|
Automobile Control Cables
| Product Code |
: |
374846006
|
| Quality and Standards
|
: |
IS 1978 |
| Production
Capacity |
: |
Qty. : 60,000 dozens
(per annum)
Value : Rs. 34.2 Lakhs |
| Uploaded
on |
: |
May
2007 |
Introduction
Auto control cables are widely used in
various controls of two/three wheel vehicles. Twisting of
desired/required number of S.S. wires, of standard wire gauge
of different diameter into one cable makes these. The numbers
of S.S. wires of standard gauge depends upon the end use of
the auto control cables like brake wire, clutch wire, accelerator
wire etc. Each type of cable is of different size depending
upon the specific purpose of the cable. The S.S. standard
guage wires are twisted in the twisting machine and cut to
the required length. One end of the cable is butted and dipped
in the molten zinc to avoid ends opening and at the other
end of the cable a Zinc stopper of required size/design is
fixed by Die- casting process.
The Auto control cables are the fast moving
spares used in two/three wheel vehicles and have very good
replacement market. These cables enable the driver to control
the various vehicle functions, and have a very wide market
all over the country. The machines, equipment and raw material
for manufacturing these cables are easily available and the
technology is fully indigenised. The Unit can be set up in
all major cities or near the city area and requires very nominal
investment in plant and machines.
Market Potential
Auto control cables have a very wide and
never ending replacement market, as the various control cables
have to be replaced in any Scooter, Motorcycle, Auto Rickshaw,
Moped etc. These are always required by Mechanics and Service
stations. Different cables for different end use are packed
in printed poly bags and marketed in dozen packing through
the Auto part dealers/shops.
Basis and Presumptions
The project report has been prepared keeping
in view the following basis and presumptions while calculating
the cost of project and that of production:
1. Unit will run 8 hours per day for 300
working days in a year.
2. Unit will manufacture all types of Auto Control Cables
for two/three Wheelers for brake, clutch, accelerator etc.
3. Poly bags are got printed as per the requirements from
outside.
4. Rates in respect of Machines and Equipment are based upon
the rates quoted by a particular manufacturer.
5. Rates of Raw material and other inputs
are based upon those prevailing in local market.
6. Unit will be running on single phase power motors.
Technical Aspects
Process of Manufacture
S.S. wire of required standard wire gauge
are reeled into the bobbins on the reel winder and loaded
onto the bobbins holder of the wire twisting machine. Now
with the help of wire twisting machine the required number
of S.S. wires are twisted and converted into a single stranded
wire of continuos length. The number of S.S. wires and gauge
depend upon the type and use of Auto control cable to be made.
The stranded/twisted cable thus made is
cut with the help of wire cutting machine into the required
size. One end of this wire is butted and dipped into molten
Zinc to avoid opening of strands of the cable. At the other
end of the cable a zinc stopper of required design/size is
fixed with help of a die on a die-casting Machine. The cables
thus made are checked/inspected and packed in printed poly
bags for marketing.
Implementation Schedule
The implementation schedule for the project
will be as under:
i) Preparation of project report after
getting current rates for Machines and Raw material.
ii) Arrangement for shade (rented) and electricity connection.
iii) Provisional Registration.
iv) Arrangement of Finance and placement of orders for Machinery
and Equipment.
v) Procurement and Installation of Machinery & Equipment.
vi) Procurement of Raw material.
vii) Commencement of production.
Process Flow Chart
| |
S. S. Wires |
| |
† |
| |
Reeling into Bobbins
|
| |
† |
| |
Twisting on Wire Twisting
Machine |
| |
† |
| |
Cutting to Required Size
on Wire Cutting Machine |
| |
† |
| |
End Finishing and Dipping
into Molten Zinc |
| |
† |
| |
Flowering of Other end
and Stopper Casting |
| |
† |
| |
Inspection |
| |
† |
| |
Packing |
| |
† |
| |
Store/Despatch |
Quality Control and Standards
The Bureau of Indian Standards has laid
down following Indian Standard for Auto Control Cables IS
1978.
Production Capacity
Based upon the single shift working of
8 hours per day and taking 25 working days in a month, the
production of the unit will be as under:-
| Production (per year)
|
60,000 Dozens |
| Value |
Rs. 34.2 Lakhs |
Motive Power
Power requirement for the unit will be
5 HP (approx.) with single phase supply.
Pollution Control
The production activities are very simple
in nature and there is no pollution involved. However, while
melting zinc provision for exhaust of gases be made through
a small chimney and exhaust muffler.
Financial Aspects
A. Fixed Capital
| (i) Land and Building
|
Amount
(In Rs.) |
| (i) Land 100 sq. mtr.
@ Rs. 6000 per sq. mtr including registration |
600000 |
| (iii) Total built-up
area 100 sq. mtrs.@ Rs 5000/- sq Mtr |
500000 |
| Total civil cost= cost
of land + building (i) |
1100000
|
(ii) Machinery and equipments (proposed)
| Sl. No.
