Project Profile Car Repairing.docx

PROJECT PROFILE ON HOT CHAMBER VEHICLE PAINTING AND REPAIRING NIC Code

:

50200

Product Code

:

97102

Month & Year of Preparation:

March, 2010

PREPARED BY

Micro, Small & Medium Enterprises Development Institute Near Urkura Railway Station, Industrial Area, Bhanpuri, Raipur (C.G.) Phone : (0771) 2102700

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1.

INTRODUCTION:The repairing and painting of vehicle (two wheeler/four wheeler) on labour charge basis is having high potential these days. The vehicles need regular check up and servicing lfor tis smooth running. This is a labour oriented unit and skilled labour are generally employed to get the quality of work.

2.

MARKET POTENTIAL:There is tremendous growth in the number of vehicles running on the roads. As more people go in for purchasing these vehicles there would be need for repairing, denting painting of vehicles. The project can be started at any place but it is always better if it is established at a place where there are a number of vehicles. The prompt and efficient service in such activity will not find any problems in getting the job work.

3.

PROCESS:The process involved in this industry depends upon the type and nature of servicing needed for the vehicle broadly tinkering, overhauling, cleaning, welding, painting, polishing etc. The vehicle is cleaned firs. If any tinkering or denting is required, it is carried out first after engine is separated from the chassis. The surface is scraped and putti/luppum is applied and allowed to dry. After spray painting, the vehicle is kept under the hot chamber electrically heated and then polished, once it is dried.

4.

FINANCIAL ASPECTS:A. Land & Building-

Open area with boundary wall & office (on rent)

Rs.

Cost of construction of slope for four wheelers

Rs. 1,80,000/-

2

6,000/-

platform, washing & servicing & water tank etc. B. Machinery & Equipments:Sl. No. 1

Machinery ______________ Arc welding machine 3 phase with cable & other accessories completed

Quantity _________ 01 No.

Amount (Rs.) 30,000

2

Gas welding unit complete with hose, gas generator, welding torch, cylinder etc.

01 No.

18,000

3

Air compressor with 1 HP motor, hose pipe, spray gun etc.

01 No.

30,000

4

Auto battery charger 12 volts complete

01 No.

9,500

5

Chain pully block with steel bars 2 ton capacity

01 No.

12,000

6

Cost of hot chamber electrically heated

01 No.

1,20,000

7

Cost of car washing machine 2 HP electric motor with hose complete

01 No.

68,000

8

Hand tools – spanner set, banal vice, jacks, screw driver, plug wrench, monkey plier, and wheel wrench, denting & painting equipments

--

15,000

9

Testing equipments – Battery tester, compression tester, tune vulcanizing etc.

01 No.

8,000

10

Water pump set 1 HP

01 No.

9,000

11

Diesel generator 10 KV

01 No.

60,000

12

Furniture & Fixtures, tools, benches etc.

18,000

Total cost of machinery & Equipments

3,97,500

Add. Transportation cost @ 10% of machinery

39,750

Electrification and installation

15,000

Total:

3

4,52,250

C. Working Capital Requirement (P.M.) Personnel – Sl. No. a.

Particular ___________ Manager cum supervisor

Nos. _____ 01

Salary (Rs. P.M.) 6,000

Amount (Rs.) 6,000

b.

Accountant

01

5,000

5,000

c.

Skilled Workers

04

3,500

14,000

d.

Semi skilled workers

04

3,000

12,000

e.

Unskilled workers

02

2,500

5,000

f.

Storekeeper/Bill clerk

01

2,800

2,800

g.

Watchment

2,000

2,000 ______ 46,800

01

Total:

Raw Materials/Consumables – Sl. No. a.

Particular __________

Salary (Rs. (P.M.) 2,000

Welding electrodes

b.

Gas Cylinder

2,000

c.

Diesel, Mobile oil, grease etc.

4,500

d.

Paints, varnishes, chemicals etc.

e.

Screws, bolts and nuts, cleaning brushes etc.

f.

Miscellaneous consumables

10,000 4,000

Total :

4

1,500 ______ 24,000

Other Contingent Expenses – Sl. No. a.

Particular ___________

Salary (Rs. (P.M.) 800

Telephone

b.

Conveyance & Traveling

2,000

c.

Rent

6,000

d.

Electricity charges

1,800

e.

Water Charges

500

f.

Stationery, postage etc.

800

g.

Misc. Expenses Total :

1,000 _____ 12,900

Total Recurring expenditure (P.M.) Sl. No. a.

Particular ___________

Salary (Rs. (P.M.) 46,800

Personnel

b.

Raw Materials/Consumables

24,000

c.

Other Contingent Expenses

12,900 ______ 83,700

Total :

5.

TOTAL CAPITAL INVESTMENT:Fixed Capital – Construction cost

1,80,000

Machinery & Equipments

4,52,250

Working Capital (For two months) – Rs. 83,700 x 2 months

1,67,400

Pre-operative Expenses

15,000 _______ 8,14,650

Total:

5

6.

COST OF OPERATING (PER ANNUM):1

Recurring Expenditure (83,700 x 12 months

10,04,400

2

Depreciation on machinery & Equipments @ 10%

3

Interest on Capital Investment @ 12%

39,750 97,758 ________ 11,41,908

Total:

7.

REVENUE EARNINGS (PER ANNUM):1

Service charges by vehicle washing, cleaning & minor repairs

Appx. 600 vehicles

3,00,000

2

Engine Overhauling including major repairs

Appx. 500 vehicles

2,50,000

3

Spray painting, Denting & Chamber drying

Appx. 185 vehicles

9,25,000

4

Other Misc. income from repairs, battery charges etc.

--

50,000 ________ 15,25,000

Total :

8.

PROFIT (PER ANNUM):Revenue Earned – Cost of Operating 15,25,000 – 11,41,908

9.

3,83,092

PERCENTAGE OF PROFIT ON REVENUE – 3,83,092 x 100 15,25,000

10.

=

=

25.12%

PERCENTAGE OF PROFIT ON CAPITAL INVESTMENT – 3,83,092 x 100 8,14,650

=

6

47.02%

BREAK EVEN PONTS –

11.

B.E.P.

=

Fixed cost x 100__ Fixed cost + Profit

=

4,96,068 x 100 4,96,068 + 3,83,092

=

56.43%

Fixed Cost – Rent

72,000

Depreciation on Machinery & Equipments @ 10%

39,750

Interest on Capital Investment @ 15%

97,758

40% of Salaries & Wages

2,24,640

40% of Other Expenses Total:

61,920 ________ 4,96,068

Addresses of Machinery Suppliers –

12. 1.

M/s. White India Machines, No. 18, 2nd Floor, School Road, Nandanam, Chennai – 600035

2.

M/s. Armstrong Smith & Co., 45, Armenian Street, Chennai – 60001

3.

M/s. Hindustan Machine Corporation, Unit Building, J.C. Road, Bangalore – 560002

4.

M/s. Elgi Equipment Ltd., Mission school street, Secunderabad (A.P.)

5.

M/s. Thermal Equipments, 2-Lataiee Bridge Road, Chennai.

6.

M/s. Tempo Industrial Corporation, 394, Bhadkankar Road, Mumbai – 4

7.

M/s. Therlek Electrical Furnace manufacturing Co., Tripunithera, Kerala.

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CONTENTS

Sl. No.

Particulars Executive Summary

1. 2.

Page No.

Section 1

Present Indian Manufacturing Industry Profile

3.

Section 2

Manufacturing Technology Status

4.

Section 3

Machining and Fabrication Units – Process and Issues, Status in

01 03 07

13

Chhattisgarh State 5.

Section 4

Details of Machinery and Process of Manufacture in General Engineering and

52

Fabrication Industries 6.

Section 5

Advanced Technologies Applicable in General Engineering and Fabrication

54

Industries 7.

Section 6

Technology Development Initiatives

58

8.

Section 7

Machine Tools

62

9.

Section 8

Technology and Other Initiatives

68

,

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Technology study report on “General engineering and fabrication Industries” Executive Summary : In 1990, India and China had almost the same GDP per capita. Since then, driven by its manufacturing sector, China’s economy has grown much faster than has India’s and its GDP per capita on a PPP basis is 90% higher than India’s GDP per capita. To achieve faster rates of economic growth India urgently needs to strengthen its own manufacturing sector. The growth in manufacturing sector is dependent on the investment climate. The structural reforms since 1990s have made some progress. Despite recent setbacks, it is universally acknowledged that the reforms process in India cannot be reversed and sooner or later these reforms will be implemented. However, the long term competitive ability of Indian firms would depend on production efficiency. Production efficiency, in turn, is dependent on ability to develop, import and adapt new technologies among other factors. India has made significant progress in various spheres of science and technology over the years and can now take pride in having a strong network of S&T institutions, trained manpower and an innovative knowledge base. Given the rapid pace of globalization, fast-depleting material resources, increasing competition among nations and the growing need to protect intellectual property, strengthening the knowledge base is an important issue. While India’s technical talent is recognized world over, there have been serious institutional gaps in promoting industry-research institutions interaction. This report takes a critical look at the Indian manufacturing sector with respect to the technology and scientific resource availability. The current technology status, technology development initiatives and future imperatives have been identified to propel Indian manufacturing industry achieve high growth rates in as far as General Engineering and Fabrication Industries are concerned. Iron and Steel is crucial to development of any modern economy and is considered to be the backbone of the human civilization. In fact level of per capita consumption of iron and steel is treated as one of the important indicators of socio-economic development and living standard of the people in any country. All major industrial economies are characterized by the existence of a strong iron and steel industry and growth of many of these economies, at least in their initial stages of development has been largely shaped by the strength of their Iron and Steel industries. Products of Iron and Steel Industry are Pig Iron, Sponge Iron, Flat Steel Products, Long Products, Alloy Steel products, foundry products etc. Major consumers of steel products are engineering application, automobiles, construction and consumer durables.

GLOBAL SCENARIO-

Global Iron and Steel demand is rising on the back of accelerated infrastructure activity in China and India. Total output of Sponge iron in the world was 54.6 Million tons (Year 2004), an increase of 10% over the previous year. The three biggest producers in the world are: India (9.4 MT); Venezuela (7.8 MT) and Iran (6.4 MT). These four countries together account for around 40% of the global trade. China is the biggest consumer of sponge Iron. Exports from India are less than 10% of its production, while

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there is a marginal premium in exports along with the duty draw back facilities. The increase in Demand for sponge iron is further fuelled by scarcity as it is being used as an alternative for metallic scarp, as is the case of the India subcontinent. The demand supply gap in Iron and steel products and machined parts is expected to increase and even the global industry is not prepared for this demand onslaught. For these reasons it is expected that Iron and Steel prices, as a whole, will continue to firm up.

As far as castings are concerned, the major producers of castings, ferrous and non ferrous are as depicted in the table. Country

CHINA U.S.A. JAPAN GERMANY INDIA

Castings (Million Tons) Iron Steel Non- FerrousTotal

14.83 8.26 4.47 3.68 3.24

1.77 0.99 0.24 0.18 0.47

1.55 2.86 1.41 0.86 0.33

18.15 12.11 6.12 4.72 4.04

Operating Foundries (Numbers) 12000 2620 1713 651 4500

Productivity/metal casting plant (Thousand Tons/Year) 1.5 4.0 3.5 7.0 0.6

India is the third leading nation in the production of Grey Iron and cast steel casting after China and U.S.A. India has exported graded castings worth USD152.05 Million and sanitary casting worth USD64.12 Million in 2003-04 mainly to USA and Europe. This has been strengthened and supported by closure of some foundries in Europe due to global environment concerns. In fact lot of foundry work has been shifting to low labor cost centers like India and Eastern Europe. On the machining front, Germany, U.S.A. and U.K. have dominated the industry. Of late some Asian countries have also emerged as a major force both in terms of production and consumption further fuelling demand and driving growth of the industry. One of the key factors for growing stature of the Asian countries is price competitiveness and availability of cheap manpower. The machining and fabrication sector, which includes the global engineering projects, including auto component industry, was expected to touch $1.9 trillion by 2015, of which around 40% ($700 billion) was potentially expected to be sourced from low cost countries like India. Of the total global trade of $185 billion, India’s share is merely 0.4% while China accounts for 1.2% and Mexico 5.9%. It is expected that the present sourcing of Engineering projects and auto components from low cost countries (LCCs) worth $65 billion may actually reach $375 billion by 2015. (Reference : ASSOCHAM study dated April 8, 2005).

