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Project Report on Manufacturing of Engineering Fabrication & Machinery Components for EOT Cranes, Valves, Pressure Vessel, Conveyors

& Rollers.

Process Flow Diagram :

The following process flow diagram is followed for the unit operations as per sequences.
Cutting of MS/SS Plate, Round, Rolled Section. Bending Grinding Power Press Drilling Grinding

Lathe Machining For Components

Machining

Assemble

Testing

II PLANT & MACHINERY

Plant & Machinery Electrical Welding Set Tig & CO, Welding Machine Mig Welding Machine Line Cutter Drilling - Machine Gas Cutting Set Hyd. Press 70 MT Cap X 1 Mt Gap Grind inn M/c Bench Drilling M/c Magnetic Drilling Machine Hand Grinder Total

Quantity 8 no 1 no I no 1 no 2 no 5 no 1 no 1 no 1 no 3 No 6 no

Amount (Rs.) 5,40,000/ 80,000/ 1.35,000/ 10.000/ 5O.OO0/20,000/80.000/ 4,500/ 22,000/ 60,000/ 15,000/ 10.16,500/13,50,000/1,00.000/ 1,65,000/9,00,000/2,10.000/ 2,10,000/1,90,000/10,00,000/4,00,000/3,50,000/4,50,000/2,50,000/35,000/5.000/20,000/30,000/35,000/12,000/20,000/1,20,0011/9,500/4,500/58,66,000/2,34,500/61,00,500/71,17,000/-

Heavy Duty Power Press 500 Ton capacity with motor and 1 no Electrical accessories X 3 Mts Gap Welding Rectifier Plasma (air) Cutting Machine Plate Rolling Machine capacity up to 50 mm with Motor Electrical accessories Lathe Machine 10 Length, Free chuck and Electrical panel board Lathe Machine 8.5 Ft Length, Free Chuck and Electrical panel board Lathe Machine 6 Ft length, Free Chuck and Electrical panel board C.N.C Lathe Machine Hydraulic Operated Surface Grinding Machine Vertical Milling Machine Universal Milling Machine Radial Drilling Machine 1 Capacity Magnetic Drilling Machine Bench Grinding Machine Handing Grinding Machine Electrical Hacksaw 12" Capacity AirConipressor3HP Height Gauge 12" Height Gauge 24" Inspection Surface Plate Micro Meter 0 mm to ISO mm Dial Indicator Total Add VAT@ 4 % against C Form Total Proposed Machinery Total Plant & Machinery I No 1 no 1no 1 No 1No 1 no 1 no 1N0 1 No 1 No 1 No 1 No 2 No 1 No 1 No 1 No 1 No 1 No 1 No

7. Cost of the project : I) Land & Building : II) Plant & Machinery : III) Working Capital Requirement Total Sources of Finance (Proposed) : I) a) b) a) b)

Amount Rented Rs.71,17,000/Rs 35,65,000/Rs. 105,82,000/-

Promoter's Contribution on Fixed Capital : Rs. 10,16,500/Term Loan for Plant & Machinery (Proposed) : Rs. 61,00,500/II) Working Capital Margin @ 10 % : Rs. 3.45 Lakhs Working Capital Loan (CC Loan) :Rs. 31.20 Lakhs Total Rs. 105.82 Lakhs 10 Subsidy from State Govt. on Plant & Machinery Investment @ 25% Rs. 15,25,000/-

Calculation of Recurring Expenses a) Cost of Manpower ( Per Month) Particulars Manager Skilled Worker Un skilled Worker Accountant/Sales Personnel/Office Assistant Watchman / Assistant Total Number 1 10 10 2 2 25 wage/Salary 10,000/5000/4500/5000/4,000/Amount(Rs.) 10,000/50,000/45,000/10,000/8,000/1,23,000/-

b) Utility Expenses : ( Per Month) Electricity & water ( 75X25X8X.70X6.0/-) c) Raw Materials (( Per Month) Items Quantity MS / SS Plate, Round & Rolled 20 MT Including Transportation & Duty. Total d) Miscellaneous other Expenses (Per Month): Items Rent for Sheds Y-73 & Y-76 Telephones/Postage/Stationery Repair/ Maintenance Consumables Transportation/Travel Charges Insurance Premium/Audit Fee/Tax Rate Amount(Rs.) Rs. 60/- average 12,00,000/Rs. 12,00,000/Amount(Rs) 21,665/2000/4,000/4,000/3,000/3,000/Ks. 63,000/-

