proposal for a stamping plant

8/10/2019 PROPOSAL FOR A STAMPING PLANT

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MINOR PROJECT

ON

PROPOSAL

FOR A STAMPING PLANT

Group no : 5Guided By Presented By

Mr. Niraj Bhatnagar Deepak Bakshi(077104

Rohit Singh Bisht(03

Himesh Razdan(0761

Gautam Kumar Chau


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ConceptValidation

Production Feasibility Definition of material taking intoaccount

STAMPING PLANT PLANNING

PROCUREMENT OF TOOL AND MACHINERY

Punch die procurement Machinery procurement Other facilities

PROCRDURE PLANNING

TO GET THE BANKS PROPOSAL

PROCEDURE


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PRODUCT

Type Washer 1 Washer 2 Washer 3 Washer 4 Washer 5 Washer 6 Washer 7 Wa

Dia OD22 ID11 OD24 ID13 OD28 ID15 OD30 ID17 OD34 ID19 OD37 ID21 OD39

Thickness 2 2.5 2.5 3 3 4 4

Washer

Standard washers are produced with steel as material

Proper tolerance and Quality standards are maintained using proper tool and machinery


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MARKET TRENDS

0

1

2

3

4

5

6

2009 2010 2011 20

Swarna Fastener DM Enterprise

P r o

d u c t i o n

o f w a s h e r s

( t o n

) x 1 0 ^ 5

Leading Fastener Industries Swarana Fasteners (Delhi) and DM Enter


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Total Area = 8*15 sq. meters= 120 sq. meters Symbol For a worker

Plant Layout with Material Flow

Process Flow


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Strip feed

Lower Part Upper Part

S.NO. PART MATERIAL COST(Rs)

1 Punch HcHCr(D2 grade) 3000

2 Die HcHCr(D2 grade) 2500

3 Support Plate EN38 10000

4 Base plate and top plate Mild Steel 15000

5 Extra(Spring ,guide poles , bushes) According to requirement 5000

Total cost=Rs.31000

DIE DESIGN AND STRIP LAYOUT

Inner Dia dOuter Dia DPitch Step 1.Width of stri


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Press MachineSpecs On the basis of which Press Machine has been selected Cost Tonnage Required = 2.5 [(Shearing area x Shear strength of material) +Stripping Force]

10 ton SPM required = for the production of 144000 washers (By one machine) a year (with working

hours 6x250 in a year)Min SPM Required 40

MACHINERY SELECTION

FeederMax Width ( Required width is 60 mm )Max Thickness ( Required thickness is 2 mm )

SPM (Required SPM is 40 )

De coilerMax Weight ( Required weight is weight ofMax Width ( Required Width is 60 mm

Turret Punch PressTurret punch press is also a possibility where wedon't need any de coiler and feeder and alsothere cascading in stamping process can be done


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PRESS SELECTIONManufacturer Tonnage Strokes per

minuteDimension Price ( RS ) Power

RequiredBasant Press

Pvt. Ltd.30 65 32x30x50 2,55,000 3 HP

Basant PressPvt. Ltd.

50 55 39x39x75 2,95,000 5 HP

Revatech AndSons

50 35 57x34x86 3,10,000 4.5 HP

Revatech AndSons

40 35 40x41x80 2,90,000 3.5 HP

Sri Krishna

Hydro Project30 60 39x42x75 2,45,500 3 HP

Ravi PowerPress

50 45 40x41x80 3,05000 4.5 HP

Power Press

Turret punch Press

P

Turre

Tonnage 200 Ton Hit Rate 500 SPMStroke Length 27mm

Max Thickness 6mm


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Feeder

Manufacturer

Type withMax

Weight

Max.Width

Powe

Press roomautomation

Pvt.Ltd(vd5)

SingleJaw

500 kg

150 mm 0.5 H

Hertzcontrol Pvt.

Ltd

DoubleJaw

500 x 2Kg

150 mm 0.5 xHP

De coiler

Combination Units Can also be used instead of using twoseparate machines

Manufacturer MaxWeight

MaxWidth

MaxThickness

Dimension(mm) Cost(RS)

Press RoomAutomation

& FeedFixtures(India)

Pvt. Ltd

2000kg

150mm

0.5 to2.5 mm

2000 x 1000x 1400

1,50,000

ManuInternational

Pvt. Ltd

1050kg

150mm

1.5-5mm

1500 x 1000x 1100

2,10,000

Manufacturer(Model)

Type Max. Width Max.Thickness

SPM Dimension Cost(Rs)

Jay shantipneumatic

feeder(Extramild series)

Pneumatic

100 mm 2.5 mm 140 100 x100 cm

45,180

Jay shantipneumatic

feeder(Extramild series)

