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Tumbler Locks
Introduction
As is revealed from the name itself, Tumbler
Locks are used for locking of doors, shutters of houses/shops.
Tumbler locks are a kind of pad locks. The body of the tumbler
lock is pressure die casted from Aluminium or Zinc alloy.
The tumbler locks are available in different shapes and sizes,
among them the most common are 20, 25, 30, 35 and 46 mm. These
locks are opened with the help of a key made from either brass,
mild steel or die casted non ferrous metal, To operate the
lock, the key is inserted in the key hole provided at the
bottom of the
| Product Code |
: |
343301008 |
| Quality and Standards
|
: |
IS 4230:1967 |
| Production Capacity |
: |
Qty. : 2.40 Lakh Nos.
(per annum)
Value : Rs. 148.8 Lakhs |
| Uploaded
on |
: |
April
2007 |
lock, opposite side to shackle. These
locks are used to lock windows, Almirah, trunks etc.
The alloy used to manufacture such locks is known as “Mazak”
Alloy. Mazak alloy is an alloy having Zinc as the base material.
The composition of other elements in Mazak alloy used for
this purpose is as follows:
| Aluminium |
: |
4% |
| Copper |
: |
2.7% |
| Magnesium |
: |
0.1 to 0.3% |
The alloy having the above composition
is hard and strong and can be easily diecasted. Pressure die-casting
has been widely used to produce sound and strong castings
of accurate dimensions as they need no final machining to
size. The surface is smooth and good.
Market Potential
Since Lock is an essential household item,
its demand is ever increasing.Tumbler lock being a stout lock
is considered to be a good quality lock.
Basis and Presumptions
It is considered that the unit is run
300 days in a year with 16 hours per day. The rates for raw
material, labour, machinery etc. have been taken as prevailing
at the time of preparation of project scheme. Margin money
requirement, terms of loan, interest rates may vary from time
to time and institution to institution providing finance,
which may be verified. In this project profile, the rate of
interest has been considered as 12% per annum.
Implementation Schedule
It is estimated that it may take 4-5 months
from conception to commercial production including preparation
of project report, finalization of loan from financial institutions,
procurement of machinery, erection and commissioning, recruitment
of staff and labour, registration and clearance from authorities
Technical Aspects
Process of Manufacture
Tumbler lock consists of the following
main components: (a) body (b) cylinder (c) levers and its
mechanisms (d) shackle and (e) Tumbler key.
(a) Body: Housing of lock mechanism, which
contains all the parts except key and shackle is known as
body of the tumbler lock. However, one end of the shackle
is also fitted in the body. The body of the lock is pressure
die casted from Aluminium or Zinc alloy called Mazak Alloy.
After pressure die casting, the burrs and sharp edges are
removed and polished. Body can also be painted or plated depending
upon the requirement.
(b) Cylinder: Cylinder is also pressure die casted part from
Aluminium or Zinc Alloy. It is the housing for lever tumbler
mechanism. It is fitted inside the body of lock during assembly.
(c) Lever and Lever Mechanism: Levers are mostly press cut
from brass or mild steel sheets. These levers along with springs
are fitted inside the cylinder which rotates inside the body
to keep open or close the lock with the help of key.
(d) Shackle: It is that part of the lock which passes through
the staple loop on the door and is engaged to lock bolt when
pushed inside the lock and key is turned lock. Shackle are
made from mild steel rods, cut to size, notched and bent to
the shape. These are generally nickel plated.
(e) Key: The key is an important member of lock and key arrangement.
It is made of brass or mild steel. It is flat, has long bit
or blade with V groves made on one or both edges according
to the lever mechanism.
All these components are manufactured
in various sizes and shapes of the lock. Manufactured components
are then assembled and movement of lever cylinder, shackle
fixed in position with the help of a pin. The tumbler locks
are painted or nickel plated before packing for dispatch.
Quality Control
and Standards
Tumbler locks are to be manufactured as per IS 4230 :1967.
Since the locks are directly related to the safety of house–hold
the manufacturer must ensure the following in addition to
IS specification:
(a) All the components must be in accordance with the dimensional
accuracy. Manufacturing defects in no case be allowed. The
raw material must conform to the specifications.
(b) Strength of cylinder and shackle must be ensured and it
should not lead to failure/break on jerks.
(c) The components, particularly levers and keys should be
noninterchangeable.
(d) Smooth function of the lock must be ensured.
Production Capacity (per annum)
| Item |
Qty. in Nos |
Price Per Piece |
Total
(In Rs.) |
| Tumbler Lock Size 20
and 25 mm |
96000 |
55 |
5280000
|
| Tumbler Lock Size 30
and 35 mm |
120000 |
65 |
7800000
|
| Tumbler Lock Size 40
mm |
24000 |
75 |
1800000
|
| Total |
240000
|
|
14880000
|
Pollution Control
No special arrangements are suggested
for pollution control. However, proper disposal of electroplating
waste must be ensured.
