturing project involves producing forged components used in vehicle assemblies and related applications. The process generally converts heated metal into required shapes using controlled forming operations, followed by machining and inspection where necessary. For products such as front axle beams and stub axles, manufacturing may include forging, machining, drilling, milling, turning, deburring, cleaning and surface protection. Quality-control processes are important because automotive components must meet specified dimensional, material and performance requirements.
Front axle beams and stub axles are structural and functional components used in vehicle axle and steering assemblies. A front axle beam supports and connects relevant front-end components and contributes to load transfer and vehicle stability. A stub axle is associated with the wheel and steering arrangement and enables the required wheel movement and support. Their precise design and manufacturing depend on the vehicle type, load requirements, suspension configuration and applicable technical specifications.
Common machining operations include milling, drilling, boring and turning, followed by deburring and cleaning where required. Milling can include face milling and gang milling, while drilling may involve spot drilling, center drilling and deep-hole drilling. Turning operations can include facing, parting and grooving, with boring also used for internal surfaces. The selection of operations depends on the component geometry, dimensional requirements, material characteristics, production volume and required surface finish.
Magnetic particle inspection is used to detect certain surface and near-surface discontinuities in suitable ferromagnetic components. During the inspection, the component is magnetised and magnetic particles are applied so that relevant discontinuities can produce visible indications. The procedure typically requires controlled surface preparation, equipment and consumable checks, appropriate lighting, defined magnetising directions, evaluation of indications and acceptance criteria. Personnel qualification and referenced inspection documents are also important parts of a controlled inspection system.
Deburring removes unwanted raised edges, sharp projections and machining-related burrs from manufactured components. Burrs can form during operations such as milling, drilling, turning and other material-removal processes. Removing them can improve component handling, assembly compatibility, dimensional consistency and surface condition. Depending on component geometry and production requirements, manufacturers may use manual, mechanical or automated deburring equipment, including linear and double-sided machines and suitable brush systems.
Anti-rust oiling helps protect susceptible metal surfaces from corrosion during storage, handling and transportation. Cleaned and machined components can be exposed to moisture and other environmental conditions that promote rust formation. Applying an appropriate rust-preventive oil creates a protective barrier between the metal surface and corrosive environmental influences. The treatment is generally selected according to the material, storage conditions, required protection period and subsequent manufacturing or assembly processes.
Important factors include product specifications, manufacturing process selection, plant layout, machinery requirements, raw-material availability, utilities, quality-control systems, material handling and environmental and workplace requirements. A facility producing axle components may require forging and machining capabilities supported by equipment such as milling, drilling, turning, grinding and material-handling systems. Inspection and testing arrangements should be integrated into the production flow, while supplier planning should cover raw materials, consumables, machinery, electrical systems and other plant-support requirements.
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