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PROJECT REPORT ON GLASS GRINDING MACHINE

PREPARED BY

S-021006012 SOLANKI SANJAY M. S-021006010 BOLIYA SURESH B. S-021006024 PARMAR RAJU G.

GUIDED BY SHREE N.D.OZA. SHREE M.K.SHUKLA. SHREE J.B.PATEL. SHREE K.P.SHAH.

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SIR BHAVSINHJI POLYTECHNIC INSTITUTE, BHAVNAGAR CERTIFICATE This is to certify that, Mr. . Reg no...of program D.M.E. Has satisfactorily completed his term work in Code no- SM-602, Subject-PROJECT in the term ending 29/01/2009 to 16/05/2009.

Signature of in charge- ...

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Head of department- .. Date of submission-. Place-..

INDEX
SR. NAME OF THE TOPIC NO. 1 2 3 4 5 6 7 8 9 10 Acknowledgement Introduction Project selection & market survey Working principle Detailed drawing Assembly drawing Material specification List of machine tools List of hand tools List of measuring instruments
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11 12 13 14 15 16

Manpower requirement Process planning chart Flow process chart Costing Testing of product Conclusion

ACKNOWLEDGEMENT
This phase project give me a golden opportunity to thanks each and every persons who supported me to make my project successfully. It is fact that behind the success of a student there is always a good teacher to be the right direction at the right speed. Though the work was to great magnitude, it was great pleasure working as a team, in achieving the above. I would like to express my sincere thanks to; SHREE N.D.OZA.
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 SHREE M.K.SHUKLA. SHREE K.P.SHAH. Who guided and helped us through out the entire project. They gave us maximum knowledge both theoretical & practical. They gave us full support, guidance & arranged for acquiring of suitable material requirements for the project work. Last, but certainly not the list I wish to express my profound appreciation to all my friends for all of their in my project. Sincerely; S-021006012 SOLANKI SANJAY M. S-021006010 BOLIYA SURESH B. S-021006024 PARMAR RAJU G.

INTRODUCTION
AIM OF THE PROJECT To develop attitude of the inquiry in the student. To develop skill to work as a team To develop ability to analysis and solve the problem, assess error and eliminate them.
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 To develop ability of production planning and control. To develop ability to manipulating skills, selecting and handling tools and equipments. To develop judge magnitude without physical measurement. To observe safety awareness. To prepare the students and treat them not only to make project but also to decide factor like cost, advantages and disadvantages themselves to have a good entrepreneur. To develop ability creative thinking.

SELECTION OF THE PROJECT

Selection of the project is most important task. When you are going to make the project, you must clear your concept about idea of manufacturing processes, capital level, working hours is limited, detail about the all parts on the project work.
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In the selection we have to see similar product is floating in the market or not. it is also required to make survey regarding the number of project, if he select some project you must prepare number of visit regarding to the project after observing. We will come on deciding to choose the project or not. The project which we had considered before starting work on the project is as follows: Wind direction indicator Knuckle joint Solar concentrator Glass grinding machine

After considering several factor like size, group, material availability, production, cost, technical possibilities and limited time and etc.., at last we have select the project of GLASS GRINDING MACHINE. Because this machine is not available in the market and the equipment and machine required to manufacture the product are available in our work shop.

MARKET SURVEY
Definition of market:

Market is an organization where buyers and sellers are kept close touch with each other and the products can be exchanged by money or any thing else. Marketing research includes following steps: 1. Classification of problem 2. Research planning 3. Field work 4. Information analysis 5. Report preparation Important of market research: It provides information about product development and product planning It indicated the empty portion of the market at where consumer is unsatisfied. It gives vital details to market safe forecasting It magnifies the market value. It finally represents the actual demand of customer etc.., We visited various local markets and communicated with customer. We collect the information such as data, opinion etc.., we also collect prizes from a number from various station. A meanwhile we also examine that is there any product with high value substituting the product.

