Sunil Ppt Tech

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Submitted by

SUNIL KUMAR2012AMD2612

Submitted To

Prof. D K Sehgal

Applied Mechanics Department,

Indian Institute of Technology, Delhi


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Need of the product


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Problem we faced??


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A BRIEF INTRODUCTION OF PRODUCTPiezoelectric Road Produces Electricity From Traffic

Piezoelectric pads is made of multiple,tiny, interlocking crystal domainsthat have positive and negative charges

piezoelectric sensors/crystals thatproduce electricity when squeezed.

produce up to 400 kilowatts from a 1-kilometre stretch

materials are Quartz, Rochelle salt, Cane sugar, Topaz,Tourmaline, Berlinite (AlPO4), Gallium orthophosphate(GaPO4), Langasite, etc.


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Electricity Generation from Speed Breaker

simple energy conversion from mechanical toelectrical

generate electricity using the vehicle kinetic energy asinput

Different proposed mechanisms:-

1. Roller mechanism

2. Crank-shaft mechanism


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. Roller mechanism


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Crank Shaft mechanism

Produce I kw power in every single min where 100 vehicle pass in 1 min.


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Various Parts

SPUR GEAR

FLY WHEEL

BEARINGS SHAFT

SPRINGS

ELECTRIC DYNAMO

PIEZOELECTRIC CRYSTAL

BATTERY


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Advantage capable of producing large amounts of electricity

without increasing the consumption of fuel.

relatively inexpensive and easy to install

Suitable at parking of multiplexes, malls, toll booths,signals, etc.

Charging batteries and using them to light up thestreets and traffic lights..etc

Easy maintenance


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Selection of Alternative technologies

Level of Automation

1. Our manufacturing processes are not complicated

2. full level of automation

o Manufacturing technology1. gear manufacturing

2. flywheel manufacturing

3. Spring manufacturing


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Manufacturing EquipmentsAutomatic Punching machine Roll bending machine

Welding machine

Gear shaping machine Gear milling machine

Lathe machine

Grinding machine


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Type of manufacturing

process

Parts produced Level of

automation

Machines used

Sheet cutting Sheets of equal dimensions Medium Sheet cutting machine

QC12Y-10X3200

Punching Punching of holes in sheet High Punching machine

Roll machine shop Piezo crystal fitting on

sheets

High Roll Bending Machine

W11G-1.2x1530

Gear manufacturing Gears Medium Milling, Shaping mchine

Workshop Spring, shaft, battery

,bearings

High Lathe machine , all tools ,

Painting Complete product Medium Spray painting machine

Supplier-Mec Shot Blasting Eqip Pvt.

Ltd.

Assembly Complete product

Piezoelectric sheets, roller

mechanism, rack pinion

mechanism

High

Assembly machines-10 no.s, Supplier-

India Robotics & Automation Pvt.

Ltd.
http://www.tradeindia.com/Seller-228844-338827-1014-1HS/Industrial-Machinery-Parts/MEC-SHOT-BLASTING-EQUIPMENTS-PVT-LTD-.htmlhttp://www.tradeindia.com/Seller-228844-338827-1014-1HS/Industrial-Machinery-Parts/MEC-SHOT-BLASTING-EQUIPMENTS-PVT-LTD-.htmlhttp://www.tradeindia.com/Seller-299043-2271884-1011-CATALOGS/Hydraulic-Products-Equipment/INDIA-ROBOTICS-AUTOMATION-PVT-LTD-.htmlhttp://www.tradeindia.com/Seller-299043-2271884-1011-CATALOGS/Hydraulic-Products-Equipment/INDIA-ROBOTICS-AUTOMATION-PVT-LTD-.htmlhttp://www.tradeindia.com/Seller-299043-2271884-1011-CATALOGS/Hydraulic-Products-Equipment/INDIA-ROBOTICS-AUTOMATION-PVT-LTD-.htmlhttp://www.tradeindia.com/Seller-299043-2271884-1011-CATALOGS/Hydraulic-Products-Equipment/INDIA-ROBOTICS-AUTOMATION-PVT-LTD-.htmlhttp://www.tradeindia.com/Seller-228844-338827-1014-1HS/Industrial-Machinery-Parts/MEC-SHOT-BLASTING-EQUIPMENTS-PVT-LTD-.htmlhttp://www.tradeindia.com/Seller-228844-338827-1014-1HS/Industrial-Machinery-Parts/MEC-SHOT-BLASTING-EQUIPMENTS-PVT-LTD-.html


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Estimation of Inventories

FOR A SINGLE PRODUCT :-S.NO NAME OF THE

COMPONENT

MATERIAL UESED QUANTITY

1. RACK MILD STEEL 1

2. SPUR GEAR CAST IRON 2

3. FLYWHEEL CAST IRON 2

4. SHAFT MILD STEEL 2

5. SPRINGS CHROME-VANADIUM

AALLOY STEEL

4

6 BEARINGS HIGH CARBON STEEL 4

7 PIEZOELECTRIC SHEET QUARTZ,TOPZ 1


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ESTIMATION OF INVENTORIES

Sr. No. Part Description Size/dimensions Quantity (a)

1 Steel billets ton 80

2 Gear blank Pieces 50

3 Rods for springs Pieces 70

4 Finished shafts dia:8mm 50

5 Battry 12 volts 80

6 Bearings Pieces 200

7 Piexzoelectric

crystal

Pieces 1000

8 Wires pieces 500

9 Flywheel pieces 100


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Plant CapacityAccording to the forecasting done earlier, the total

market sale estimation is 24000 per annum.

