Karmen International Pvt. Ltd.
Corporate Overview
Machined Cast parts – Precision Components – Contract Assembly Services
Engineering Design Support & Prototyping – Testing & Validation
Presentation Outline
Karmen Corporate Overview
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Background
What we do
Product Offerings
Milestones 2000 - 15
Overview
Manufacturing Facilities – Engineering Division with pictures
Manufacturing Facilities – Castmetals Division with pictures
What’s Unique about Karmen
High 5
Health, Safety and Environment
Plan for the future
Why Karmen
Background
Past Experience & Expertise of the management group :
– The Management team of Karmen had earlier founded and managed the most
successful Export Oriented Indian Steel Foundry – Sivanandha Steels Ltd., up to
1999.
– Set up in 1967 with technology from Demag, Germany and Cronite Foundry Group,
UK, Sivanandha was the Top exporter of steel castings for 14 years from 1985 to
1999 and winner of the Govt. Of India’s Top Exporter Award for 10 years.
– Supplied the Global Valve industry including Tyco Vanessa, Velan, Cameron, Crane
Co., DeZurik, BHEL (Toa Valve Licensee) and earth moving equipment customers
such as Caterpillar India and BEML (Komatsu Licensee).
Management Background
1.
Ramesh Venkatesan, CEO & Managing Director is a Production Engineer and holds a Master’s
Degree from The University of Warwick, UK in “Engineering Business Management”. He has
over 16 years experience in Steel foundry operations, global sourcing, precision engineering and
International sales.
2.
R.Marudachalam (RM), Executive Director is a Mechanical Engineer from Coimbatore
Institute of Technology and has over 36 years of experience in valve casting technology. He has
been closely involved the sourcing activity of global companies from India and has been trained
at Cronite Foundry Group, UK.
3.
Divya Biyani Venkatesan, Director and COO is an Economics graduate from the University of
Madras and holds a Masters in Business Economics. She has been involved with Karmen as
Operations Head since 2005. Prior to joining Karmen, she was National Sales Head for
Thomson Reuters.
4.
K.Subramanian (KS), Vice President – Management Processes holds a graduate degree in
Physics and is one of the earliest ANST Level III certified professionals in India. During his
career spanning over 40 years, he has built up a strong track record within the industry as an
uncompromising Quality professional focused on NDT. He is also responsible for auditing and
approving all Karmen suppliers.
Karmen – What we do
We are a Tier 1 manufacturer of high integrity machined cast parts and precision
components to the valve, pump, and locomotive industries worldwide.
• Machined Castings: Ferrous and Non Ferrous using sand and investment castings
from less than 1 lbs to a maximum 10000 lbs.
• Machined Forgings: Open die, closed die and ring rolled forgings fully machined upto
2000 lbs in a variety of alloy steel and stainless steels for the oil / gas / energy industries.
• Precision Components: High precision machined components in a variety of materials
grades including alloy steels, stainless steels, Inconel for the valve, locomotives, oil / gas
and energy industries.
Product offerings
Industry Domains – Valves, Pumps, Earth Moving, Oil & Gas, Locomotive
Machined Cast High Precision machining and value added services including hard facing and ground
/ lapped finish. Large casting capability added – 4000kg single piece.
Parts
Components
Precision parts and components from bar stock and forgings. Full range of valve,
pump, locomotive and precision parts for Oil & Gas applications.
Materials
WCB, LCB/LCC, CF8M, CF3M, CA6NM, CA15, Alloy Steels (WC6, WC9),SS Duplex ,
Super Duplex , Inconel, Monel, Aluminum, Aluminum Bronze, GCI and Ductile Iron.
Contract
Manufacturing
Services
Value Added
Supply Chain
Consolidation
Complete assembly and testing services for pumps , valve and sub assemblies using
machined cast , forged and fabricated components
Integrating customer’s existing supplier base for higher value addition / inventory
consolidation / Kanban / assembly in order to deliver better efficiencies
Engineering Working with customers for design support services including Fab to cast conversion,
cast to forge, improve manufacturability.