Energy Conservation
No special energy conservation measures
are to be taken. However, energy efficient machines have been
suggested.
Financial Aspects
A Fixed Capital
| (i) Land and Building
|
Amount
(In Rs.) |
| (i) Land 300 sq. mtr.
@ Rs. 5000 per sq. mtr including registration |
1500000 |
| ii) Cost of land development,
fencing, approach road, inside roads, land scaping, drainage
etc. @ Rs. 1000 per sq. mtr. |
300000 |
| (iii) Total built-up
area 250 sq. mtrs. as follows: |
|
| Administrative building
50 sq. mtrs. construction cost @ Rs. 7,500 per sq. m |
375000
|
| Hall cum shed 150 sq.
mtrs. construction cost @ Rs.6000 per sq. mtr. |
900000
|
| Stores, staff canteen
etc. 50 sq. mtrs. @ Rs. 6,000 per sq. mtr. |
300000 |
| Water System (including
Bore Well + over head tank etc) |
500000 |
| Total civil cost= cost
of land + building |
3875000 |
(ii) Machinery and Equipment
| Sl. No. |
Description |
Ind./ Imp. |
Qty. |
Rate |
Total
(In Rs.) |
| 1. |
Hand operated Hot chamber
Pneumatic pressure die casting Machine upto 400 gm.capacity
with double Toggle Adjustable all steel made ejector and
high speed diesel burner and electricals etc. |
Ind. |
5 |
120000 |
600000
|
| 2. |
Power Press 10MT capacity
with 1HP motor and electricals |
Ind. |
2 |
95000 |
190000
|
| 3. |
Air compressors 150 to
200 lbs Sq. inch capacity with 1 HP motor suitable for
Pressure die casting machine above at S.No. (1). |
Ind. |
5 |
20000 |
100000
|
| 4. |
Bench Drilling machine
10 mm drill dia capacity with 1/2 HP motor and electricals.
|
Ind. |
2 |
16000 |
32000
|
| 5. |
Bench Grinder 200 mm
dia wheel and 3/4 HP motor |
Ind. |
1 |
9000 |
9000 |
| 6. |
Lathe 1500 mm bed with
2 HP motor and electricals floor model |
Ind. |
1 |
125000 |
125000 |
| 7. |
Electroplating plant/painting
equipments |
Ind. |
L.s. |
|
150000 |
| 8. |
Generator Set(electricity
Backup) |
|
|
|
300000 |
|
Total
|
1506000 |
| Erection
and Commissioning @ 10% of the cost of the machinery |
150600 |
| Cost of Dies,
Tools and Measuring instruments |
150000 |
| Cost of Office
equipment and furniture |
100000 |
|
Total(i)
|
1906600 |
| (iii) Pre-operative
Expenses |
50000 |
| Total Fixed
Capital ( i+ii+iii ) |
5831600 |
B. Working Capital (per month)
(i) Personnel
| Sl.No. |
Designation |
Nos. |
Salary (Rs.) |
Amount
(In Rs.) |
| 1. |
Foreman |
2 |
10000 |
20000 |
| 2. |
Skilled workers |
10 |
6000 |
60000 |
| 3. |
Semi-skilled workers
|
16 |
5000 |
80000 |
| 4. |
Clerk-cum-Typist |
1 |
8000 |
8000 |
| 5. |
Watchman/Peon |
2 |
3000 |
6000 |
|
Total
|
174000 |
| Add: Perquisites
@ 22% |
38280 |
|
Total
|
212280 |
(ii) Raw Material
| Sl. No. |
Particulars |
Ind./Imp. |
Qty. |
Unit |
Rate/Unit (Rs.) |
Amount
(In Rs.) |
| 1. |
Mazak Alloy |
Ind. |
3.00 |
MT |
150000 |
450000 |
| 2. |
Springs |
Ind. |
200 |
Kg |
50 |
10000 |
| 3. |
MS Sheet 24 SWG |
Ind. |
1000 |
Kg |
45 |
45000 |
| 4. |
Misc. items such as electroplating
salt, paint, oil, diesel etc. |
Ind. |
LS |
|
- |
200000 |
|
Total
|
705000 |
| (iii) Utilities |
(In Rs.) |
| Power 4000 kWH units
@ Rs. 5.5 /unit |
22000 |
|
Total
|
22000 |
| (iv) Other Contingent
Expenses |
(In Rs.) |
| (1) Postage and Stationery
|
3000 |
| (2) Transportation |
15000 |
| (3) Telephone |
3000 |
| (4) Maintenance and Repair
|
3000 |
| (5) Packing |
10000 |
| (6) Insurance |
2000 |
| (7) Misc. Expenses |