Pneumatic 100 mm 2 mm 100 150 x150 cm 39,250


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Other Tool Room Machines

Lathe Machine Drill Machine

Bhavya Machine Tools Bhavya Machine Tools

Specs

8 Variable speedCentre Height 165 mmMax Swing Over Bed 330mmCross Slide Travel 225mmLed Screw TPI 4 TPI

Specs

Drilling Capacity 25 mm8 Variable SpeedSpindle RPM 110-2880Max Drill Radius 910mm

Milling Machine

List of MaS No

1 2

2 2 Co

3 4

5

Other FRacks, Bin

Bhavya Machine Tools

Specs

Table Dim 800 x 175 mm6 Variable Spindle SpeedVertical Travel 450mmHorizontal travel 400mm

Fork Lifter

Conveyer


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PRODUCT COST

DIAMETER MATERIAL

COST INTEREST &

DEPRECIATION ELECTRICITY

COST RENT SALARY PACKAGING

COST PROMOTION

AL COST

REPAIR &MAINTENAN

CE TRANSPORTATI

ON COST

ID11 0.47 0.03 0.016 0.03 0.16 0.030 0.07 0.09 0.1ID12 0.50 0.03 0.016 0.03 0.16 0.040 0.07 0.09 0.1ID14 0.76 0.03 0.016 0.035 0.16 0.050 0.07 0.09 0.1ID16 0.86 0.03 0.016 0.035 0.16 0.050 0.07 0.09 0.1ID18 0.96 0.03 0.016 0.035 0.16 0.050 0.07 0.09 0.1ID20 1.58 0.03 0.016 0.035 0.16 0.060 0.07 0.09 0.1ID22 1.79 0.03 0.016 0.035 0.16 0.060 0.07 0.09 0.1

ID24 1.94 0.03 0.016 0.035 0.16 0.060 0.07 0.09 0.1

Material Cost = Strip Thickness x Width x Material density x per kg cost / Total no washers per day

Electricity Cost = Net Power Consumption x Per unit Cost / Total no of Washers per day

Salaries = Sum of all Employers/ Total no of washers per day

Rent =Rent per Day / Total no of Washer per day

Interest And depreciation = Interest + Dep. Per Day / Total no of Washer per day


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BREAK EVEN ANALYSIS

TOTAL COST(TC)TC=F+V

TC=F+QC.(1) TOTAL REVENUE( TR)TR=QP.......................(2)

WhereF=Fixed costV=Variable costQ=no. of unitsC=unit assembling cost

P=unit selling cost

Fixed cost=machine cost + rent + promotion+ maintenance=2,310,000+1,200,000+2,31,000=6,141,000

Unit assembling cost(C)=material +electricity+ wages+ tra= 1.3275+0.0165+0.16+0.1= 1.604

AT break even point(profit=0)Total Revenue=Total CostQP=F+QCorQ=F/(P-C)

Number of units at BEPQ=F/(P-C)

=6,141,000/(2.15-1.604)=11,457,090 units

Revenue=QP=11,457,090*2.15

=24632744


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BREAK EVEN POINTREPRESENTATION

For Profit(TR>TC)Profit=TR-TC

=Q1-(F+Q1*=12,000,000-= 2,91,000

Margin of Safety(MO

MOS=(sales at Q1)-=[(Q1-Q)]*P=[12,000,000-1= 5,42,910


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OUR TARGET

Grow with value customer together

Do effective things with the effective way

Help customer solve supply problem

Supply High quality part with competitive cost.


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LIST OF PROPOSED INVESTORS

Bank NamABN baAxis baBank ofICICI bIDBI baPunjab State baYes ban.........m


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Project Plan12-Aug 1-Sep 21-Sep 11-Oct 31-Oct 20-Nov 10-Dec

TEAM PLANING

LITERATURE SURVEY

MARKET SURVEY

DESIGNING

COST ANALYSIS

FINAL LAYOUT OF PROPOSAL

FINAL REPORT


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Tool design by Cyril Donaldson, Donaldson MN. Fundamentals of press working by David Alkire Smith Bralla, James G. (1999). Design for Manufacturability Handbook .McGraw-Hill. Carlon fastener Survey, Google Survey for fastener Database of Swarna Fasteners and DM Enterprises www.wikipedia .com Google Database PROJECT PROFILE ON M.S. AND HIGH TENSILE NUTS AND BOLTS By Micro, Small & Mediu

Enterprises Project Profile on the establishment of Nails producing Plant By Development Studies Associates (DSA) FORECASTING FUNDAMENTALS

REFERENCES


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Thank You

proposal for a stamping plant

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