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Section 1 Indian Manufacturing Industry

Present Indian Manufacturing Industry Profile : The Indian economy is firmly on the path of steady growth. Even during the last decade when other countries were in the grip of a massive slowdown, India continued to enjoy a comfortable economic position. This recent spurt in growth is propelled by radical reforms such as the removal of restrictions on foreign investment and industrial de-licensing. Tailoring the EXIM policy to promote exports and aligning the import duties to meet WTO commitments further contributed to this development. This trend is expected to continue over the next five years, driven by a favorable business policy environment in terms of tax cuts, broadening tax base, and reduced interest rates. The liberalization of the economy has opened new windows of opportunity for manufacturing sector. Increasingly the success of manufacturing industries is dependent on innovations, research and development. It is critical not only to remain competitive but also, significant advantages can be gained by developing and commercializing new technologies With a size of Rs. 1012 billion, the engineering sector exports stood at Rs. 303.6 billion in 2001-02 and imports at Rs. 225.4 billion the same year. Indian engineering manufacturing sector employs over 4 million skilled and semi-skilled workers. The engineering manufacturing sector comprises of Heavy engineering (70%) and light engineering (30%). India’s growing integration with the global economy and the government’s recognition that infrastructure needs to be overhauled are likely to ensure that the trend rate of growth increases in the next decade.

Importance of manufacturing sector in India’s economic growth : The structural transformation of the Indian economy over the last three decades has been spectacular growth of the services sector, which now accounts for about 50 per cent of the GDP. However, the rapid growth of the services sector much before the manufacturing industry attaining maturity is not a healthy sign. A knowledge -based economy cannot be sustained in the long run unless it is adequately supported by a growing manufacturing economy. Moreover, a service economy cannot continue to thrive on a long-term basis in a country where over 80 per cent of the population is education below the middle-school level.

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Some sectors, such as IT, ITES and pharmaceuticals, will compete globally, employing perhaps 2% of the population and bringing wealth to many parts of India. At the same time, around 60% of the population will remain dependent on the agricultural sector, sharing less than one-quarter of India’s GDP. Without reform, the agriculture will continue to suffer from endemic underemployment, low wages and monsoon dependency. This will result in continued urban migration, but without the development of an industrial sector this will lead to rising unemployment in the cities. Recognition that this pattern is unsustainable is growing. It is estimated that India needs to create 7-8 million new jobs each year outside agriculture to stay at its current unemployment level of 7 percent. Manufacturing jobs are ideal for workers transitioning out of agriculture as service jobs require high level of education and professionalism. The revival of manufacturing sector can create close to 2.5 Million new jobs every year. With the removal of all quantitative restrictions on imports and the falling import tariffs under the WTO regime, it is all the more important for the Indian industry to improve its competitive edge. The sheer volume of international trade with over 70 per cent of the seven trillion dollar market being in processed manufacturing, strongly indicates the necessity of developing global competitiveness in this sector. Thus the above 8% growth of manufacturing industry in India is critical to ensure healthy balance of income parity, employment generation and sustenance of growth.

Industrial growth : The manufacturing sector grew by 8.9% in 2004-05, comfortably outperforming the sector’s long-term average growth rate of 7%. The sector has remained one of the engines of economic growth since the start of 2005-06. Industrial growth averaged 7.1% per annum in the 1980s. It accelerated slightly to 7.6% per year in the first five years following the beginning of the economic policy reform process in 1991. In the second half of the 1990s industrial growth trended lower at around 5% per annum. However, since 2002-03 industrial growth has accelerated markedly on the back of recent strong GDP growth. Rising disposable incomes, easy access to finance and the changing attitudes of India’s rapidly rising middle class (with a traditional focus on savings) have resulted in a consumer lending boom. Industrial growth rose above 8% in 2004-05, with consumer durables and non durables showing exceptionally strong growth. Capital-goods production has been growing at double-digit rates since 2002-03, suggesting increased investment in the industrial sector and the economy as a whole.

Critical Issues for growth : The primary reason for Indian manufacturing not being competitive enough is the significant presence of small-scale unregistered manufacturing units across the entire spectrum, even in classically scale and capital-intensive segments. Such unregistered manufacturing accounts for 23 per cent of the total capital employed and 84 per cent of the workforce. Even the registered manufacturing sector is highly skewed towards low scale. Eighty five per cent of factories in India have less than 92 lakh invested in plant and machinery. While this is not to belittle the value of small and medium enterprises, in India, a large number of such enterprises have been created because of artificial market distortions. The deliberate fragmentation of units has been detrimental to competitiveness.

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The other important reasons for the Indian manufacturing being not competitive enough include: Poor quality of transport infrastructure across all sectors including port facilities (where productivity is among the lowest in the world), surface roads, railways, airports and waterways. High cost of power. Industrial power continues to be among the most expensive in the world. It is about 50 per cent more expensive than in China. - High cost of capital: It continues to be 10-12 % against international average of 6-8 %. The Government has to play a crucial role in providing the industry with a favorable investment climate in terms of better infrastructure support, institutional finance at affordable rates of interest, and designing fiscal policies aimed at promoting accelerated growth of the manufacturing sector. In particular, special efforts are needed to upgrade infrastructure facilities. At the same time, the manufacturing firms should concentrate on internal changes aimed at improving efficiency and reducing costs. For E.g. a CII-Mckinsey study identifies the difference in labour productivity across multiple sectors between India and China from 10% in TV assembly to 360% in footwear. Following imperatives are required at firm level: - Upgrading manufacturing technology levels - Redesigning organisation structures to enhance accountability and responsiveness - Enhanced emphasis on attracting and retaining talent - Eevolving product-mix strategies, explicitly factoring in the opportunities in export markets - Re-engineering core processes to dramatically improve efficiency and drive business value - Enhancing quality focus and customer orientation.

Industry Structure : Although reforms have reduced licensing and regulation, heavy industry is still dominated by public-sector enterprises. State-owned companies have accounted for the bulk of activity in steel, non-ferrous metals (virtually 100% for copper, lead and zinc, and about 50% for aluminum), shipbuilding, engineering, chemicals and paper. The government had pledged to reduce its holdings in non -strategic public-sector undertakings to a maximum of 26%, and to close down non-viable enterprises.

Profile of Key manufacturing sub-sectors : Automotive The automotive industry’s turnover stood at Rs. 878.6 billion in 2003-04 and has been one of the fastest - growing sectors in recent years. Rising income levels, continuing poor public transport systems, wider availability of car finance and the increase in the young population are the main drivers of growth. Total production of vehicles rose from 4.2 m units in 1998-99 to 7.3 m units in 2003 -04. In volume terms, vehicle production is dominated by two-wheelers, which accounted for 5.6 m units of total production in 2003-04.

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The production of passenger cars stood at 842,000 units in 2003-04, followed by three-wheelers (340,000), commercial vehicles (275,000) and multi-purpose vehicles (146,000). Most local product ion is sold domestically, but rising quality has contributed to a surge in vehicle exports, which registered growth rates of over 50% in 2002-03 and 2003-04.

Steel India produced 31.8m tones of crude steel in 2004 -05, making it one of the ten largest steel producers in the world. A variety of grades are produced and the quality is at par with producers such as South Korea and the US. Increased demand from China as well as strong domestic demand, particularly by consumer -durables and automotive manufacturers and the construction sector are the key drivers of production growth. Around 40% of output is produced in integrated steel plants; the Remaining comes from mini-plants, of which over 180 exist, almost all in the private sector.

Light Engineering The size of Indian Light Engineering industry is estimated at Rs. 322 billion. In India, the light engineering industry has a diverse industrial base with significant unorganized market. It is estimated that light engineering sector contributes to 8-10% of total exports of the country and its exports were Rs. 138 billion in 2002-03. The exports from the light engineering industry in India mainly consists of structured steel products; motorcycles, cycles and auto components; electrical, electronics, telecommunication and automation equipments; hand and machine tools; fans, filters and pumps; and metal machine tool parts. The Light Engineering Industry is a diverse industry with a number of distinctive sectors and sub sectors. This sector includes low-tech items like castings, forgings and fasteners to the highly sophisticated micro-processor based process control equipment and diagnostic medical instruments. This group also includes industries like bearings, steel pipes and tubes etc. The products covered under the engineering industry are largely used as input to the capital goods industry.

Machine Tools An industry, which has undergone a radical shift in its paradigm thinking, the Indian machine tool industry is now recognized as a provider of low-cost high quality lean manufacturing solutions. The industry resiliently supports all its users to enhance productivity as well as improve competitiveness, for the betterment of the end user. The Indian machine tool industry is approximately a Rs. 23000 million industry. There are 138 major companies manufacturing metal cutting, metal forming, conventional and automated machine tools.

INDIAN SCENARIO : The Indian Iron and Steel Industry is nearly a century old with Tata Iron and Steel Co. (Tata Steel), the first integrated Steel Plant coming up 1907. At the time of independence in 1947, India already has a small but viable Iron and steel capacity of around 1 million top per annum. Today India is the 10th largest producer of steel. The initial period in the industry was dominated by bigger units. However 70’s sas the emergence of small scale secondary Iron and steel producers in the private sector to bridge the gap between the

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rising demand and stagnating supply from the existing integrated plants. During the 90’s Sponge iron industry has been specially promoted so as to provide an alternative to steel melting scrap which was increasingly becoming scarce. Today, India is the largest producer of sponge iron in the world accounting for 12% of the global output. Total production of sponge iron for our country was less than 5.6 million tons as recently as 2001, and has skyrocketed to nearly 9.4 million tons in 2004, an increase of 68% in only three years. The year on year increase over 2003 was 22%. Indian demand and production are likely to further firm up as explained earlier. The biggest sponge iron unit in India is M/s. Jindal Sponge Iron Ltd., at Raipur. SMEs contribute 9.4 million tons (40%) to the national output. The major clusters for sponge iron production are in Hazira, Bhandara at Gujrat, and are gas based. However, in the eastern part of the country, the plants are coal based, owing to the local availability of coal. In foundry sector India produced a total of 4.04 million (Ref: 38th Census of world casting production-2004) tons, increasing close to 8 lakh tons over last year, 90% of the foundries in India are in SSI sector. Major clusters for foundries in India are Howrah, Coimbatore, Belgauam, Bangalore, Agra, Rajkot, Kolhapur, Hyderabad and Panipat. In the machining and fabrication sector, despite still competition from countries like China and Mexico, India is increasingly becoming a sourcing base for engineering projects and auto majors seeking completely built-up units (CBUs) as well as outsourcing of components. India’s advanced tooling and machining industry has enabled indigenization of capital equipment and reduced capital costs in addition, India manufacturing sector has the potential of continuously improving capabilities and operational excellence.

Section 2

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Manufacturing Technology Status Technology development is critical to a country's efforts in improving productivity, efficiency and competitiveness of its industrial sector. Factor cost advantages are being replaced by technology - related factors such as zero-defect product quality and international certification of firms' quality assurance systems (e.g., ISO 9000) in determining international competitiveness. Central to maintaining competitiveness is the ability of producers to respond quickly and effectively to the changing demands of the international market. Technological cap abilities can be best described in terms of three levels: the basic level involves the ability to operate and maintain a new production plant based on imported technology, the intermediate level consists of the ability to duplicate and adapt the design for an imported plant and technique elsewhere in the country or abroad, while an advanced level involves a capability to undertake new designs and to develop new production systems and components. Indian firms present a full spectrum of technological capabilities - while there are few firms close to the international frontier in terms of product design capability and process technology, technological capabilities of most players are extremely limited due to growing technological obsolescence, inferior quality, limited range and high costs. This adversely affects the ability of the organizations to respond to the challenges, not only of increasing international competition from other low-wage countries like China, but also from trade liberalization within the context of WTO. Most Indian manufacturing firms appear to be stuck at the basic or intermediate level of technological capabilities. Though Indian manufacturing industry has mastered standard techniques it has remained dependent for highly expensive and complicated technologies. Photo-4

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Factors in Technological Competitiveness : The technology competitiveness of a country is determined by a combination of policy factors and industry specific factors. This section outlines the factors and their status In Indian context.

Policy Factors : Import Substitution The import strategy of the Indian government, which fostered the development of a wide range of industries, also facilitated the unpack aging of technology imports, and hence helped absorption and accumulation of technological learning. Though India achieved self-reliance in technologies for local production and consumption owing to the policy of import-substitution and self-reliance, it could not build capacity to create internationally competitive technologies to produce for international markets. As a result, export competitiveness capabilities could not be acquired.