Support Services
Karmen Milestones 2000 - 15
Year
2000 - 01
Milestones
Set up of facilities and commencement of business (Machining & Test – Unit 1)
ISO Certification (Lloyds Registrar UK)
Increased focus on Machined Castings “ready for assembly”.
2002 - 03
CNC Machining Capability added.
Supply of “Valve kits” and precision components.
ERP Implementation.
2004 - 05 Supply of fully assembled valves to customer drawings on exclusive basis.
Lapping capability added.
Wind Energy Division: 750 Kw Vestas Wind Mill set up.
2nd manufacturing site at Coimbatore- Focused factory with dedicated manufacturing cell for volume, repetitive products.
2006 - 07 Investment Program for expansion and up gradation of Unit I .
Wind Energy Division: 2nd 750 Kw Vestas WEG set up.
Karmen Cast metals Division Set up (Captive Steel Foundry) in Chennai.
2008 - 11 New Machining facility Unit III started production in Chennai.
Supply of precision machined components for the oil / gas industry.
Engineering Division – Unit IV under construction expected to be finished Q3 2015 to focus on precision machined
components and assemblies.
Expansion of facility including dedicated metrology area with CMM to be completed by April 2015 @ Unit II. Addition of
2012 – 15 new CNC turning capacity for large dia parts upto 1300 mm.
Up gradation of facilities at Unit I including conversion of conventional to CNC.
RT facility to be completed by Q1 2015 at Castmetals Division.
Overview
• Years in Business : 15
• Sales Turnover :
– FY 2004-05 : US$ 2.7 Million
– FY 2005-06 : US$ 5.0 Million
– FY 2006-07 : US$ 7.9 Million
– FY 2007-08: US$ 13.60 Million
– FY 2008-09: US$ 15.00 Million
– FY 2009-10: US$ 9.60 Million
– FY 2010 – 11: US$ 11.00 Million
– FY 2011 – 12: US$ 15.00 Million
– FY 2012 – 13: US$ 19.00 Million
– FY 2013 – 14: US$ 16.00 Million
– FY 2014 – 15: US$ 19.00 Million
• People Strength : 300 +
• Manufacturing Facilities:
– Engineering Division : 3 [Chennai & Coimbatore]
– Castmetals Division : 1 [Chennai – Sipcot Oragadam]
• No. of Customers : 24
• Geographies Covered : USA, Canada, UK, Germany, Australia, Japan, Indonesia
Karmen Manufacturing Facilities
Engineering Division:
– Three machining facilities (Unit 1, 2 and 3) equipped with state of the art
CNC horizontal and vertical machining centers, CNC VTL’s and other
conventional equipment.
– Every facility equipped with Faro / Romer Portable CMM Arm and other
sophisticated measuring instruments.
– Bridge type CMM (Zeiss) commissioned this month at Unit II
– This division sources its input materials (castings, forgings, bar stock) from
approved suppliers across the country. Key material grades supplied include
Carbon Steels, Stainless, Alloy Steels, Ductile Iron, Aluminum, Al Br and
exotics.
Karmen Locations
Unit-2
Corporate office & Unit-3
Unit -4 Under construction
Castmetals Division
Engineering Division
Engineering Division
Engineering Division – QA Facilities
Zeiss CMM
Faro CMM Arm
Trimos Height Gauge
Flatness check
Air Gauge
Magnetic Particle Inspections
Kings Hardness Tester
Portable Hardness
Tester
PMI Check
Oil & Gas – BOP Parts (Cast and Forged/Components)
11”& 13” Ram Blank
Made From : Forging
Material Specification : AISI 4140
Upper Head
Made From : Rolled Bar
Material Specification : SS 17 – 4
PH, Condition H 1150 D
7”,11”& 13” Lock Screw
Made From : Casting
Material Specification : ASTM A
487/487M
Insert
Made From : Rolled Bar
Material Specification : Inconel 718
11”& 13” Bonnet
Made From : Casting
Material Specification : ASTM A
487/487M
7” Gate
Made From : Forgings
Material Specification : SS 316 L
Dual Plate Check Valve Machined Castings
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Fully machined
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Lapping / Grinding for plates and body seats
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2” to 48” upto 1500 class pressure rating
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All materials including Al Br, exotic materials
Valve Parts
Machined sand & investment castings in ferrous
& non ferrous material grades for valves
Locomotive parts
Forged – Ball Valve Body & End cap
3” & 4”Ball Valve Body
Pressure Class: 1500
Make : Forging
Material Specification : F 316
3” &4” End cap
Pressure Class: 1500
Make : Forging
Material Specification : F 316
Components
Karmen Manufacturing Facilities
Castmetals Division (Steel Foundry):
• The modern steel foundry has been set up on a 5 Acre site near Chennai, India.