In the first year, , I estimate to capture about 30% of

the market i.e 7200 per annum


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Selection of Manufacturing Equipment


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Selection of Material Handling Equipment

Hand trolley

Bucket

Hand

stacker


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Design of organization

Stores Machining shop Production shop Gear manuf. shop

Electronics shop

Assembly shop

Quality control shop

Painting shopR & DHR departmentAccounts office

Security and safety

Service department

Canteen Transportation and logistics

Recreational club

Hospital

Estimation of man power space for pro uction


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Estimation of man power, space for pro uctionshops and offices

Department Manpower Area (10^2 sq. ft.)

R & D

4-Designer engineer

3-drafts man

300

Sheet metal cutting shop 8- M/c operators 225

Welding shop 6-welders 225Machining shop 5-Engineers,

15-M/c operators1200

Assembly shop 5-Engineers25-operators

600

Quality control shop 2-Engineers5-helpers

600

Paint shop 6- M/c operators 75

Stores 4-workers 400HR department 1-GM

4- ManagementExecutive

300

Service department

2-electricians, 2waterservices men,5-sweepers 400

Security and safety 1-head, 15-securities 50Accounts and purchase 4-accountants

3-puchase officers600

Transportation and logistics 8-drivers 100Canteen 2-chef, 6-helpers 200Hospital 1-Doctor

1-Nurses

50


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WORK INVENTORY

FOUNDARY SHOP

MACHINE SHOP

FABRICATION SHOP

SCRAP YARD

ASSEMBLY LINE

MAINTENANCE

PAINT SHOP

FINISHED

GOODS

RECREATI-

ONAL CLUB

PARKING

SECURITY

CHECK

SECURITY

CHECK

MGMENT OFFICE

GATES

PLANT LAYOUT


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Building needs

Special f looring construction for heavy productionequipment.

Shock and vibration isolation of certain areas ofmachining.

Power and water facilities.

Surrounded by Security wall

Enough Parking space.

Proper Ventilation


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Building general location

Factory location is selected as Manesar, Gurgaon

Many small scale industries are situated near this area.So raw material is easily available.

Better connectivity through roads and railways

Demand of product is high


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NON-RECURRING:Sr.no.

Element Cost/unit

(Rs.)

Quantity Total cost

(in lakhs)

1 Land

100 /sqft 750x700 sqft 525

2 Building construction

250

3 Needs of the building 10

4 Safety

Fire indicators

First aid4000

5 0.2

0.05


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Element Cost/unit

(Rs.)

Quantity Total cost

(in lakhs)

5 Machinery

CNC lathe 5,00,000 4 20

CNC milling 4,00,000 3 12

Drilling M/c 75,000 5 3.75

Cutting M/c 1,00,000 6 6.0

Welding M/c 1,00,000 3 3.0

Painting M/c 80,000 3 2.4Press M/c 1,30,000 2 2.6

Assembly M/c 75,000 10 7.5

Installation cost 1.0


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Element Cost/unit

(Rs.)

Quantity Total cost

(in lakhs)

6 Material handling

Trolleys 3000 5 0.15Fork lifts 1,00,000 2 2.0

7 Maintenance equipment

Grinding machine 50,000 1 0.5

Tools, spare parts etc. 0.38 Office equipment

Fixtures and furnitures 1.0

9 const. like roads, lawn 0.5

TOTAL 847.95


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RECURRING COST

Sr.no. Element Cost/unit(Rs.) Quantity Total cost(in lakhs)

Per month

1 Material cost

Steel 35000/1 ton 1.451/day 0.507 x 30Bearings 150 200/day 0.3x 30

Flywheel 800 25/day 0.2x 30

Shafts 1000 25/day 0.25 x 30

Battery 10000 25/day 2.5x 30

Sheet metal 40000/1ton 1.36/day 0.544 x 30

Piezoelectric crystal 0.05


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RECURRING:

Sr.

no.

Element Cost/unit

(Rs.)

Quantity Total cost

(in lakhs)Per month

2 Direct labour

M/c operators 5000 61 3.05

Engineers 15000 19 2.85

Material handling 3000 8 0.24

Maintenance 3000 19 0.57

Manager 18000 3 0.54

Office staff 4000 18 0.72

Cleaners etc. 3000 8 0.24


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RECURRING:Sr.

no.

Element Cost/unit

(Rs.)

Quantity Total cost

(in lakhs)Per month

3 Overhead costs

Power 6/unit 40000 2.4

Security 5000 10 0.50

Telephone, stationery etc.

0.4

TOTAL 142.04


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= Rs (847.95 + 142.04) Lakh

= Rs 9.89 crore


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Sunil Ppt Tech