Human Resource Development and Technology Infrastructure : The expansion of infrastructure for technical and higher education under the Scientific Policy Resolution, 1958 has ensured an adequate supply of qualified technical personnel and high degree of self-reliance – facilitating quick replacement of foreign personnel and absorption of imported technology. Although Indian organizations are served by a network of national laboratories and institutional infrastructure, these institutions generally fall short of quality when compared to those in industrialized countries – putting India at a comparative disadvantage. The role of national laboratories in designing and innovations varies from industry to industry. The main determinants of success of national R&D institutes appear to be the nature and extent of laboratory-industry Interaction, the extent of market orientation of products and accessibility. Since most of the R&D effort is limited to specialized institutes, rather than in-house, market orientation is a weak link. Some key R&D institutes and testing facilities directly related to manufacturing industry are: Central Manufacturing Technology Institute (CMTI) Council of Scientific & Industrial Research (CSIR) Central Mechanical Engineering Research Institute (CMERI) Central Power Research Institute (CPRI) Indian Institute of Petroleum (IIP) National Institute of Foundry & Forge Technology (NIFFT) Bureau of Indian Standards (BIS) In-house R&D units of large enterprises The range of activities of these institutes includes education/training (both academic and practical), research and development (academic, practical, product, process and input material

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related), provision of information services, and provision of services like testing & inspection etc. Although the range of activities undertaken by these institutes is quite wide, resource constraints with respect to budget, staffing and equipment limit their effectiveness in both quantitative and qualitative terms. Some of them are located in areas away from the industrialized zones like Mumbai, Delhi etc. Apart from R&D institutes, a number of engineering colleges - Regional Engineering Colleges (RECs) and Indian Institute of Technology (IITs) – provide a steady stream of engineering graduates, while the Bureau of Indian Standards (BIS) is responsible for activities related to the development, promulgation and maintenance of industrial and other standards. The culture of collaborative research involving different institutes has not been promoted in past and the limited resources are not pooled through networking to develop core technologies in sectors where Indian industry has potential. Another vital link missing is the isolation of universities from R&D. While universities are the major research centres in almost all developed countries, especially Germany, Taiwan and Korea, in India they are isolated from scientific research and advancements. This is largely because government funding of the research institutes does not goad them to seek funding from industry and industry associations through fees and royalties charged for work performed. This results in low commercial orientation. This has also affected the quality of higher scientific education, which is becoming increasingly irrelevant over the years. Direct intervention Public sector enterprises - i.e. HMT, EIL, BHEL etc. – initially emerged to be the nuclei for technological development. Public sector industrial enterprises, because of the relatively large scale of their operations, were able to finance and coordinate the requisite level of technological activity – thereby overcoming high entry barriers for innovation. Standardization of unit sizes For process industries, the choice of unit size has an important bearing on the development of local technological capability. Standardization of unit sizes by the government in the case of power equipment, petroleum refining, and fertilizers has helped rapid absorption and mastery of technologies because it has made possible the frequent replication of similar plants.

Structural and Industry-specific factors : Technological maturity and pace of technological change Technological self-reliance is achieved more easily in industries with relatively mature and stable technologies, such as the process industries, than in those undergoing rapid technological change.

Availability of Scientists & Engineers High quality human resources, and rich stock pool of engineers and scientists is necessary for innovation. The availability of engineers and scientists determines the ability of a nation to develop competitiveness through differentiation. In terms of availability and quality of scientists and engineers, India scores very highly as seen in the table below.

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However it is necessary to continuously upgrade the manpower skills in technical and techno managerial dimensions. In a labour -surplus economy, new and efficient technologies tend to be discouraged unless sufficient redeployment opportunities are created. These results in a vicious cycle where new technologies are not introduced, the engineers and technicians continue to work inefficiently, and the technical manpower quality deteriorates with respect to the world. Thus the advantage accruing from the rich pool of engineers has been frittered away by not continuously upgrading the talent pool. This has, in turn, resulted in the brain drain phenomenon leading to flight of talent to advanced countries where the opportunities to upgrade exist. India has been ranked low on the ability to retain its qualified manpower when compared with the reference group of countries. Therefore, Indian scientific and engineering talent pool is at the disposal of countries that create conditions conducive to the nurturing and advancement of this talent pool.

Technology Acquisition : Technology acquisition has traditionally been viewed as a source of techniques necessary for initiating production and hence was considered as substituting domestic R&D. In the absence of the inflows of new and advanced technologies, however, there has been little incentive, direction and capability to update the existing technologies. Technology continues to be sourced from other nations, but the firm-level technology absorption is low. This is in sharp contrast to firms in Taiwan and Korea, which absorb sourced technology and improve upon it.

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The table shows that Capital Goods firms invest less than 1 percent of their sales turnover in research and development. Also the private sector firms invest marginally more than the public sector firms, which makes it look further worse, considering that the major machine tools firms are in the public sector. This could be due to lack of confidence in domestic technology. In the absence of the internationally competitive quality and standards in technology development, industry has created demand for foreign technologies that are tested abroad and are easily available.

Nature of international technologies markets : The nature of international markets, in respect of the seller concentration and the degree of vertical integration in an industry, affects national attempts to achieve technological self-reliance. The choice of the mode of technology import has been found to influence local technological capability building.

Product Technology : World Bank study (1990) on the Indian Capital Goods sector notes that the share of human resources devoted to design and engineering activity in Indian Capital Goods enterprises is low compared to other industrialized countries - roughly 20 to 50 per cent of what might be expected in comparable enterprises in those countries. Sound product design and engineering work could have greater impact on ultimate product cost, value and quality than comparable efforts undertaken further down the manufacturing chain. In the firms that were sampled during the World Bank survey, there was evidence that greater engineering resources are devoted to downstream manufacturing activities than upstream conceptual design activities.

Process Technology : 21

India has the technical ability to achieve a high level of precision, yet Indian firms are unable to produce quality products due to lack of supporting technologies, such as precision measuring, material engineering and process control. The defect rates of final products are many times 5-10 time than that of Japan and those of USA. In addition, about 20 per cent of the firms have equipment, which is more than 20 years old, and therefore obsolete. Most Indian firms are vertically integrated and rely far less on subcontracting arrangements, although such trend is beginning to emerge.

Summary :

The competing imports of products, increasingly allowed on quality and cost considerations, have led to a greater consciousness of quality and costs on the part of domestic manufacturers. The more liberalized technology import policy is also helping to bridge the technology gap. All these factors are putting pressures on the organizations to develop best-practice technology, either by importing or by generating their own. Few solitary achievements notwithstanding, there is clear evidence that technological dynamism has not taken firm root in the Indian industry. In sum, the disjointed policies in India with lack of focus have resulted in a weak innovation system and under-utilization of research capabilities created during the first phase of growth. Thus, the overall problem relates to the lack of appropriate linkages between different actors of the national innovation system. India needs to address constraints on technology development as an important part of its overall strategy for improving manufacturing sector competitiveness. The role of government in enhancing technological competitiveness is critical to make this happen.

India: Global R&D Hub : The Indian government has put in significant effort in last 50 years to develop the scientific and technical infrastructure of the country. With more than 250 universities, 1,500 research institutions and 10,428 higher -education institutes, India churns out 200,000 engineering graduates and another 300,000 technically trained graduates every year. Besides, another 2 million other graduates qualify out in India annually. The combination of state-of-the-art infrastructure and highly qualified manpower ensures that India is poised to be the next Global R&D hub. This is increasingly being observed in Ind ustry as large MNCs including GE, Microsoft, Bell Labs etc have opened there R&D Centers in India – a first outside US for most of these output from India.

Global Comparison :

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India has been spending 0.8% of its GDP in R&D which is much less than 2-3% range amongmost of the developed countries. Even China and Brazil spend more than India on R&D. This is reflected in the relatively poor rankings on innovation in the global competitive index.

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Section 3 General Engineering and Fabrication Industry Status in Chhattisgarh State-

Machining and Fabrication Units – Process and Issues: Raw Material: Machinery and fabrication units buy their material i.e. steel rods, sheets and plates locally and through dealers. Retails branch of BSP also supplies in small quantity. Special steels and stainless steel is procured from Kolkata and Mumbai. Sometimes inventories have to be maintained for such items. Products and Markets: More than 200 Machining and fabrication units- some only into machining and many a combination of both – depend on NALCO, NTPC, L&T, OCL and Bhil plants for orders. The units have to get registered with them to participate in there tendering process. Bhilai Steel Plant and NTPC orders. Large consulting firms like EIL and Daniel Consultant get some of their fabrication and machining of export items done at Rourkela. However no direct exports are reported from the sub cluster. Capacity of small and tiny units (tier III) are underutilized as they do not get sufficient orders. As a whole the machining units lack market intelligence and expertise to bid for large machining and fabrication works which they are capable to execute. The units were having sufficient work few years back due to emergence of number of sponge iron plants. With the present hold on setting up new sponge iron plants. Some of the machining and fabrication units have to close shop. The units feel that even though prices of raw materials and inputs have gone up they are getting the same rate for there jobs which they used to get 5 years back. The delay in payments worsens the situation. Technology and working practices: Most of the units are using general purpose machines, Drilling, Vertical boring machines, Lathes, and Shaping machines mostly purchased from Punjab. Some units have installed imported second hand machines. There is no CNC or SPMs to be seen at Rourkela. Due to use of old machines which are not maintained properly, quality suffers. The entrepreneur continue to use tools, jigs and fixtures which have outlasted their service life. Poor housekeeping further hampers their work. Improper shop floor layouts, lack of best manufacturing practices and lack of multiskill of the workforce maker the productivity low. Safety measures are often ignored which causes frequent injuries and loss of man days.

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Labour : Both contract labor and regular workers are employed in the machining and fabrication units. The rate for machining a job varies from Rs. 300 to Rs. 400 per hour. Fabrication contractors charge approx. Rs. 3000/ton for fabrication work contractual lobour is not properly trained. There is shortage of skilled manpower.

Other Common Problems : Absence of Operation Systems: No records or systems are in place to keep track of the production, labor, maintenance etc. The units do not have the knowledge of batch costing, which is necessary to exercise control when the next batch is taken for production. High employee Turnover: Process engineers, Production supervisors, Mechanical and electrical supervisors, fabricators etc. are in demand. They frequently change jobs for higher salaries. Absenteeism is the major area of concern in the unskilled and semi skilled categories. Poor Distribution Infrastructure in Power Sector: The units face problems in implementing technological up-gradation (Ex. for setting up induction furnace units which are power intensive) due top poor transmission and distribution system, which delays in getting additional power connection. Details of General Engineering/Fabrication industries of enterprises based in Chhattisgarh state is enclosed herewith from pages ------ to -------, which are received by MSME-DI, Raipur. Even though letters have been sent to all MSME-DIs and Br. MSME-DIs in the country, the response was very poor in as far as furnishing details to us in respect of technology status of General Engineering/Fabrication units in country is concerned.

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9.3 MACHINING & FABRICATION

VALUE CHAIN ANALYSIS OF MACHINING AND FABRICATION JOB Physical and Mechanical BASIS: ONE TON JOB NUMBER OF MANDAYS: ONE WEEK

Manufacturing cost Rs. 70125/-

Add profit approx. 28%

Dispatch

Interest for 60 days Rs.2000/- on final price

Final Price Inclusive of S.T. @ 4% Rs.94000/-

Basic Price Rs. 90000/-

Price inclusive of Administrative expenses Rs.68125/Administrative Expenses @5% of final price Rs.4700/-

Rs. 63425/Assembly 2 Man days Rs.1000/` 5. . Z 1.5 0 Ton steel (Plates/ channels/ angles/

rods etc.)

Rs. 62425/-

Basic : Rs.26000/- Ton Approx. Rs.47000/- (Inclusive of E.D. + S.T.)