10000 |
| (8) Marketing Expense
|
20000 |
|
Total
|
66000 |
| (v) Total Recurring Expenditure
(per month) (i) + (ii) + (iii) + (iv) |
1005280 |
| (vi) Working Capital
for 1½ months 1005280 x 1½ |
1507920 |
|
Say
|
1507920 |
C. Total Capital Investment
| (i) Fixed Capital |
5831600 |
| (ii) Working Capital
for 1½ months |
1507920 |
| Total |
7339520 |
Financial Analysis
| (1) Cost of Production
(per annum) |
(In Rs.) |
| Total recurring cost
|
12063360 |
| Depreciation on Machinery
@ 10% |
150600 |
| Depreciation on Building@5%
|
193750 |
| Depreciation on Dies
and Tools @25% |
37500 |
| Depreciation on Furnitures
@ 20% |
20000 |
| Interest on Capital Investment
@ 12% |
880742 |
| Total |
13345952 |
(2) Turnover (per year)
| Item |
Qty. Nos. |
Rate (Rs.) |
Total (Rs.) |
| Tumbler Lock Size 20
and 25 mm |
96000 |
55 |
5280000 |
| Tumbler Lock Size 30
and 35 mm |
120000 |
65 |
7800000 |
| Tumbler Lock Size 40
mm |
24000 |
75 |
1800000 |
| Total
|
14880000 |
| (3) Profit (per year)
|
= |
Rs. 14880000-13345952
|
| |
= |
1534048 |
| |
|
|
| (4) Percentage Profit
on Sales (Net Profit Ratio) |
| |
= |
Net Profit (per year)
× 100
-------------------- |
| |
|
Turnover |
| |
|
|
| |
= |
1534048× 100
------------------- |
| |
|
14880000 |
| |
|
|
| |
= |
10.31 |
| |
|
|
| (5) Rate of Return |
| |
= |
Net Profit × 100
--------------------------- |
| |
|
Capital Investment |
| |
|
|
| |
= |
1534048×
100
------------------- |
| |
|
7339520 |
| |
|
|
| |
= |
20.9 |
(6) Break-even Point
| Fixed Cost |
(In Rs.) |
| Depreciation on Machinery
@ 10% |
150600 |
| Depreciation on Building@5%
|
193750 |
| Depreciation on Dies
and Tools @25% |
37500 |
| Depreciation on Furnitures
@ 20% |
20000 |
| Interest on Capital Investment
@ 12% |
880742 |
| Insurance |
24000 |
| 40% of Salary and Wages
|
1018944 |
| 40% of Other Contingent
Expenses (excluding Insurance) |
307200 |
|
Total
|
2632736 |
| (ii) Profit |
|
1534048 |
| |
|
|
| B.E.P |
= |
Fixed Capital ×
100
----------------------- |
| |
|
Fixed Capital + Profit
|
| |
|
|
| |
= |
2632736 × 100
----------------------- |
| |
|
2632736 + 1534048 |
| |
|
|
| |
= |
63.18 |
Addresses of
Raw Material Suppliers
1. M/s. Basant Industries Corpn.
Industrial Area ‘B',
Ludhiana
2. M/s. Hind Engg. Works,
Opp. D.S. College,
Aligarh
3. M/s. Singhal Engg. Works
Subhash Road,
Aligarh
4. M/s. Daulat Industries Corporation
Civil Lines,
Ludhiana
5. M/s. Bhag Sons,
Indl. Area ‘B',
Ludhiana
6. M/s. Kalsi Machinery Mfg. Pvt. Ltd.
G. T. Road,
Ludhiana
7. M/s. P. K. Engg. Works
Opp. D.S. College,
Aligarh
8. M/s. Prakash Engg. Works
Agra Road,
Aligarh
9. M/s. James Engg. Works
31, Thembur Chetty Street,
Chennai
10. M/s. Atlas Engg. Works
G.T. Road,
Batala
11. M/s. Perfect Machine Tools Co.
123-Mount Road,
Chennai
12. M/s. Hindustan Metal and Engg.Co.
B–10, End. Carpenter Street,
Mumbai
13. M/s. Komal Industries Corporation
51-Biggan Street,
Mumbai
14. M/s. Non-Ferrous Metal Corpn.
174, Sardar Vallabh Bhai Patel
Road, Mumbai
15. M/s. Bombay Metal Syndicate,
106-Kila Street,
Mumbai-4
16. M/s. Essential Machine Tools Pvt. Ltd.
5-Nyaymurthi, G.N. Vaidya Marg,
Bank Street, P.O. Box No. 2,
Behind State Bank, Fort,
Mumbai - 400001.
Contact for more information:
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
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