WORKING PRINCIPLE
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 As in general, we are using emery paper for shining the surface. In the same way, the belt made of emery can be used for shining the surface of the glass. The emery belt is rotating on wooden pulley by motor and the glass is sliding on the emery belt and becomes shine. We can use different types of fixtures for different shapes of the glass. SALIENT FEATURES OF THE MACHINES Simplest concept Economically viable High safety standard

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MATERIAL SPECIFICATION:
Sr.
1 2 3 4 5 6 7 8 9 10 11

Name of
Stand Shaft-1&2 Wooden pulley Emery belt Fixture Pedestal Step pulley-1 Step pulley-2 V-belt Motor Nut - Bolt

Specification
3570105cm angle 2552&46cm 100120cm W=7.5cm&p=160cm L1=15cm,L2=20cm P-205 B-section id=25mm B-section id=18mm B-48 3phase 1HP M-61inch

Qty
1 2 2 1 2 4 1 1 1 1 16

material
M.S. M.S. Wood Emery M.S. Cast iron Cast iron Cast iron Canvas M.S.

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LIST OF MACHINE TOOL:

Manufacturing of the project was much possible in our collage workshop hence all the machine tool, equipment etc. required are available. Machine tools requires making for this project: Hack-saw machine Lathe machine Drilling machine. Welding machine. Grinding machine

EQUIPMENT AND MEASURING INSTRUMENT: EQUIPMENTS:1. Hand hack saw. 2. Centre drill 3. Centre punch. 4. Right angel. 5. Rough and smooth files

MEASURING EQUIPMENTS
1. Steel foot rule 14 2. Measure tape 3m
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3. Vernier calliper 150 mm (0.02mm L.C) 4. Outside calliper

MAN POWER REQIRMENT:

Sr. no. 1. 2. 3. 4. 5. 6. 7. 8. 9. Total Types of work Marking Cutting Fitting Welding Drilling Turning Assembly Testing & inspection Colouring Labor Rate/hr Total(Rs) hour 1 5 5 8 10 80 2 10 20 6 15 90 1 20 20 8 20 160 2 15 30 2 10 20 2 10 20 31hr Rs.445

Direct labour cost =445 Rs.

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COSTING AND ACOUNTING:

INTRODUCTION
The topic is very useful in estimating and costing. In any factory, the cost of the product is calculated before manufacture. So that exact idea of the amount of the profit can be made. We know that there are hundreds of different of expenditure, which are included in the factory and all these are calculated and added with the product manufacturing. Expenditure of any items should not be left while calculating the total cost of the product. This total cost is divided into different headings know as Element of cost.

ELEMENTS OF COST
For easy and accurate calculation the total of a product manufacture can be divided into three main elements. 1. Material 2. Labors 3. Expenses MATERIAL
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A.) DIRECT MATERIAL These are those materials which when operated or processed in the factory shop through various stages from the final useful shape of the main product of component part of the main product. These are also known as productive materials.

B.) INDIRECT MATERIAL These are those materials which are essentially needed in various shops for helping the materials to be converted in the final useful shape. LABOUR A.) DIRECT LABOUR These are those labors who are directly associated with production or process of final product. B.) INDIRECT LABOUR These are those labors that are not directly associated with the production but at required for works like office, store, security super visors etc.., EXPENSES
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A.)DIRECT EXPENSES These are the expenses incurred in the shop floor for activities like lubrication, cleaning etc.., B.) INDIRECT EXPENSES These expenses can be classified as all the expenses incurred on the management side for the production to continue.