Cutting as per drawing 2% wastage

Fabrication 2 Man days @ Rs.3000/Ton i.e. Rs.4500/-

+ Traders commission: @Rs.500/-Ton : Rs.750/+ Transport charges @Rs.250/Ton : Rs.375/-

Consumables i.e. Nuts, Bolts, Welding Rods etc. Rs.5000/-

1.2 Ton steel Rs.48125/-

Machining 40% of job. 2 Man days Rs.300/hr Machining charges i.e Rs.4800/-

Total Rs. 48125/-

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Section 4 Details of Machinery and Process of Manufacture in General Engineering and Fabrication IndustriesWelding and cutting processes which are most extensively used are : Manual Metal Arc, Tungston Inert Gas, MIG/MAG, Submerged Arc, Spot Welding and Oxyacetylene Welding and Cutting. Resistance Seam, Projection & Flash Butt Welding and Plasma Arc Welding & Cutting are comparatively less used. The processes which are sparingly used are - flux cored, electroslag, electrogas, electron beam and laser beam welding. In the arc welding category, the pattern of usage broadly is: - MMAW - Transformer Welding Sets - MMAW - Rectifier Welding Sets - MIG/MAG - TIG & SAW

70% 18% 8% 4% 100%

There are around 12 major active units manufacturing welding equipment in the organised sector, having individual annual production of about Rs one crore to Rs 50crores. Similarly, there are approximately 40 active small scale units whose individual production ranges from Rs. 2 lakhs to Rs.100lakhs. Local consumption in 1992-93 of welding equipment was in the order of Rs 73 crores which has increased to Rs350 crore in 2005-06. There is an import of specialised category of welding equipment and the import level is Rs. 20 crores to 25 crores/year. The components and raw materials required for indigenous manufacture of welding equipment have more customs duty than for complete equipment. There is very marginal export from a few welding equipment manufacturers. There are various problems faced by welding equipment manufacturers and the major ones are : - Scattered Market - Lack of quality consciousness amongst user Industry – particularly General Engineering and Fabrication Industry. - Low volume of demand for higher generation equipment. - Quality of input raw materials is not upto the mark. - Disproportionately high price of raw materials and components vis a-vis international prices.

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- Advanced technology welding equipment is expensive to manufacture because most of the power electronics components need to be imported. Some of the larger and old companies manufacturing welding equipment do have a sound manufacturing base in respect of production facilities, drawing and design capability, systematic layouts and good work culture conducive to quality production (Advani, Esab, Jai Hind Sciaky etc.). In these companies manufacturing technology methods involving plant and equipment are at par with other good and progressive engineering units in the country. As regards Product (Welding Equipment) Technology, it was based on foreign collaborations from time to time from Switzerland, Germany, U.S.A., Sweden, U.K. and Japan. These units had the credit of fully absorbing the technology then imported and they have not faced any serious problems to get along with the collaborators. Another set of welding equipment manufacturing companies, which started as small units but presently have grown into medium sized units, though have overall manufacturing capability, are lacking in upto-date, systematic and spacious production facilities. Product Technology is based on in-house expertize. As regards manufacturing technology methods, they are depending on sub-contracting, bought-outs and more labour-oriented manufacturing techniques.

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Section 5 Advanced Technologies Applicable in General Engineering and Fabrication IndustriesThyristor, transistor and inverter type power sources are the things of the past industrialised countries. Further development is the Synergic MIG/MAG welding sets wilh pulse frequency in which electrode feed speed is linked with one or more pulse parameters. In case of sub-merged rc welding the advancement available is the use of tandem wire heads and/or addition of metal powder to increase the yield. In Japan, more than 407/ of welding is done by this method in world's largest shipyard. In India, the extent of SAW is just 2% of the total electric arc welding. In case of TIG welding, use of hot filler wire and echanised/automatic movement of the TTG torch and the wire feeding are the common sights in U.S.A., U.K. and Japan. A beginning in a very small way has been made in India to produce "Tooled-up" TIG special purpose machines for automobile and electrical equipment industry. Advanced welding processes like Electron Beam Welding and LASER welding are being used in the industrialised countries for production purposes also. Electron Beam Welding Equipment of 3 to 25 KW capacity and laser welding equipment upio 5 KW capacity are being used. In India, these equipment are not manufactured and the use of processes are witnessing very slow growth because of very exorbitant cost. These processes, however, are being mostly used for R&D purposes. There has been increasing influence of electronics in the technologically advanced welding equipment. Robotics in welding processes, microprocessor controlled welding power sources, use of sensor technology are the examples of this advancement prevailing in industrialised countries. India is devoid of such technological advancements in wclding field. In the resistance welding field, the machinery currently used varies from old type to modern even for the same type of product e.g. one automobile manufacturer uses robot and special purpose welding equipment while another uses pneumatic timer controlled equipment. Updating of resistance welding technology had been a slow process, arising, if at all, due to change of collaborator's practice. It was because of lack of exposure of manufacturers as well as users to the state-of-the art technology in industrialised countries. This scene has started changing after Japanese entered into the Indian automobile industry. As regards the indigenous manufacture of complete welding equipment, technology gap exists in the following items :

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- Electron Beam Welding Equipment - Laser Welding Equipment - Electroslag Welding Equipment - Friction Welding Equipment -Stud Welding Equipment -Welding Joint Sensing & Scanning Systems -Water Jet Cutting Equipment -Ultrasonic Welding Equipment and -Inverter Type Welding Power Sources

R&D activities started taking proper visible shape only after 1970s with the establishment of Welding Research Institute (WRI), Welding Research Laboratory (WRL) and also by some large user industries. These R&D activities are more concentrated on welding joint design, fabrication methodology, materials, testing etc. as compared to design & development of higher welding equipment.

Based on the Study the following recommendations are suggested : Attention need to be focused on improving the design, manufacturing methods and use of quality input materials to produce comparatively efficient machines even in conventional type of welding equipment. Introduction of ISI certification may be considered over the products of tiny and cottage sectors. Some manufacturers in organised sector also are not very careful about producing quality products, resulting in more down-time at the users end. It is emphasised that both organised sector as well as small scale sector provide quality products to the customers. A sizeable chunk of welding sets (transformer type) are produced in the tiny & cottage sectors who are using low grade laminations and poor quality insulation material, resulting in loss of electrical energy. Conventional equipment manufacturers may go in for: (i) edge winding of transformer coils instead of one layer above the other; (ii) use of electronic choke system instead of stepped tappings; (iii) provision of ON/OFF switches on welding transformers. The reason is in layer above the layer winding heat generated in inner windings remain locked up and more quantity of insulation material is required. Electronic choke system reduces weight and heat loss. For want of ON/OFF switches, the welding set causes no load loss of electrical energy.

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Use of aluminum conductor instead of copper windings should be preferred and no user industry may specify copper as winding material in their tender specifications. Over a period, tiny and small scale sectors may abandon the conventional transformer welding sets of antiquated designs and produce thyristor controlled or fully thyristorised power sources. Concerned bodies/organissations may make thyristorised designs available to these units at a concessional charges with the assistance of R&D units like WRI & WRL etc. This is a one step technological up-gradation and by doing so national energy saving can be effected.

The usage of semi-automatic welding process (MIG/MAG) in the country, though slowly increasing, is just 8% of the total arc welding processes as compared to 50% in the industrialised countries. This usage of MIG/MAG needs to be increased as the country would gain by way of output and less energy consumption for the same amount of weld deposits obtained by MMAW. For this, welding equipment manufacturing industry may come forward by offering semiautomatic (MIG/MAG) machines at affordable prices. Today in the country the price ratio between MMAW equipment and MIG/MAG equipment is 1:5 whereas this is 1:2 in industrially advanced countries.

An automatic process like submerged arc welding has not picked up and spread as it should have been. The usage is hardly 2 to 3%. Jobs like pipe welding, pipe to flange welding, railway wagon components, crane manufacturing industries etc. can go in for SAW, but have not shown much enthusiasm in this regard. Their difficulty is the non-availability of special purpose welding fixtures/systems at affordable price. Such welding fixtures/systems are available off the shelf abroad while in India a lot of time is lost in determining the need. Often having identified the need, by the time fixture/system can be delivered, the need has already reduced. The welding equipment manufacturing industry may have a proper tieup and can keep common usage fixtures/systems used in Submerged . Arc Welding process in CKD condition - backed up by modular designs so that at a very short notice these can be assembled and provided to the users. In this regard, the bottleneck of non-availability of small size permanent magnet DC motors for cross slides and wire feeders and also liner bearings need to be removed and these are developed indigenously. Process equipment manufacturing industry in the field of chemical plants, refineries, food and dairy plants, atomic plants are using manual TIG welding spending considerable productive time and more rework. "Tooled up" TIG welding systems is the demand of user industry. There is therefore a need to strengthen the effort on the part of welding equipment manufacturers to provide fixtures and systems so as to make TIG process mechanised/automated. There could be automatic feeding of filler metal, mechanised movement of TIG torch or the component to be welded. There is a need that Indian industry should switch on to manufacture and use of static power source with solid state devices (thyristors) at the earliest. This may be based on inverter technology. By this way tremendous amount of electrical energy may be saved per year.

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For encouraging quicker adoption of technology and wider use in industry, electronic devices and components manufacturing companies (like BEL, ECIL, MELTRON, CEL etc.) should come forward to develop high end technology and create facilities to manufacture the same. These items are : -High power electronic devices like Darlington power transistors, fast recovery diodes, soft recovery diodes, MOSFET etc. -Ferrite cubes and cores for inverter type welding power sources -Tactile and inductive type sensors for making seam traders

R&D establishments can take up developmental work of welding equipment on their research programmes and allocate suitable technical skills comprising of a team of engineers from electrical, power electronics, mechanical and welding disciplines. There is a need for establishing a centre for research and development at national level in the field of Welding Equipment or enhancing the facilities of an existing centre. Welding Research Institute Trichy could be one possibility. As regards automatic/mechanised welding systems, collaboration arrangement between welding equipment. manufacturer and machine tool manufacturer need to be established so as to derive benefits of later's experience and capability. For rapid development of MIG/MAG process in synergic mode (quite popular abroad) there is urgent need for gas mixing units in the country. At present only one or two gas manufacturing units have these gas mixing unit for their own use. Users of MIG process have to essentially depend upon these two units for gases, which is very difficult. Unless the users can prepare their own gas mixtures, this process may not develop to the desired levels. Gas regulators and flow meters for dry gases are being manufactured in the country, but not for MIG/MAG welding, which requires CO2 gas. It has moisture most of the times. Indian manufacturers may manufacture good quality regulators and flow meters for use in IG/MAG process where CO2 gas is not essentially dry. A task force needs to be formed which could have members from welding equipment, research institutes and concerned government departments. This task force may identify the problems of welding equipment industry and seek feasible solutions.

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Section 6 Technology Development Initiatives-

Research AgenciesIndia has a network of scientific and academic institutions engaged in wide spectrum of research. Scientific research is carried out in about 250 research laboratories and institutions. A large part of these belong to scientific ministries. A few research organizations under non-scientific ministries and their public sector industries essentially carry out research programs of relevance to the respective ministries. There are more than 1,500 private industries with R&D establishments and a similar number of state-owned research centers. In addition, there are 264 universities, deemed universities and institutes of technology, where basic scientific research is conducted in new and emerging areas through external and internal support. Most of the research in the academic sector receives funding support from various scientific agencies of the government, namely, Department of Space, Department of Atomic Energy, Department of Science & Technology, Department of Biotechnology, University Grants Commission, and others. In recent years, several non -scientific ministries have also come forward to fund R&D in the project mode with the participation of public and private industry as well as of academic institutions. This has given a new synergy in the promotion of technology in areas of concern.

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Funding for R&DThe Government of India allocates a budget for scientific and technological (S&T) activity under an R&D fund. The allocation has increased from Rs. 828 Million in 1950-51 to Rs. 28800 Million in 2000-01. In comparison, the share of industry in R&D has become of the order of Rs. 25162 Million, about 20 per cent of the government's contribution. The percentage share of major scientific agencies in total S&T expenditure is approximately 70 percent. In the total S&T expenditure by the government, the share of non-scientific ministries has been approximately 30 per cent combined for all sectors, including agriculture, rural development, energy, industry and minerals, transport, communication and others. The total expenditure on R&D, including from industry, is about 0.8 per cent of GNP for the past several years. Compared to most advanced countries, which spent between 4 and 6 per cent on R&D, this proportion is quite low

Policies and targets-

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The Government has facilitated S&T infrastructural development in the country through a policy framework. A Science Policy Resolution (SPR) was adopted on 4 March 1958.The resolution aimed to secure benefits from the acquisition of scientific knowledge and its application. It emphasized training of scientific and technical personal to fulfill needs in the fields of science and education, agriculture, industry and defense as well as to ensure an adequate supply of scientists and to recognize their work. In January 1983, the government announced the Technology Policy Statement (TPS), with the objective of attaining technological competence and self-reliance, providing gainful employment, modernizing equipment and technology, conserving energy and ensuring harmony with the environment. In 2003, a new Science and Technology Policy was adopted with emphasis on: - Optimal Utilization of Existing Infrastructure and Competence - Strengthening of the Infrastructure for Science and Technology in Academic Institutions - New Funding Mechanisms for Basic Research - Human Resource Development - Technology Development, Transfer and Diffusion - Promotion of Innovation - Achieve synergy between industry and scientific research - Generation and management of Intellectual Property - International Science and Technology Cooperation

Key Institutional Mechanisms Department of Scientific and Industrial Research The DSIR has been providing project based support to industries under the Programme Aimed at technological Self Reliance (PATSER) for the development and demonstration of indigenous technologies. Thirty-five technology development and demonstration projects were completed. These resulted in the commercialization of products and processes and led to the filing of 20 patents.