Packaging & Forwarding Selling & Advertisement Misc. Other Contingency Expenses Total e) Total Recurring Expenditure ( Per Month) a) Raw Materials b) Manpower c) Utility d ) Misc Other Expenses Total Rs. 12,00,000/Rs. 1,23,000/Rs. 63,000/Rs. 47,000/Rs. 14,33,000/-

3,000/3,000/3,345/47,000/-

V) Working Capital Assessment: ( at 70% Capacity Utilization)Particulars Requirement ( Working Rs. In Lakhs) capital of working Cycle capitals 12.00 1 Months 7.16 2 weeks 8 96 1/2 Month 6.55 1/2 month -----34.05 Working Capital Margin @ 10% 1.20 072 0.90 0.66 3 45 Amount of Working capital Loan (Rs in Lakhs) 10.80 6.44 8.06 5.89 31.20

Raw material Work In Progress (WIP) Finished Goods Stock Bills Receivable Total

Considerations: Finished Goods Stock - Recurring Expenses X 1.25 ( At 25% Higher Margin) Bills Receivable = Recurring Expenses excluding manpower expenses

Interest Calculation on Working Capital Loan : i) Total Loan : ii) Rate of Interest iii) Total Loan Interest Rs. 31.20 Lakhs @ 11.00% Rs. 3 43 Lakhs

PROJECTED BREAK EVEN POINT (B.E.P.)


YEAR IV

1 A VARIABLE COST TOTAL DIRECT OF PROCESSING(80%) MANUFACTURING 5. K) GROSS RECIEPTS A/INCOME TOTAL A (ANNEX

II

III

132.80 147.45

157 87 158 28 158 2S

209.52 224.486 239.451 239.451 239.451

C CI D (i) (ii) (iii) (iv)

(ANNEX 5. B) CONTRIBUTION CONTRIBUTION @ 100% C.U. FIXED COST TOTAL INDIRECT COST TOTAL DEPRECIATION (W.D.V.) INTEREST ON T.L INTEREST ON W.C.LOAN TOTAL

C (B-A) C1

76.72 77.04 81.58 81.17 81.17 109.6 102.718 101.975 101.465 101 465 29.16 9.15 6.62 3.43 48.36 44.12 31.21 7.78 5.40 343 47.82 46.55 3326 6.61 3.88 3.43 47.18 46.26 33 26 5.62 2.41 3.43 44.72 44.07 33.26 4.78 092 343 42.39 41.78

BREAK EVEN POINT : D/C1 %AGE E

AVERAGE B.E.P. BREAK EVEN SALES AVERAGE MONTHLY SALES (B.E.P)

44.56% 93.357 RS. LAKH PER ANNUM RS. 7.78 Lakhs

YEAR CALCULATION OF RETURN ON CAPITAL INVESTMENT I A RETURN ON CAPITAL EMPLOYED 1 NET PROFIT AFTER TAX 2 Depreciation on Fixed asset added II III IV V

17.15 17.10 20.59 22.22 24.06 9.15 7.78 6.61 5.62 4.7 8 26.30 24.88 27.20 27.84 28.84 61 12.29 73.29 35.89 53.9838 54.20 40.60 12.29 12.29 66.49 52.89 37.42 51.42 27.00 12.29 39.29 70.85 26.50 12.29 38.79 74.34

B CAPITAL EMPLOYED 2 FIXED CAPITAL 3 Shared capital Total of 2*3 C RETURN ON CAPITAL EMPLOYED D AVERAGE RETURN ON CAPITAL EMPLOYED - % AGE

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