MINOR PROJECT

ON
PROPOSAL FOR A STAMPING PLANT

Group no : 5
Guided By

Presented By

Mr. Niraj Bhatnagar

Deepak Bakshi(07710403611)
Rohit Singh Bisht(03610403611)
Himesh Razdan(07610403611)
Gautam Kumar Chaudhary(04810403611)

PROCEDURE
STAMPING PLANT PLANNING
Concept
Validation

Production Feasibility

Definition of material taking into

account

PROCRDURE PLANNING

PROCUREMENT OF TOOL AND MACHINERY

Punch die procurement

Machinery procurement

TO GET THE BANKS PROPOSAL

Other facilities

PRODUCT
Washer
Standard washers are produced with steel as material
Type
Dia
Thickness

Washer 1

Washer 2

Washer 3

Washer 4

Washer 5

Washer 6

Washer 7

Washer 8

OD22 ID11 OD24 ID13 OD28 ID15 OD30 ID17 OD34 ID19 OD37 ID21 OD39 ID23 OD44 ID25
2

2.5

2.5

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

MARKET TRENDS
Production of washers(ton) x10^5

0
2009

2010

Swarna Fastener

Leading Fastener Industries

2011

2012

2013

DM Enterprise

Swarana Fasteners (Delhi) and DM Enterprise (Gurgaon)

Process Flow

Plant Layout with Material Flow

Total Area = 8*15 sq. meters

= 120 sq. meters

Symbol For a worker

DIE DESIGN AND STRIP LAYOUT

Strip feed

Strip layout
Lower Part

Upper Part

S.NO.

PART

MATERIAL

COST(Rs)

Punch

HcHCr(D2 grade)

3000

Die

HcHCr(D2 grade)

2500

Support Plate

EN38

10000

Base plate and top plate

Mild Steel

15000

Extra(Spring ,guide poles , bushes)

According to requirement

5000

Total cost=Rs.31000

Inner Dia d
Outer Dia D
Pitch Step 1.2D
Width of strip 1.2D

MACHINERY SELECTION
Press Machine
Specs On the basis of which Press Machine has been selected
Cost
Tonnage Required = 2.5 [(Shearing area x Shear strength of material) +Stripping Force]
10 ton
SPM required = for the production of 144000 washers (By one machine) a year (with working
hours 6x250 in a
year)
Min SPM Required 40

Feeder

De coiler

Max Width
(Required width is 60 mm)
Max Thickness (Required thickness is 2 mm)
SPM
(Required SPM is 40)

Max Weight (Required weight is weight of coil i.e. 1 ton)

Max Width (Required Width is 60 mm )

Turret Punch Press

Turret punch press is also a possibility where we
don't need any de coiler and feeder and also
there cascading in stamping process can be done

Power Press

PRESS SELECTION

Manufacturer

Tonnage

Strokes per
minute

Dimension

Price ( RS )

Power
Required

Basant Press
Pvt. Ltd.

30

65

32x30x50

2,55,000

3 HP

Basant Press
Pvt. Ltd.

50

55

39x39x75

2,95,000

5 HP

Revatech And
Sons

50

35

57x34x86

3,10,000

4.5 HP

Revatech And
Sons

40

35

40x41x80

2,90,000

3.5 HP

Sri Krishna
Hydro Project

30

60

39x42x75

2,45,500

3 HP

Ravi Power
Press

50

45

40x41x80

3,05000

4.5 HP

Power Press

Turret punch Press

Tonnage 200 Ton
Stroke Length 27mm
Max Thickness 6mm

Hit Rate 500 SPM

Turret Punch Press

Feeder

De coiler

Manufacturer
(Model)

Type

Max. Width

Max.
Thickness

SPM

Dimension

Cost(Rs
)

Jay shanti
pneumatic
feeder(Extra
mild series)

Pneumati
c

100 mm

2.5 mm

140

100 x
100 cm

45,1
80

Jay shanti
pneumatic
feeder(Extra
mild series)

Pneumati
c

100 mm

150 x
150 cm

39,2
50

2 mm

100

Combination Units Can also be used instead of using two

separate machines
Manufacturer

Max
Weight

Max
Width

Max
Thickness

Dimension(mm)

Cost(RS)

Press Room
Automation
& Feed
Fixtures(India)
Pvt. Ltd

2000
kg

150
mm

0.5 to
2.5 mm

2000 x 1000
x 1400

1,50,000

Manu
International
Pvt. Ltd

1050
kg

150
mm

1.5-5
mm

1500 x 1000
x 1100

2,10,000

Manufactu
rer

Type with
Max
Weight

Max.
Width

Power

Dimension
(mm)

Cost(RS)

Press room
automation
Pvt.
Ltd(vd5)