Council for Scientific and Industrial ResearchAs the national R&D organisation, CSIR provides through its 40 laboratories and 80 field centres, scientific and industrial R&D for India’s technological development and for meeting its strategic and defense needs.

Technology Development BoardTechnology Development Board (TDB) was set up by Government of India on 1st September 1996 and the operation of fund was assigned to Department of Science & Technology, Government of India. The Board provides financial assistance in the form of equity, soft loans or grants. TDBÕs participation in a project generally does not exceed 50 per cent of the project cost. The projects funded by the Board include sectors such as medicine and

Science and Technology Entrepreneurship ParksThe major objectives of STEPs are to forge linkages among academic and R&D institutions and industry, to promote entrepreneurship among Science and Technology persons, to provide R&D support to the small-scale industry and to promote innovation based enterprises.

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National Innovation FoundationThe Government of India started National Innovation Foundation (NIF) in March, 2000 by providing a corpus fund of Rs 200 million. NIF is an autonomous body under the Department of Science and Technology, Government of India. NIF is developing a National Register of Green Grassroots Technological Innovations and Traditional Knowledge. It also seeks to develop a new model of poverty alleviation and employment generation by helping convert grassroots innovations into enterprises.

Technology Business Incubators (TBIs)Department of Science & Technology (DST), Government of India initiated this scheme during 2000-2001. Under the scheme, grants-in-aid is provided by the Department, both on capital and recurring for a stipulated period. Presently, TBIs are being implemented at 12 locations in various academic institutes.

New Millennium India Technology Leadership Initiative (NMITLI) The Government of India has recognized the power of innovation and had launched a new initiative during 2000 to enable Indian industry to attain a global leadership position in a few selected niche areas by leveraging innovation-centric scientific and technological developments in different disciplines. In a very short span, NMITLI has crafted more than 25 path setting technology projects involving over 50 industry partners and 150 R&D institutions with an estimated outlay of Rs.1,600 million. These projects are setting new global technological paradigms in the areas such as nano material catalysts, industrial chemicals, gene-based new targets for advanced drug delivery systems, biotechnology, bio-informatics, low cost office computers, and improved liquid crystal devices and so on. The scheme is being implemented by Council of Scientific & Industrial Research (CSIR).

Conclusion The research and development activities in India have been primarily government driven and private sectors have traditionally made little investment in R&D. India has achieved great success in developing and educating a significant chunk of human resources. The technical capabilities of these resources are well and truly recognized the world over. However, there have been institutional gaps leading to poor industry-academia interaction. The outcome has been low practical orientation of Indian research and lack of technology inputs to industry. India has taken initial steps in rectifying this situation by redefining its Science and Technology policy, increasing the spend on R&D, establishment of mission mode projects and enforcing Interactions between research institutions and industry. However, it still has a long way to go in catching up with the developed world and investing 2-3% of GNP in R&D, protecting Intellectual Property and establishing product innovation culture.

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Section 7 Sector Profiles

Machine Tools Overview:

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Machine Tool industry is the backbone of any economy.Machine tools are also an integral part of general engineering and fabrication industries. It is the mother industry of Capital Goods Sector which in turn determines the share of manufacturing in GDP of any country. The Indian machine tool industry’s growth is directly linked to the growth of the manufacturing/ engineering industry. The Indian engineering industry, user of machine tools of all types, manufactures goods worth $32.6 billion. Due to India’s rapid modernization, engineering industry is now focusing on green field projects as well as the upgrading of existing facilities.

The primary users of machine tools are in the automotive, automobile and ancillaries, railways, defense, agriculture, steel, fertilizers, electrical, electronics, telecommunications, textile machinery, ball and roller bearings, industrial valves, power -driven pumps, multi-product engineering companies, earth moving machinery, compressors and consumer products industry sectors. After an economic slow-down in 2000-2003, many of these industry sectors have shown positive growth trends in the fiscal year 2003 -2004. The Indian machine tool industry manufactures a range of both conventional and computer numerically controlled (CNC) products such as metal cutting and metal forming tools. Indian firms also offer many special purpose machines, robotics and handling systems. The Indian Machine Tools Manufacturers’ Association (IMTMA) believes that CNC will be the growth driver for the Indian machine tool industry in the future. Approximately 75 percent of Indian machine tool producers have received ISO certification. Government of India-owned Hindustan Machine Tools Limited (HMT) is the single largest producer with a 32 percent market share. Public Sector Enterprises like Hindustan Machine Tools Limited and Heavy Engineering Corporation (HMTP) Limited besides Mysore Kirloskar Limited played significant role in industrialization of India in the pre-liberalization era. In a period of 50 years, India also established more than 1000 companies in private sector to produce machine tools both in small sector as well as medium sector to meet the need of the manufacturing sector. However, Liberalization of Indian Economy in 1991 seriously impaired the performance of this sector because of various ailments of protected economy: high cost, obsolete technologies, fragmented size, low investments, poor R & D base etc. Today, the structure of the machine tool industry is rather skewed, 80% production coming from 25 companies and balance from over 300 fragmented small size companies.

Trends in Machine Tool Sector : - The average growth in 2004-05 over 2003-04 was an amazing 47%. The Units expect to out perform the market growth achieving 35% over the next 2 y ears (2005-06 & 06-07) and 25% in the three years to follow (07-08, 08-09 & 09-10).

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- Units have made dramatic productivity gains from Rs. 2 million to Rs. 3 million per employee. Investments in the last three years averaged a paltry USD 400,000 (17 million Rupees) per annum, per unit. Whereas units have committed average investments of USD 1.2 Million (67 million Rupees ) per annum, per unit in the next two years. This is a clear indicator of their confidence in sustainability of growth rates and a positive response to enhancing volumes. Average bought out content will remain at 60%, an indicator that part out sourcing and part in house manufacture of critical parts will continue to remain as the business model of machine tool units in the near term future. - After languishing at less than Rs. 92 million per unit per annum, exports are set to exponentially grow to 32.2 million per Unit per annum. A sign of growing acceptance of Indian Machine Tools in the world markets. - On a scale of 10, ‘Made in India’ brand equity has moved from a score of 3 in 1995 to a score of 6 in 2005. This is an indicator of growing convergence of Indian Machine Tool Industry in the Global World of Manufacturing.

World Machine Tool Industry and India : India machine Tool Industry is way behind Global majors in production, ranking 21st in 2003. However, considering the growth prospects over the next 3 years and investments planned by the local industry, it could jump several notches to about 15th position in this period.

Technology Status : The technological competitiveness of the Indian Machine Tools sector is low. Indian machine tools firms present a full spectrum of technological capabilities - while there are few firms close to the international frontier in terms of product design capability and process technology, technological capabilities of most players are extremely limited. The advantage due to high availability of quality engineers and scientists is lost, partly due to brain drain and partly due to stagnation of skill sets of scientists and engineers within India. India has a number of high quality R&D institutions, but the industry –institute interactions are low, thereby reducing the chances of creation of commercially viable technologies. Machine tools sector has a comparative disadvantage with respect to both product and process technologies. In the case of the Indian machine tools manufacturers, the human resources devoted to design and engineering activity is about 20 to 50 per cent less than in other industrialized countries. Although Indian firms are capable of achieving high levels of precision, they are unable to produce high quality products due to lack of supporting process technologies such as precision measuring, material engineering and process control. Firm level innovation is very low in India. Indian machine tools firms source technology, but very few of them improve upon it. The research spending as a percentage of sales amongst Indian firms is low when compared to the R&D spends of companies in Taiwan and Korea. The major weaknesses are limited indigenous R&D capability and design innovation, low

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productivity, high capital investment requirement, process capabilities, finishing, safety features, costs, maintenance and operation, marketing and after sales service. Like the manufacturing sector in general, the machine tool industry also suffers from low volume production, high cost of finance and poor quality of power supply.

Technology Enhancements :

The Indian machine tool industry has made efforts for up gradation in design and productivity of machine tools in the last few years. The industry upgraded a large number of older designs or machine tools and evolves new machine designs to adapt to the specific requirements of the user sectors. In view of the growing demand of user sectors for high productivity machines, the percentage of CNC machines in the metal cutting sector has significantly improved. The number of CNC machine tools produced has increased more than threefold in just two years. This reflects increased acceptance of CNC Technology by user’s especially small companies and greater price competitiveness of Indian CNC machine Tools. The most popular types of CNC machines produced are CNC lathes, Vertical and Horizontal Machining Centers, Wire Cut EDM, CNC External Grinders and Flexible CNC SPMs’.

Quality Move in Machine Tool Sector : Nearly 100 of the 400 organised sector companies are ISO 9000 certified. Many products (Over 50) are also ‘CE’ marked. Several machine tools are TPM Compliant (Total Productivity Maintenance), Indian machines now assure high CPK values, and some even guarantee uptime. Finish and Aesthetics have dramatically improved so also have fits and fittings, safety features and environment protection devices.

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Technology Gaps : There still remain technology gaps between Indian machines and machines from Germany or Japan who are world leaders. These gaps are broadly of the following types:

Specifications – Rapid rates, tool change times, maximum spindle RPMS etc., are higher than those of Indian machines. This becomes clear if one compares specifications of Indian machines with those of the Japanese.

- Appearance – Though Indian machines have improved considerably over the years, they still lag behind those produced by countries such as Japan and Germany with respect to presentation details and appearance. This is because of the amount of attention that these countries pay to detail. Difference in appearance could be a combination of colour schemes, curvature and contours of the cladding, method of fastening the covers etc. These countries also pay attention to chip evacuation, providing slopes so that chips do not accumulate. A lot of industrial design inputs go into machine design.

- Reliability – Reliability is a part not reflected in appearance or presentation, but extremely important to a customer. Some Indian manufacturers score higher than imported machines on after sales service and spare parts supply. However, they are lower on specifications and uptime. Several imported machines have such negligible downtime that for the customer, Indian advantage is just not relevant. Indian manufacturers need to monitor MTBF (Mean Time Between Failures) and MTTR (Mean Time to Repair).

- Technology – Although Indian machine tool industry has succeeded to a significant extent in bridging technological gaps that existed vis -à-vis producers in advanced count ries such as Japan, USA, Germany, significant gaps still exist in areas such as Turning Centres, Machining Centres and NC Grinders, and particularly in the area of Gear -Cutting machines. The following areas of technology development are still nascent in India:

High speed Machining: Reduction of machining time by increase of cutting speeds. The basis of this is constituted by new machine concepts and the performance potential of cutting materials.

Dry Machining /Minimum Quantity Lubrication: reduction or elimination of coolants in machining in order to reduce environmental and cost burdens.

Hard Machining: cutting and specifically finish machining of hardened materials by means of a defined cutting edge (turning, milling, drilling boring)

Complete Machining: Integration of various machining processes such as turing, milling gear cutting, grinding in a single machine to finish the work piece in one set –up.

Micro processing: metal – cutting and non –metal – cutting processes for generation of miniaturized components, partially having geometric dimensions in the micron range.

Linier Direct Drivers: new highly dynamic drive elements of simple construction for direct generation of linear movements.

41

Rapid Prototyping: rapid realization of prototypes and preproduction series of new products for geometrical and functional testing. Internal high pressure forming: Generation of complex geometries from a single work piece by using high hydraulic pressure. Near Net Shape Forming: Generation of the final contour of a work piece as to shape, dimensional accuracy and surface quality, in a single forming process.

Technology Interventions : The industry has identified the following Key Factors of Success for making machine tool industry technically competitive. These are:

1. Technology Up-gradation: Current level of domestic taxation are not conducive to investments. In order to encourage investments, upgrade technologies and thereby competitiveness of manufacturing industry by following mechanisms: a. Establish “Manufacturing Technology Up-gradation Fund” which can provide finance at reduced interest rates on long term basis b. Credit Linked capital subsidy to SSI for the purchase of CNC Machines. c. Accelerated depreciation of equipments to encourage investments and continuously upgrade technology

2. Manufacturing Infrastructure: For managing tenfold growth, the machine tool industry has to invest heavily in the industry. At the same time investments will have to made in a manner that the manufacturing can remain competitive and meet global benchmarks of productivity. a. Encourage public private partnerships in establishing Machine Tool Parks at centers where machine tool manufacturing clusters are active. Bangalore Machine Tool Cluster meets 60% requirement of the country.