• Moulding Line: Equipped with fully automatic IMF moulding line (Italy) including transfer cars, roll over,
mould heating ovens, mould pushers, shakeout and mechanical reclamation system.
• Sand System: Alkaline Phenolic Resin System (Alphaset). Flask size 1800 x 1400 x 550 mm. Max single
piece weight of 1750 lbs.
• Melting: The plant is equipped with 3000 / 2200 / 1100 lbs Inductotherm Furnace.
• 4500 lbs Dual Trac Inductotherm Furnace under evaluation for Phase 2 of project for 330 tons per
month capacity.
Quality:
• Fully equipped with latest spectrometer, mechanical lab, sand lab and complete range of NDT equipment
all calibrated by TUV Nord.
• ISO 9001 and PED certifications from TUV Nord and recently NORSOK approved
• Latest LPG Fired and Electric Heat Treatment furnaces with automatic quenching arrangement.
Capacity:
• Current Capacity: 175 MT per month in Phase 1
• The capacity of the plant is expected to be 330 + tons after addition of 4500 lbs Dual Trac furnace in
Phase 2 and will eventually increase to 500 tons in Phase 3.
Karmen Castmetals - Facilities
Certification & Approval
Engineering Division
Castmetals Division
ASNT – ACCP
Professional Level –III
Certificate
ASNT – NDT Level –III
Certificate
NORSOK Approval
Customers
Valve Industry :
Transportation Industry:
Oil & Gas Industry :
Our Uniqueness
• Our size – “ Small by Design”
– Right size - Large enough to be reliable and small enough to be agile and highly
responsive
– Serviced by Karmen “A” Team
• Excellent Track Record
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100% referable clients
Technically competent and experienced team with global exposure
Trust, Credibility and Confidentiality aligned with corporate culture and strategy
Financially Sound – willing and ready to make investments in new projects and
opportunities to meet customer expectations.
• “Goal Sharers” – instantly align to Customer’s goal
• Non-commodity business is our niche
Karmen HIGH 5
The Karmen HIGH 5
We are a performing team, delivering stretched goals and are motivated by measuring monthly our –
1.Delivery Performance (QOTD)
95% Quality On Time Delivery of line items
2.Customer Experience of our Product &
Service (CEPS)
Not more than 1 instance /quarter/customer
3.New Product Development (NPD)
90 days for machined sample after FAI
4.Responsiveness (RESP)
48 hours to respond internally & externally
5.First Time Right (FTR)
80% ( From Pattern to Final Inspection of
Machined component)
Why Karmen ?
1. Established and successful track record of forming and nurturing international alliances for
over 30 + years with long term vision.
2. Proven capability in supply of machined valve castings and components to global standards
backed by:
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Strong manufacturing base including steel foundry.
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Committed and dedicated team with hundreds of years of collective experience in
valve supply chain, NDT & QA.
3. Recently established capability in manufacture of specialty valves to customer’s
specifications including high end test requirements supplied direct to demanding customers.
4. Family owned and professionally managed by 3rd generation entrepreneurs.
5. Proximity to growing markets.
1 committed team backed by diverse, world-class,
manufacturing capabilities focused on consistently
delivering value to the customer.
Thank You for your time
For more information:
Karmen International Pvt. Ltd.
Corporate Office
DP 48 & 51 Sidco Industrial Estate
Thirumazhisai, Chennai – 602 107
India
Tel: +91-44-26810750
Fax: +91-44-26810753
Email: Sales@karmengroup.com
www.karmengroup.com