sunil ppt tech
TRANSCRIPT
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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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NON-RECURRING:Sr.no.
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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NON-RECURRING:Sr.no.
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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