3. Promote Research Design & Development: All machine tool exporting countries have well established research institutions that develop new technologies & help industry to productionize these technologies like- Germany, France, Switzerland etc. Though Government of India established Central Machine Tool Institute in 1960, it has not been able to deliver its objective. The machine tool industry is starved of technology development in the country and it requires priority attention of the government. a. Revitalize activities of CMTI for development of Machine Tool Technologies for the benefit of Indian industries b. CMTI should have satellite centers at key locations where machine tool manufacturing SSIs are located to render service to them to improve their quality and technologies e.g. Ludhiana, Faridabad, Rajkot, Pun, Hyderabad etc. c. Encourage joint R & D projects resulting from Industry Institute interaction d. Government Laboratories to focus on developing technologies that have impact on manufacturing and machine tool technologies

42

4. Availability of Qualified People: The industry requires knowledge workers in the field and there is acute shortage of these people. a. Machine tool industry requires urgent focus on technology development. This requires post graduates and research scientists for designing new products as well as absorption of new technologies. More Engineering colleges need to be advised to offer graduate as well as post graduate courses in Machine Tool Engineering including mechatronics. b. To meet the demand of expert workmen Government ITIs must produce workmen having basic knowledge of mechatronics - Diploma in Mechatronics needs to be introduced at institutions offering diploma in engineering.

Conclusion : The Indian machine tools industry has poor technology competence due to the inward looking economic policies and dominance of public sector organizations. While this helped India initially in attaining self-sustenance, it also led to adoption of obsolete technologies in the developed countries and limited efforts to absorb and improve the imported technology. This is in contrast to the experience of Japan and Korea which developed significant scale and technology competence. Today India’s competence is primarily in design and tooling industry due to availability of low-cost skilled manpower. Significant gaps exist in CNC controls, precision bearings and sensors.

43

Section 8 Technology and Other Initiatives-

Technology InitiativesThis section highlights the technology initiatives required to enhance the technical competitiveness of Indian manufacturing sector and profiles the initiatives of Korea to highlight the importance of such changes. Develop and restructure technology infrastructure to support firms striving to improve their technological capabilities and competitiveness: - Drive public R&D institutes and laboratories to become more demand -driven and service oriented, and make the resource allocation (government budgetary support) more performance driven. R&D institutes should acquire international accreditation for granting product certification in India and for providing, in competition with private consulting firms, effective technological extension services in order to help firms improve their manufacturing and design capabilities. - Improve coordination among R&D programs thro ugh merger and consolidation of institutions that work in similar areas to create "Centres of Excellence". Institutionalise use of peer and technical panel reviews of public R&D proposals and programs to promote joint public/ private sector R&D activities for better monitoring and evaluation systems. - Promote strong linkages between R&D institutes, universities, industrial extension agencies and manufacturing enterprises. Emphasize on international cooperation between R&D institutes and build linkages for technology development and technology transfer. Equip national institutes for providing contract R&D services to international players. - Promote industry networks for a consortium approach to industry R&D activities and integrated development of new product designs and production processes, with the intensive involvement of and collaboration with suppliers.

Focus on selected manufacturing technologies and products

44

- Encourage firms, through the dissemination of relevant information, to acquire arms’ length technology through technology licensing, technology transfer agreement, reverse engineering and adaptation to build their own capabilities - Establish Technology Trackers in leading countries (Germany, Taiwan, Japan and USA) to track development of technology in key segments - Encourage application of technologies (like business-to-business e-commerce, CRM, TPM, TQM etc.) at the enterprise level through rapid build-up of awareness of need, diagnosis of critical technological requirements, technology transfer management, and monitoring and forecasting of technology, as well as entrepreneurship development. - Promote technology -based FDI partnerships between foreign and local enterprises especially inmedium -scale SMEs with the view of developing India as global outsourcing and subcontracting base - Establish entrepreneurship development programs at engineering and R&D institutes for goaldirected promotion of business ideas - Maintain competitive pressures on the demand side by adopting a well-formulated competition policy and intellectual property protection regime. Promote application of environment-friendly and safety standards to upgrade the standardisation level to global level and hence promote export competitiveness

Upgrade Technological capabilities of SMEs : - Provide an effective outreach program to SMEs through designated public R&D institutes, starting with effective dissemination of information on standards to help SMEs improve technological capability - Develop subcontracting and encourage integration of SMEs in the overall manufacturing sector, through vendor improvement and certification programs, as suppliers of raw materials, intermediate inputs and components

Provide fiscal benefits to manufacturing firms for R&D : - Provide tax exemption and other incentives for R&D and in-plant technical training by using any of the following instruments: tax credits for R&D expenses, and accelerated depreciation and reduced import duties for investments in R&D facilities Utilize Technology Development Fund (TDF) to finance indigenous R&D activities. Energize Technology Upgradation Fund (TUF) by extending this grant to select non-textile industry and providing flexibility in its usage.  

Develop technical education and training facilities : - Revive interest for existing higher technical education towards core engineering stream by revising outdated curriculum, adopting interdisciplinary approach and increasing relevance to industrial application. Manufacturing industry should strive to attract and retain the best engineering talents.

45

- Encourage private sector to establish and operate demand-driven technical training centres through financial and other incentives, under carefully designed industry initiatives, supported and coordinated by government, for quality control and accreditation systems

OTHER INITIATIVESINSTITUTIONAL LINKAGES : Financial Institutions: Most of the units are financed through term loan and working capital from banks and entrepreneurs equity. All major banks are having their branches in Chhattisgarh. Each bank has its own assessment about the sector and is cautious in loan disbursement. As per present report of banks in SLBCs (2010), General Engineering/Fabrication units have very low NPA, so banks are willing to finance these sectors. NSIC is also providing finance in this sector in the state of Chhattisgarh.

District Trade and Industry Centres – All DTIC help the industry in getting provisional and permanent registrations and also assist large organizations like BALCO, NTPC, SECL and SAIL etc. to identify units for enlistment as vendors. DTIC networks between entrepreneurs and MSME-DIs, NSIC, KVIC and financial institutions etc. It also guides entrepreneurs to set up industries.

National Small Industries Corporation Limited – NSIC – The prime aim of NSIC is to foster growth of small scale industries in India through various developmental activities such as hire-purchase and leasing, raw material assistance, marketing support, tender marketing, export development finance, composite term loan and single point registration scheme.

MSME Development Institute in RaipurThe office of MSME-DI in Raipur ------ to the need of MSMEs by giving various assistances like – Project Report, Capacity Assessment, NSIC Inspection, Conducting various programmes, like – on topic of IPR, WTO, Bar Code, ESDPs, MDPs, IMCs etc. Also the institute is engaged in reimbursement towards ISO 9000/ISO 14000, Bar Code etc. MSMEDI, Raipur also organizes Vendor Development Programme, Buyer Seller Meet etc. for the benefit of micro and small scale enterprises. . Machining & Fabrication Units- (SWOT Analysis)Strengths-

46

     

Easy availability of raw material, power and workforce. Existence of undergraduate and graduate technical institutions, including one of high repute. Proximity to mother plants. Entrepreneurs are experienced in the core area of machining and fabrication. Cordial labor reations. Financial institution’s willingness to fund viable projects.

Weakness    

Low technology levels. Dependence on one or two customers coupled by lack of market information. Lack of marketing skills. Absenteeism of workforce. Lack of guidance in cost management. Let us discuss this.

Opportunities Increased infrastructure activity within and outside the country gives good scope for executing large projects.  Expertise of machining and fabrication of Sponge iron plants can be put into maximum use in emerging sponge iron clusters in other states.  Opportunity exists for common procurement of raw materials, consumables and joint marketing.  Opportunity exists for becoming a competitive fabrication and machining centre for automobiles and engineering projects due to 3M advantages.

Threats

Slowdown in infrastructure activities will adversely affect the units.

Action Plan :Machining and Fabrication   

Sensitization of unit on cluster approach: Individual and group meetings with the units of the cluster will be conducted to sensitize the units about the cluster approach. Fostering common vision: Exposure visit to other developed cluster and common meetings will help to drive trust among the units. Sub cluster will be helped to slowly evolve a common vision. A product association will be formed to drive the cluster activities. Awareness creation: Specialized inputs on product diversification, precision engineering, quality improvement, productivity and management development programs in collaboration with local and outside BDS would be planned for the cluster. Formation of consortia: After identification of common needs, consortia of like minded firms would be facilitated. These consortia would be exposed to successful consortia in other clusters and helped to evolve a common business plan. Slowly capacities of these consortia would be built.

47

 

    

Credit linkages: Smaller units of less than Rs. 40 lakhs per annum turnover will be focused for assessing credit from financial institutions. If need be linkages with MFIs would also be explored. Market development: All the three tiers of firms would be helped to build linkages with new markets. For this visit of firms to potential customers and vice versa will be planned. Marketing brochures, marketing CDs and other relevant tools will be deployed. Consortia will evolve appropriate marketing channels as the needs emerge. Product diversification: To help firms reduce their dependency on job working new products would have to be developed and marketed by the cluster. For this suitable BDS would be used and activities would be driven on consortia platforms. Improvement in production efficiencies : Firms will be assisted to improve their production efficiencies by improved welding, better shop floor practices, better inventory management, joint procurements etc. Design development centre: To take up turnkey projects a common testing and design development centre will be created in public private participation. Manpower development: To overcome the shortage of skilled manpower, the cluster would jointly contribute resources to ITI, diploma institutes to train manpower as per the cluster requirements, SISI training centre will be upgraded. Sub contracting relationships between the three tiers: Attempts would be made to develop sub contracting relationships between the three tiers by constant dialogue and addressing needs of the upper tier firms.

48

PROJECT PROFILE ON “HACKSAW BLADE MANUFACTURING” NIC Code

:

28939

ASICC Code

:

71303

Year of Preparation

:

2010-11

PREPARED BY

Micro, Small & Medium Enterprises Development Institute Near Urkura Railway Station, Industrial Area, Bhanpuri, Raipur (C.G.) Phone : (0771) 2102700

49

INTRODUCTION A hacksaw is a fine-tooth saw with a blade under tension in a frame, used for cutting materials such as metal. Hand-held hacksaws consist of a metal frame with a handle, and pins for attaching a narrow disposable blade. A screw or other mechanism is used to put the thin blade under tension. A power hacksaw (or electric hacksaw) is a type of hacksaw that is powered by electric motor. Most power hacksaws are stationary machines but some portable models do exist. Stationary models usually have a mechanism to lift up the saw blade on the return stroke and some have a coolant pump to prevent the saw blade from overheating MARKET POTENTIAL The demand of hacksaw blade is considerably increasing day by day with the growth of industrilisation,engineering sector,real estate,automobile sector etc.It is used in almost every sector for cutting of materials like angle, channel, flat plates, rods and such other things. It is also required in auto repairing shops,general repairing workshops,fitting shops,welding shops and technical institutes.Govt. department like Railway,Defence,PWD,Postal & Telegraph and others are one of the main user of it. In India large nos. of small enterprises are engaged in its manufacturing. By considering its demand, new production unit has great prospect. .

BASIS AND PRESUMPTIONS  The information supplied is based on a standard type of manufacturing activity utilizing conventional techniques of production and optimum level of performance.  75% of the envisaged capacity is taken as efficiency on single working shift of 8 hrs & 300 working days in a year..  Labour and wages are required as per present circumstances.

50

 The cost in respect of land & building, machine & equipment, raw material & selling price of finished product etc are those generally obtained at the time of preparation of project profile and may vary depeding upon the location, make and for variety of resons.  The interest on total capital has been assumed @ 14% p.a

IMPLEMENTATION SCHEDULE

 Selection of site & Preparation of bankable project report 3 months  Filing of EM part-I with GM, DIC 3 days  Submission of project report & sanction of finance from financial institution/ Bank 4 months  Procurement of Plant, machinery & equipment 1 month  Commissioning and erection of Plant & machinery and trial run 3 months  Purchase of raw material & recruitment of labour & staff 1 month  Start of commercial production Immediately as soon as above activities completed  Filing of EM Part-II with GM, DTIC Immediately after the Enterprises has gone into regular production

TECHNICAL ASPECTS DESIGN

51

Blades are available in standardized lengths, and with anywhere from three to thirty-two teeth per inch (tpi). The blade used is based on the thickness of the material being cut, with a minimum of three teeth in the material. Hacksaw blades are normally quite brittle, so care needs to be taken to prevent brittle fracture of the blade. Bi-metal blades are meant to minimize this risk.