Single
Jaw
500 kg

150 mm

0.5 HP

1200x
1500 x
1400

40,450

Hertz
control Pvt.
Ltd

Double
Jaw
500 x 2
Kg

150 mm

0.5 x2
HP

2000 x
2000
x1800

55,050

Other Tool Room Machines

Lathe Machine

Bhavya Machine Tools

Drill Machine

Bhavya Machine Tools

Milling Machine

Bhavya Machine Tools

List of Machines
S No

Machine

2 Power Press

2 Combination Units

1 Lathe

1 Milling

1 Radial Drill

Other Facilities
Racks, Bins

Specs

Specs

Specs

8 Variable speed
Centre Height 165 mm
Max Swing Over Bed 330mm
Cross Slide Travel 225mm
Led Screw TPI 4 TPI

Drilling Capacity 25 mm
8 Variable Speed
Spindle RPM 110-2880
Max Drill Radius 910mm

Table Dim 800 x 175 mm

6 Variable Spindle Speed
Vertical Travel 450mm
Horizontal travel 400mm

Fork Lifter

Conveyer

PRODUCT COST
Material Cost = Strip Thickness x Width x Material density x per kg cost / Total no washers per day
Electricity Cost = Net Power Consumption x Per unit Cost / Total no of Washers per day

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

Rent=Rent per Day / Total no of Washer per day
Interest And depreciation = Interest + Dep. Per Day / Total no of Washer per day
MATERIAL INTEREST & ELECTRICITY
DIAMETER COST DEPRECIATION
COST

ID11
ID12
ID14
ID16
ID18
ID20
ID22
ID24

0.47
0.50
0.76
0.86
0.96
1.58
1.79
1.94

0.03
0.03
0.03
0.03
0.03
0.03
0.03
0.03

0.016
0.016
0.016
0.016
0.016
0.016
0.016
0.016

RENT

0.03
0.03
0.035
0.035
0.035
0.035
0.035
0.035

REPAIR &
PACKAGING PROMOTION MAINTENAN TRANSPORTATI
SALARY
COST
AL COST
CE
ON COST

0.16
0.16
0.16
0.16
0.16
0.16
0.16
0.16

0.030
0.040
0.050
0.050
0.050
0.060
0.060
0.060

0.07
0.07
0.07
0.07
0.07
0.07
0.07
0.07

0.09
0.09
0.09
0.09
0.09
0.09
0.09
0.09

0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1

Unit Cost
PRICE

Unit Selling
PRICE

0.99
1.04
1.31
1.41
1.50
2.13
2.35
2.49

1.29
1.31
1.35
1.83
1.95
2.78
3.05
3.24

BREAK EVEN ANALYSIS

TOTAL COST(TC)
TC=F+V
TC=F+QC.(1)
TOTAL REVENUE( TR)
TR=QP.......................(2)
Where
F=Fixed cost
V=Variable cost
Q=no. of units
C=unit assembling cost
P=unit selling cost
Number of units at BEP
Q=F/(P-C)
=6,141,000/(2.15-1.604)
=11,457,090 units
Revenue=QP
=11,457,090*2.15
=24632744

Fixed cost=machine cost + rent + promotion+ maintenance

=2,310,000+1,200,000+2,31,000
=6,141,000
Unit assembling cost(C)=material +electricity+ wages+ transportation
= 1.3275+0.0165+0.16+0.1
= 1.604

AT break even point(profit=0)

Total Revenue=Total Cost
QP=F+QC
or
Q=F/(P-C)

BREAK EVEN POINT

REPRESENTATION
Margin of Safety(MOS)
MOS=(sales at Q1)-(sales at Q)
=[(Q1-Q)]*P
=[12,000,000-11,457,090]*2.5
= 5,42,910
For Profit(TR>TC)
Profit=TR-TC
=Q1-(F+Q1*C)
=12,000,000-0.536*6,141,000
= 2,91,000

OUR TARGET
Grow with value customer together
Do effective things with the effective way
Help customer solve supply problem

Supply High quality part with competitive cost.

LIST OF PROPOSED INVESTORS

Bank Name
ABN bank
Axis bank
Bank of India
ICICI bank
IDBI bank
Punjab national bank
State bank of India
Yes bank
.........many more

Project Plan
12-Aug

1-Sep

21-Sep

11-Oct

31-Oct

20-Nov

10-Dec

TEAM PLANING

LITERATURE SURVEY
MARKET SURVEY
DESIGNING
COST ANALYSIS
FINAL LAYOUT OF PROPOSAL
FINAL REPORT

Start Date
Days Completed
Days Remaning

REFERENCES

Tool design by Cyril Donaldson, Donaldson MN.

Fundamentals of press working by David Alkire Smith
Bralla, James G. (1999). Design for Manufacturability Handbook.McGraw-Hill.
Carlon fastener Survey, Google Survey for fastener
Database of Swarna Fasteners and DM Enterprises
www.wikipedia .com
Google Database
PROJECT PROFILE ON M.S. AND HIGH TENSILE NUTS AND BOLTS By Micro, Small & Medium
Enterprises
Project Profile on the establishment of Nails producing Plant By Development Studies Associates (DSA)
FORECASTING FUNDAMENTALS

Thank You