COSTING:
Direct material cost:1. Stand Material Quantity Rate Volume Weight Cost 2. Shaft Material Quantity : M.S :2
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: M.S :1 :22 Rs/Kg :4480cm3 = volume x density = 4480 x 7.8 =34944gm =34.94kg = 22 x34.94 = 768.76Rs

Rate Volume Weight Cost

: 22 Rs/Kg : 772.07 cm3 =volume x density = 772.07x 7.8 =6022.20gm =6.02kg =6.022 x 22 = 132.48

3.Wooden pulley Material Quantity Rate Volume Weight Cost 4. Ficture Material Quantity Rate Volume : M.S :2 : 22 Rs/Kg =218.75 cm
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: M.S :2 : 17 Rs/Kg :883.57 cm3 = volume x dencity = 883.57 x 1.8 = 1590.43gm =1.59kg =1.59 x17 x2 =54.07 Rs

Weight Cost

= volume x dencity = 218.75 x 7.8 = 1706.25gm =1.7kg = 1.7 x 22 x2 = 75.07 Rs

5.Emery belt= 50 Rs. 6.Pedestals =100 x4 =400 Rs. 7.Step pulley =45+50 =95 8.V-belt =45 Rs.

9.Bolt & Nut =5 x16 =80 Rs.

DIRECT MATERIAL COST:

Sr.no Part 1. Stand 2. Shaft 3. Wooden pulley 4. Ficture 5. Emery belt 6. Pedestals 7. Step pulley 8. V-belt 9. Bolt & Nut Total Material M.S. M.S. Wood M.S. Emery paper Casting Casting Canvas M.S. Cost 768.76 132.48 75.52 75.07 50 400 95 45 80 1721.83 Rs.
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ESTIMATING AND COSTING:

PRIME COST = Direct material cost +direct labors cost +direct expenses = 1721.83+445+333.17 = Rs 2500 OVERHEAD COST = 10% of prime cost =Rs 250 ADMINISTRATIVE COST = 10% of factory cost = Rs 250 PRODUCTION COST
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=prime cost +administrative cost +overhead cost = 2500+250+250 = Rs 3000 PROFIT = 20% of total cost = Rs 600 SELLING PRICE = Total cost + profit = 3000+600 = Rs 3600 DISCOUNT = 5% of selling price = Rs 180 CATALOGUE PRICE = Selling price + Discount = 3600 + 180

= Rs. 3780

TESTING OF THE PROJECT:

Testing is the process of checking a particular things working properly or not. Testing process of Glass grinding machine. Was organized in sir B.P.T.I. workshop and results obtain were satisfactory.
Glass grinding machine was tested according to the

method specified. Hence we can say that our project can be used grind the glass.
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CONCLUSION:
Finally this Glass Grinding machine was designed and prepared after completing the project. We are very happy and glad with all and satisfied that we are able to make the project our selves and get the knowledge about planning of different manufacturing process and solve the different problems, hence acquiring the knowledge to fulfill the aim of the project. It was great fun while making this project .we has able to learn a lot and understand various aspects of manufacturing. Though the glass grinding machine has very simple concept but it is
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important. We can use different types of fixctures to make different shapes of glass. I hope this machine will be helpful to our workshop.

FLOW PROCESS CHART FOR STAND

Discription Angle from store Marking for cutting Hacksaw cutting Inspection

Qty. Dist.

Time O

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To drilling machine Drilling To welding shop welding Filling To store Total

FLOW PROCESS CHART FOR SHAFT

Discription Round bar from store Marking for cutting

Qty. Dist.

Time O

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To hacksaw machine Cutting Inspection To lathe machine Facing Turning Inspection To the store Total

FLOW PROCESS CHART FOR WOODEN PULLEY

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Disscription Wood from store Marking for cutting Hacksaw cutting Inspection To lathe machine Facing Turning Inspection Drilling Boring Inspection To the store Total

Qty.

Dist.

Time O

FLOW PROCESS CHART FOR FIXCTURE

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Discription Angle from store Marking for cutting Hacksaw cutting Inspection Strip from store Drilling To welding shop welding Filling To store Total

Qty.

Dist.

Time O

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GLASS GRINDING MACHINE

PREPARED BY S-021006012 SOLANKI SANJAY M. S-021006010 BOLIYA SURESH B. S-021006024 PARMAR RAJU G. SHREE N.D.OZA. SHREE M.K.SHUKLA. SHREE J.B.PATEL. SHREE K.P.SHAH

GUIDED BY-

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