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SEForge

SEForge OPENS 120,000 TONNE CAPACITY CASTING UNIT IN INDIA

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The worldwide demand for ductile Iron castings stands between 25-30 billion tonnes every year. Naturally, this USD 55 billion dollar market has seen a steady rise in the number of solution providers to the industry in recent times to combat the rising demand.

The new entrant to this sector is SEForge, a new age Hand Moulded No Bake Ductile Iron casting company. SEForge has a manufacturing facility for castings in Coimbatore, Tamil Nadu and a dedicated unit for seamless forged products, with a capacity of handling up to 5000 mm diameter rings.

The semi- automated foundry plant located in en SEZ near Coimbatore will specialise in providing end-to-end solutions for an international clientele. SEForge will match an annual production demand of 120,000 tonnes good castings of specialized Ductile Iron castings and high volume demands of casting requirements ranging from 1 tonnes to 50 tonnes. This capacity puts SEForge in the league of the biggest in the world.

SEForge is poised to emerge as a single source for R and D solutions, casting design assistance, patterning, casting production and finish machining and will also address customised surface treatment solutions like painting. The comprehensive concept to product facility will bring to international clientele, the convenience of sourcing their complete casting needs with a one stop solutions provider.

Given the highly critical and size of the castings produced by the company, it is vital that each process is monitored and governed by a philosophy that will ensure that the quality of the products is unmatched. SEForge therefore has modelled its business plan for the Foundry unit on implementing a zero defect philosophy trough Six Sigma quality tools of practice in every stage.

The zero defect mantra will be implemented across the development and production life cycle from sourcing of the raw material to training of the people on the shop floor and instituting practices that will embrace the zero defect philosophy.

Raw material from pig iron to sand and additives used in the no bake process are being sourced from a global supply chain to ensure consistent delivery of high quality material.

The casting process will involve developing and documenting process controls that allow the foundry to produce consistent quality trough high quality standards.

The process will be optimised using advanced simulation software applications that will ensure accuracy of castings and aid maximum production capabilities at optimal cost.

The right process will be implemented and taken forward by bringing together the best of engineering and casting talent from around the world. The team at SEForge will be routed trough intensive theoretical training for 3 months, intensive hands on training for another period of time, before being introduced to the various system processes.

SEForge will build on this three pronged initiative of bringing together the right processes, the right people and the right material to maintain its zero defect philosophy.

Another unique value addition that SEForge will bring to its clientele is a completely machined, finished product that would otherwise have to be assembled from several components. Thus, client organisations will not only benefit from restricting their supply chain to one solutions provider with a proven track record, but also bring down their administrative costs significantly.

The application areas for castings from SEForge can be as varied as power, engineering, mining equipment, railways, earth moving industries and machine tool applications.

In addition to embracing the quality philosophy of the foundry unit, the SEForge Forging unit is set to redefine manufacturing process. The unit is the first of its kind, and has a fully automated process for heavy and big size Rings to serve the wind mill tower business, bearing industry, power industry, mining and other verticals.

The Forging unit is also equipped with ultra modern CNC Machines to ensure consistency in delivery and build the right shape for rings with high accuracy. This unit will be able to cater to an annual production of 70,000 rings.

SEForge is owned by a group of eminent Indian industrialists. At the helm of operation is Executive Director Mr. Hugo L. Schippmann, who is a well known strategist in the global power and engineering solutions industry.

At the World Foundry Congress, SEForge showcased its capabilities and its complete mastery over advanced metallurgical processes. The company is looking to entering engaging partnership with a global clientele seeking to source their casting trough one enterprise.

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