RECOMMENDED TEETH PER 25MM (TPI) FOR EACH MATERIAL TYPE:

Material diameter (mm) Material

10-30 30-100 100-250 Teeth per inch (25mm)

Free machining steel Building irons Structural steel

14-8

8-6

6-4

Heat-treated steel Nitridated steel

14-8

8-6

6-4

Spring steel

14-8

8-6

6-4

High temperature steel 8-6 Stainless steel

6-4

6-4

Cast iron

10-8

8-6

6-4

Aluminium Brass

6-4

6-4

6-4

The common sizes of hexablades are: High carbon steel Dimension (mm) 250x12.5x0.60 300x25x0.80

TPI 18,24 18,24 52

300x12.5x0.60

14,18,24,32

High speed steel Dimension (mm) 250x12.5x0.60 300x12.5x0.60

TPI 14,18,24 14,18,24

Power hacksaw blade Dimension (mm) 350x25x1.20

TPI 10,14

MANUFACTURING PROCESS Hacksaw blades (both hand & power hacksaw) are generally made up of carbon steel or high speed steel strip rolls. The blank of required size is obtained by fixing the strip rolls on the stand of semi automatic strip cutting machine and punched a hole at their both ends. Then, teeth are being made on the blank by milling or hobbing process. Once teeth are being cut, the hacksaw blades are heat treated and tempered for the required hardness. The last step in the manufacturing process is surface cleaning, painting, printing and packing of the hacksaw blades for market supply.

The flow chart of the manufacturing process is given below:

Raw material ↓ Strip rolls ↓ cutting of blanks & punching at their ends ↓ 53

teeth making on milling machine ↓ heat treatment & surface preparation ↓ painting & packing

PRODUCTION CAPACITY (per year)

Sr. no. 1 2 3

item Carbon steel hand hacksaw blade 250x12.5x0.60 Carbon steel power hacksaw blade 350x25x1.20 High speed steel power hacksaw blade 350x25x1.20

quantity 7,00,000 3,00,000 3,00,000

QUALITY CONTROL The job should be checked after completion of each stage so that chance of rejection at the end is eleminated. Hacksaw blades are manufactured as per IS : 2594-1963. For the inspection process proper callibarated gauges & equipment should be used.

POLLUTION CONTROL

54

As these unit do not create pollution, so there is no requirement of No Objection Certificate from pollution control board.

POWER CONSUMPTION Approx. power consumption is 50H.P

FINANCIAL ASPECTS

 FIXED CAPITAL 1. Land & building 600 sq. mtrs. With covered area of 300 sq. mtrs 10,000(approx.)on monthly rent basis 2. Machinery & Equipments

Sr. No. 1 2 3 4 5 5

6

Description

Qty

Semi automatic metal strip cutting machine,50mm with 5 H.P. motor Strip straighting &cutting m/c cap50mm width, with 5 H.P. motor Universal milling m/c with attachment with 7 H.P. motor Stamping m/c Power press 20 T Automatic temp. control heat treatment plant,3 H.P motor,70kva LT transformer Bench grinder,250mm wheel dia,1H.P motor

55

Price (Rs.)

1

3,70,000

1

4,50,000

1

4,00,000

1 1 1

25,000 4,50,000 3,50,000

1

10,000

7 8

Rockwell hardness testin m/c Gauges,tools & other equipments

1 L.S

20,000 50,000 Total=

21,25,000 Installation & electrification charge @ 10% of cost of machine= 212500 13 Furniture & office equipment 20000 TOTAL 23,57,500

WORKING CAPITAL ( per month) 1. Personnel Sr. no. 1 2 4 5 7 8 9 10

Designation

No.

Manager Supervisor Skilled worker Unskilled worker Store-keeper Clerk-cum-Typist Peon Watchman

1 1 2 2 1 1 1 1

Salary (per month) 7000 5000 4000 3000 4000 4000 3000 3000 Total

40,000/-

2. Raw material (per month)

56

Total 7000 5000 8000 6000 4000 4000 3000 3000

Sr. no. 1

item 12.5mm width & 0.60mm thick carbon steel strip @ Rs.55/kg 25mm width & 1.20mm thick carbon steel strip @ Rs.48/kg 25mm width & 1.20mm thick high speed steel strip @ Rs.80/kg Packing material

2 3 4

Quantity (kg) 1200

amount

2200

105600/-

2600

208000/-

L.S

50000/-

66000/-

Total - 429600/- or say 4,30,000/-

3. Utilities (per month) Electricity & Water

Rs

40,000 4. Other expenses (per month)

Sr. no. 1 2 3 4 5 6 7

Description

Rs.

Stationary Transport charges Telephone Maintenance Insurance Miscellaneous Rent

4000 5000 2000 4000 3000 5000 10000 33000

TOTAL Total recurring expenditure (per month) 1+2+3+4 = 5,43,000/-

57

Total working capital (for 3 months) 5,43,000/-x 3 = 16,29,000 / TOTAL CAPITAL INVESTMENT 1. Fixed capital 23,57,500/-

Rs.

2. working capital 16,29,000/-

Rs.

Total =

Rs.

39,86,500/-

FINANCIAL ANALYSIS  Cost of production (per year) Total recurring cost per year 65,16,000

Rs.

Depreciation on machinery & equipment @ 10% 21,2500

Rs.

Depreciation on office furniture @ 20% 4,000

Rs.

Interest on total investment @ 14% 5,58,110

Rs.

Total cost of production 72,90,610

Rs.

58

 Turnover (per year) Item Value(Rs.)

Qty.

Carbon steel hand hacksaw 8,75,000 blade 250x12.5x0.60 mm

7,00,000

Carbon steel power hacksaw 44,00,000 blade 350x25x1.20

2,00,000

High speed steel power hacksaw 32,00,000 blade 350x25x1.20

1,00,000

@Rs.1.25/each

@Rs.22/each

@Rs.32/each Total -

84,75,000

 Net profit (per year) =84,75,000 – 72,90,610 = 11,84,390 or say 11,84,000/ Net profit ratio = Net profit per annum x 100 Turnover per annum = = =

1184000 x 100 8475000 13.97 % 14%

 Rate of return

59

=

Net profit per annum x 100 Total investment

=

1184000x 100 3986500

=

29.70%

 Break even point 1. Fixed cost per annum

Rs.

a. Depreciation on machinery & equipments @10% b. 40% of other expenses (excluding rent & insurance) c. Depreciation on office furniture @20%

212500 96,000 4,000

d. 40% of salary & wages 1,92,000

e. Interest on capital investment @14% 5,58,110 f. Rent

1,20,000

g. Insurance

36,000 Total= 12,18,610 Or say

12,18,000 2. Breakeven point = Fixed cost x 100 Fixed cost + profit = 12,18,000 x 100 12,18,000 + 11,84,000

60

= 50.70%

13.

Addresses of Machinery Suppliers –

1. Benco Thermal Technologies Private Limited , Plot Nos 236 And 237, SIDCO Industrial Estate, Thirumudivakkam, Chennai - 600 044, India 2.Quartet Thermal Engineering Pvt. Ltd , : No. 2, Sion Vijayanand Chs Plot No. 267, Scheme No. 6, Road No. 31, Near Gandhi Market, Sion, Mumbai 400 022 61

3. Gauri Wood Craft , 2 K/46-A, B. P., Opposite FCI Godown, NIT, Faridabad - 121 006 4. Industrial Thermal Engineers Plot 66/13, Phase No. 1, G. I. D. C., Vatva, Ahmedabad - 382 445, India 5.JK Automation Gate No.12, Swami Samarth Indd. Co.- Op. Society, S116/4 MIDC, Bhosari, Pune - 411 026, 6.United Lathes India: G.T. Road, Jugiana, Opposite UCO Bank,, Ludhiana -

141 017, India 7.Asia Machines: No. 50, Balleshwar Upvan, Near Axis Bank, BopalGhuma Road, Ahmedabad - 380 058,

62

PROJECT PROFILE ON “METALLIC WASHERS” NIC Code

:

28991

ASICC Code

:

71354

Year of Preparation

:

2010-11

PREPARED BY

Micro, Small & Medium Enterprises Development Institute Near Urkura Railway Station, Industrial Area, Bhanpuri, Raipur (C.G.) Phone : (0771) 2102700

63

INTRODUCTION A washer is a thin plate (typically disk-shaped) with a hole (typically in the middle) that is normally used to distribute the load of a threaded fastener. Other uses are as a spacer, spring (belleville washer, wave washer), wear pad, preload indicating device, locking device, and to reduce vibration (rubber washer). Washers usually have an outer diameter (OD) about twice the length of their inner diameter (ID). Washers are usually metal or plastic. Rubber or fiber gaskets used in taps or valves to stop the flow of water are sometimes referred as washers but, while they may look similar, washers and gaskets are usually designed for different functions and made differently. Common materials include steel, stainless steel, and plastic. Hardened washers are steel washers that have been heat treated. Other materials include aluminum, bimetals, bronze, brass, ceramics, copper, felt, fibers, iron, leather, mica,

MARKET POTENTIAL Being a general item washers are used in almost every sector of Engineering.It is used in sectors like mechanical,electrical,automobile,aeronautical,real estates etc. which require it regularly and in bulk quantity. It is also uses in auto repairing shops,general repairing workshops,fitting shops,welding shops and technical institutes.Govt. department like Railway,Defence,PWD. In India large nos. of small enterprises are engaged in its manufacturing. By considering its demand, new production unit has great prospect.

. BASIS AND PRESUMPTIONS

64

 The information supplied is based on a standard type of manufacturing activity utilizing conventional techniques of production and optimum level of performance.  75% of the envisaged capacity is taken as efficiency on single working shift.  Labour and wages are required as per present circumstances.  The cost in respect of land & building, machine & equipment, raw material & selling price of finished product etc are those generally obtained at the time of preparation of project profile and may vary depeding upon the location, make and for variety of resons.  The interest on total capital has been assumed @ 14% p.a

IMPLEMENTATION SCHEDULE

 Selection of site & Preparation of bankable project report 3 months  Filing of EM part-I with GM, DIC 3 days  Submission of project report & sanction of finance from financial institution/ Bank 4 months  Procurement of Plant, machinery & equipment 1 month  Commissioning and erection of Plant & machinery and trial run 3 months  Purchase of raw material & recruitment of labour & staff 1 month  Start of commercial production Immediately as soon as above activities completed  Filing of EM Part-II with GM, DTIC Immediately after the

65

Enterprises has gone into regular production

TECHNICAL ASPECTS Washers are of different types and are used as per their requirement. Some of the types are: 1.Plain washer 2.Lock washer 3.Spherical washer 4.Internal lock washer 5.Spring washer 6.Taper washer 7.Square washer 8.Check nut etc.

Washers are made up of some of the common materials like steel, stainless steel, and plastic. Hardened washers are steel washers that have been heat treated. Other materials include aluminum, bimetals, bronze, brass, ceramics, copper, felt, fibers, iron, leather, mica, Washers usually have an outer diameter (OD) about twice the length of their inner diameter (ID).

MANUFACTURING PROCESS Washers are generally made up by punching process. The method comprising forming each washer in a successive operations from a washer blank strip, a washer being punched out in a final punching operation.

The flow chart of the manufacturing process is given below:

66

Raw material (metal sheet) ↓ sheet cuting ↓ punching ↓ polishing ↓ heat treatment & surface preparation ↓ packing

PRODUCTION CAPACITY (per year) Metallic washers - 50 MT QUALITY CONTROL

Product should be thoroughly checked right from the selection of raw material to the final stage of finishing. Different type of washers are manufactured as per different standards, for example Spring lock washers are manufactured as per following standards: IS : 3063-1994 and IS : 67351994.where as plain washers are as per: IS : 2016 , IS : 6610 , IS : 5372-75 , IS : 5374-75 , IS : 6649-85

67

POLLUTION CONTROL As these unit do not create pollution, so there is no requirement of No Objection Certificate from pollution control board. POWER CONSUMPTION Approx. power consumption is 10H.P

FINANCIAL ASPECTS  FIXED CAPITAL 1. Land & building 500 sq. mtrs. With covered area of 300 sq. mtrs 5,000(approx.)on monthly rent basis 2. Machinery & Equipments Description Sr. No. 1 2 3 4 4

Qty

Power press inclinable 20 T Hand operated shearing machine Bench grinder,250mm wheel dia,1H.P motor Tumbling barrel machine Gauges,tools & other equipments

Price (Rs.)