|
Particulars
|
Qty. |
Rate |
Amount
(In Rs.) |
| 1) |
Wire twisting machine
(19 bobbins-1 hp motor) |
4 |
25000 |
100000 |
| 2) |
Pressure Die Casting
machine |
1 |
50000 |
50000 |
| 3) |
Compressor (1 HP motor)
|
1 |
18000 |
18000 |
| 4) |
Size Cutter |
1 |
2000 |
2000 |
| 5) |
Flower Machine |
1 |
5000 |
5000 |
| 6) |
Hand Press |
1 |
3000 |
3000 |
| 7) |
Reel Winder |
1 |
4000 |
4000 |
| 8) |
Grinder |
1 |
5000 |
5000 |
| 9) |
Hand Cutter |
2 |
800 |
1600 |
| 10) |
Dies (For Die-casting)
|
6 |
6000 |
36000 |
| 11) |
Shearing Machine |
1 |
5000 |
5000 |
| 12) |
Small Bobbins |
100 |
17 |
1700 |
| 13) |
Big Bobbins |
20 |
120 |
2400 |
| 14) |
Poly Bags sealing machine
|
2 |
1000 |
2000 |
| 15) |
Jigs Fixture and other
tools etc. |
L.S. |
|
20000 |
|
Total
|
255700 |
| Installation
and transportation charges @ 15% |
38355 |
|
Total
|
294055 |
| Office Equipment
and Furnitures |
40000 |
|
Total (ii)
|
334055 |
| iii Preoperative
Expenses |
30000 |
| Total
Fixed Capital (i)+(ii)+(iii) |
1464055 |
B. Working Capital (per month)
(i) Salary and Wages
| Sl. No.
|
Particulars
|
Nos. |
Rate |
Amount
(In Rs.) |
| 1. |
Production supervisor
cum-Inspector |
1 |
15000 |
15000 |
| 2. |
Skilled Workers |
2 |
6000 |
12000 |
| 3. |
Semi–skilled Workers
|
3 |
5000 |
15000 |
| 4. |
Un–skilled Worker-cum-Helper
|
1 |
3000 |
3000 |
|
Total
|
45000 |
(ii) Raw Materials
| Sl. No.
|
Particulars
|
Rate |
Qty. |
Amount
(In Rs.) |
| 1. |
SS Wire per Kg |
70 |
1800 |
126000 |
| 2. |
Zinc Alloy per Kg. |
80 |
150 |
12000 |
| 3. |
L.P.G. cylinders |
600 |
5 |
3000 |
| 4. |
Packing Material (poly
bags printed) |
|
L.S. |
10000 |
|
Total
|
151000 |
(iii) Utilities (per month)
| Sl. No.
|
Particulars
|
Nos..
|
Amount
(In Rs.) |
| 1 |
Power requirement- 5
HP single phase supply
Electricity Charges |
|
4103 |
| 2 |
Other Misc. Expenses
|
L.S. |
3000 |
|
Total
|
7103 |
(iv) Other Contingent Expenses
| Sl. No.
|
Particulars
|
Nos..
|
Amount
(Rs.) |
| 1 |
Maintenance/Repair |
L.S |
2000 |
| 2 |
Postage and Stationery
|
L.S |
2000 |
| 3 |
Travelling and Conveyance
|
L.S |
8000 |
| 4 |
Misc. and Insurance |
L.S |
2000 |
|
Total
|
14000 |
(v) Working Capital (per month)
| Sl. No. |
Particulars |
Amount
(In Rs.) |
| 1 |
Raw Material |
151000 |
| 2 |
Salary/Wages |
45000 |
| 3 |
Utilities |
7103 |
| 4 |
Other Contingent Expenditure
|
14000 |
| |
Total
|
217103 |
C. Total Capital Investment
| (i) Fixed Capital |
1464055 |
| (ii) Working capital
for 2 Months |
217103 |
|
Total
|
1681158 |
Financial Analysis
(1) Cost of Production (per year)
| Sl. No. |
Particulars |
Amount
(In Rs.) |
| 1 |
Total Recurring expenditure
|
2605236 |
| 2 |
Depreciation on Building
@ 5 % |
55000 |
| 2 |
Depreciation on Machines
@ 10% |
29406 |
| 3 |
Depreciation on Office
Equipment @ 20% |
8000 |
| 4 |
Interest on capital @
12% |
201739 |
| |
Total
|
2899381 |
(2) Turnover (per year)
| Sl. No. |
Particulars |
Amount (In Rs.) |
| 1 |
By sale
of 60000 Dozens of auto control cables of various types
at an average rate of Rs. 60 per dozen |
3600000
|
| |
Less sale expenses @
5% |
180000 |
| |
Total
|
3420000 |
| (3) Profit (per year)
|
= |
520619 |
| (4) Profit % on Sales
|
= |
15.22 |
| (5) Rate of Return |
= |
30.97 |
(6) Break-even Point
| Fixed Cost |
(In Rs.) |
| Depreciation on Building
@ 5 % |
55000 |
| Depreciation on Machines
@ 10% |
29406 |
| Depreciation on Office
Equipment @ 20% |
8000 |
| Interest on capital @
12% |
201739 |
| 40% of staff and labour
|
216000 |
| 40% of Other Contingent
Exp. and Utilities |
67200 |
|
Total
|
577345 |
| B.E.P |
= |
577345 × 100
------------------ |
| |
|
577345 + 520619 |
| |
|
|
| |
= |
52.58 |
Addresses of
Machinery and Equipment Suppliers
1. M/s. Lolita Manufacturing Works (Regd.)
9340, Katra Ganga Vishan,
Gaushala Road, Kishanganj,
New Delhi-110006
2. M/s. Ajit Wire Products
Gokul Da Bagh, Near 100 Ft. Road,
Amritsar-143006
3. M/s. S. S. Sabharwal and Sons
664, Military Road, Anand Parbat,
Industrial Area,
New Delhi-110005
Raw Material
Local Market.
Contact for more information:
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
|