1 1 1

3,25,000 20,000 10,000

1 L.S

25,000 50,000 Total= 4,30,000

Installation & electrification charge @ 10% of cost of machine= 43000 13 Furniture & office equipment 20000 TOTAL 4,93,000 WORKING CAPITAL ( per month) 1. Personnel

68

Sr. no. 1 2 3 4 5

Designation

No.

Manager Supervisor Skilled worker Unskilled worker Watchman

1 1 1 1 1

Salary (per month) 6000 5000 4000 3000 3000

Total 6000 5000 4000 3000 3000

Total 21,000/1. Raw material (per month) Required guage (8 SWG to 20 SWG) of M.S sheet scrap @ Rs. 11000/MT 1,10000/-

10 MT

3. Utilities (per month) Electricity & Water

Rs

15,000 4. Other expenses (per month)

Sr. no. 1 2 3 4 5 6 7

Description

Rs.

Stationary Transport charges Telephone Maintenance Insurance Miscellaneous Rent

4000 4000 2000 4000 3000 2000 5000 24000

TOTAL

69

Total recurring expenditure (per month) 1+2+3+4 = 1,70,000/Total working capital (for 3 months) 1,70,000/-x 3 = 5,10,000 / TOTAL CAPITAL INVESTMENT 1. Fixed capital 4,93,000/-

Rs.

2. working capital 5,10,000/-

Rs.

Total =

Rs.

10,03,000/-

FINANCIAL ANALYSIS  Cost of production (per year) Total recurring cost per year 20,40,000

Rs.

Depreciation on machinery & equipment @ 10% 43,000

Rs.

Depreciation on office furniture @ 20% 4,000

Rs.

Interest on total investment @ 14% 1,40,420

Rs.

Total cost of production 22,27,420

Rs. Say

Rs.22,27,000

70

 Turnover (per year) Item Value(Rs.) Different types of M.S Washers avg.@ Rs.32,000/MT 19,20,000/

Qty.

Scrap sheet @ 9000/MT 5,40,000/

60MT

60MT

Total -

 Net profit (per year) =24,60,000– 22,27,000 = 2,33,000/ Net profit ratio = Net profit per annum x 100 Turnover per annum = 233000 x 100 2460000 = 9.47 %  Rate of return =

Net profit per annum x 100 Total investment

71

24,60,000/

=

233000x 100 1003000

=

23.23%

 Break even point 1. Fixed cost per annum

Rs.

h. Depreciation on machinery & equipments @10% i. 40% of other expenses (excluding rent & insurance) j. Depreciation on office furniture @20%

76800 4,000

k. 40% of salary & wages

100800

l. Interest on capital investment @14%

140420

43000

m. Rent

60000

n. Insurance

36,000 Total= 461020

2. Breakeven point = Fixed cost x 100 Fixed cost + profit = 461020 x 100 461020 + 233000 = 66.42%

72

14.

Addresses of Machinery Suppliers –

1.Asia Machines: No. 50, Balleshwar Upvan, Near Axis Bank, BopalGhuma Road, Ahmedabad - 380 058, 2.Ess Kay Lathe Company: 127, Focal Point Batala, Batala - 143 505, 3.Emtex Machinery Private Limited: No. 4-E, Vandhana Building, No. 11, Tolstoy Marg, Connaught Place, Delhi - 110 001 4.Modi Traders: 829, M. T. P. Road, ( Near Flower(Poo) Market Bus Stop) R. S Puram, Coimbatore - 641 601 5.India International Marketing Company: No. B-73, Phase-1, Mayapuri Industrial Area, New Delhi - 110 064, India

PROJECT PROFILE ON “PISTON RING” NIC Code

:

73

29121

ASICC Code

:

75156

Year of Preparation

:

2010-11

PREPARED BY

Micro, Small & Medium Enterprises Development Institute Near Urkura Railway Station, Industrial Area, Bhanpuri, Raipur (C.G.) Phone : (0771) 2102700

INTRODUCTION. Piston ring is one of the most important part of the Deisel/Petrol engines.It is an open-ended ring that fits into a groove on the outer diameter of a piston in a reciprocating engine such as an internal combustion engine or steam engine. The principal function of the piston rings is to form a seal between the combustion chamber and the crankcase of the engine. The goal is to prevent combustion gases from passing into the crankcase and oil from passing into the combustion chamber The three main functions of piston rings in reciprocating engines are:

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1. Sealing the combustion/expansion chamber. 2. Supporting heat transfer from the piston to the cylinder wall. 3. Regulating engine oil consumption. During the compression and power strokes, the compression ring seals the combustion gases and prevents blow-by. Although blow-by is not completely eliminated it is kept to an acceptable limit. During the compression and exhaust strokes the cylinder walls are lubricated with oil by throw off from the connecting rod bearings. Excess oil is wiped off by the piston rings. Not only does the oil ring have the responsibility of wiping the excess oil off the cylinder walls, but the job is also shared by all of the rings, leaving a fine layer of oil on the wall to provide lubrication for the following ring. As rings wear, the ability to perform these functions is decreased resulting in oil consumption and blow-by. When this happens it is time for a new set of rings. MARKET POTENTIAL Piston ring is the one of the most replaceble part of the diesel/petrol engines.It has great demand in the replaceble market as well as in new engines market.For the last few years there is noticeble increase in the automobile industry, which is the vast market for it. Piston rings are not only used in the automobile industry but also used in :         

Railway Engines Compressors Steam Hammers Cars Retaining Rings Pumps Industrial Applications Cranes Gearboxes

So, by maintaining quality and using proper marketting techniques there is alwayes a great market of this product. 75

BASIS AND PRESUMPTIONS  The information supplied is based on a standard type of manufacturing activity utilizing conventional techniques of production and optimum level of performance.  75% of the envisaged capacity is taken as efficiency on single working shift.  Labour and wages are required as per present circumstances.  The cost in respect of land & building, machine & equipment, raw material & selling price of finished product etc are those generally obtained at the time of preparation of project profile and may vary depeding upon the location, make and for variety of resons.  The interest on total capital has been assumed @ 14% p.a

IMPLEMENTATION SCHEDULE

 Selection of site & Preparation of bankable project report months  Filing of EM part-I with GM, DIC days  Submission of project report & sanction of finance from financial institution/ Bank months  Procurement of Plant, machinery & equipment month  Commissioning and erection of Plant & machinery and trial run months  Purchase of raw material & recruitment of labour & staff month  Start of commercial production Immediately as

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3 3

4 1 3 1

soon activities completed  Filing of EM Immediately after the

Part-II

with

GM,

as

above DTIC

Enterprises has gone into regular production

TECHNICAL ASPECTS MATERIAL The materials used to make Piston Rings are one of the most critical factors in its performance. Listed below are some of today's common material used in manufacturing of piston rings and metallic seals:        

Cast iron Cast iron alloyed for piston rings Nodular cast iron alloyed for piston rings Bronze Aluminum Bronze Phosphor Bronze Steel Stainless Steels for use in high temperature

MANUFACTURING PROCESS Piston rings are generally made up of cast iron. The blanks of cast rings of required size and desired properties are procured from the local foundries. After that blanks are cleaned and get ground. Then the blanks are undergone through various processes like facing, rough diameter, rough bore, finish diameter & finish bore. The rings are generally machined to the required shape by means of turning, a process in which the ring blank, already axially ground, is copy turned on the inside and outside diameters. After a segment equivalent to the free gap is cut from the ring it assumes the free shape that will give it the required radial pressure distribution when fitted into the cylinder.. 77

Piston Ring Coatings After the completion of machining process the following surface treatments for piston rings are principally designed to provide corrosion protection for storage, enhance appearance and improve running.        

Bronze Coating Ceramic Chrome Plating Chrome Plating Copper Plating Molybdenum Phosphate Coating Plasma Sprayed Coating Tin Coating

PRODUCTION CAPACITY

Approxemetly 45,000 set of different sizes per year. QUALITY CONTROL The procured blanks castings should be checked very carefully as per given requirement (size,grade etc). This is the very first step in quality control.The product should be monitored after completion of each stage so that chance of rejection at the end is eleminated. Piston rings should be manufactured as per IS : 5791-1971 & IS: 8422 for IC engines.The entire operation of surface treatment/ coating should be closely controlled. For the inspection process proper callibarated gauges should be used.

POLLUTION CONTROL As this unit doesnot comes under heavy polluted industry, although No Objection Certificate from pollution control board should be taken. POWER CONSUMPTION 78

As this is a small unit it has less power consumption, which is approx. 30H.P

FINANCIAL ASPECTS FIXED CAPITAL 1. Land & building Rs. 400 sq. mtrs. With covered area of 300 sq. mtrs 5,000(approx.) on monthly rent basis 2. Machinery & Equipments

Sr. No. 1 2 3 4 5 6

Description

Qty

Lathe machine,1800 mm bed with 3 H.P motor Lathe machine,900 mm bed with 2 H.P motor Face grinder with special attachment, 4 H.P motor Bench drill machine.12mm capacity Bench grinder,250mm wheel dia,1H.P motor Gauges,tools & other equipments

Price (Rs.)

2

3,40,000

1

2,60,000

1

60,000

1

15,000

1

15,000

L.S

40,000 Total=

7,30,000 Installation & electrification charge @ 10% of cost of machine= 73,000 13 Furniture & office equipment 20000 TOTAL 823000

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WORKING CAPITAL ( per month) 1. Personnel Sr. no. 1 2 4 5 7 8 9 10

Designation

No.

Manager Supervisor Skilled worker Unskilled worker Store-keeper Clerk-cum-Typist Peon Watchman

1 1 2 2 1 1 1 1

Salary (per month) 7000 5000 4000 3000 4000 4000 3000 3000

Total 7000 5000 8000 6000 4000 4000 3000 3000 Total

40,000/2. Raw material (per month)

Sr. no. 1

Description

Qty.

Rs.

Piston ring castings @ Rs.48/kg

1300kg

62,400

3. Utilities (per month) 20,000

Electricity & Water

Rs

80

4. Other expenses (per month) Sr. no. 1 2 3 4 5 6 7

Description

Rs.

Stationary Transport charges Telephone Maintenance Insurance Miscellaneous Rent

4000 5000 2000 4000 3000 5000 5000 28000

TOTAL

Total recurring expenditure (per month) 1+2+3+4 = 1,50,400/-

Total working capital (for 3 months) 1,50,400/-x 3 = 4,51,200or say 4,51,000/ TOTAL CAPITAL INVESTMENT 1. Fixed capital 8,23,000/-

Rs.

2. working capital 4,51,000/-

Rs. Total =

12,74,000/-

FINANCIAL ANALYSIS 81

Rs.

 Cost of production (per year) Total recurring cost per year 18,04,800 Depreciation on machinery & equipment @ 10% 73,000

Rs.

Rs.

Depreciation on office furniture @ 20% 4,000

Rs.

Interest on total investment @ 14% 1,78,360

Rs.

Total cost of production 20,60,160

Rs.

 Turnover (per year) Qty. Value(Rs.)

Rate

45000 26,10,000/-

@ Rs. 58/-

 Net profit (per year) =26,10,000 – 20,60,160 = 5,49,840 or say 5,50,000/ Net profit ratio = Net profit per annum x 100 Turnover per annum = 550000 x 100 82

2610000 21.07 % 21%

= =  Rate of return

= Net profit per annum x 100 Total investment = 550000 x 100 1274000 = 43..17%  Break even point 1. Fixed cost per annum

Rs.

o. Depreciation on machinery & equipments @10% p. 40% of other expenses (excluding rent & insurance) 96,000 q. Depreciation on office furniture @20% 4,000

73000

r. 40% of salary & wages 1,92,000 s. Interest on capital investment @14% 1,78,360 t. Rent

60,000

u. Insurance

36,000 Total= 6,39,360 Or say 6,

39,000 2. Breakeven point 83

= Fixed cost x 100 Fixed cost + profit = 6,39,000 x 100 6,39,000 + 5,50,000 = 53.74%

15.

Addresses of Machinery Suppliers –

1.Emtex Machinery Private Limited: No. 4-E, Vandhana Building, No. 11, Tolstoy Marg, Connaught Place, Delhi - 110 001,

2.R. K. Foundry And Engineering Works: G.. T. Road, Batala - 143 505, India

3.Accurate Auto Lathes Private Limited: Dugri Road, Near Canal Bridge, Ludhiana - 141 002, India 4.Atul Machine Tools: Metoda GIDC, Plot No. P-103, Opp. Makrana Marble, Kalawad Road, Metoda, Rajkot - 360 003,

5.Memco Machinery Mart , No. 4094, 1st Floor, Kuch Dilwali Singh, Ajmeri Gate, Delhi - 110 006, India

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