Detailed Project Report (DPR) on manufacturing shoes (safety boots and school shoes) using rubber powder

MANUFACTURING SHOES (SAFETY BOOTS
& SCHOOL SHOES) USING RUBBER POWDER
[CODE NO. 3182]  


Safety Boots are wide term and are sub divided into differet types of boots like  combat boots, Jungle boots, high altitude boots etc. The requirement is  increasing day by day. In addition to this boots with or without deviation are used by mines and steel workers. Police and Para Military forces, as such, there is wide scope for marketing this product.

School shoes are used for protecting the children foot from injuries due to stones nails, broken glass pieces infection from dust diet, mud, water and to feel conform during different climatic condition.

Children shoes in particular are very important in order to save the foot. School shoes are very common part of school uniform introduced by many Government and Public School.

Canvas shoes are used as footwear by all groups of people. It  is made of thick cloth and sole of soft rubber sheets.  Large number  of  variations  in  quality  of  canvas  sheet  and  sole materials  are  used for different purposes  and  selling  price. Canvas  shoes  are  available  in  different  sizes  and  designs suitable according to one's need and liking.

Traditionally, footwear was manufactured by hand assembling, preshaped  component parts on a lst or tree and vulcanizing in  a autoclave.   Although this method is still used but a great  deal of  advances  in machinery, equipment  and  automated  processes, thereby  reducing the high labour content of the  hand   assembled product.

The canvas footwear industry has also taken advantage of new developments  in  polymer  science &  technology  to  formula  to compounds which meet the new process requirements & give products with practically any desired feature.

COST ESTIMATION

Plant  Capacity                               :      500.00 Pairs/day
land & Building (1500 sq.mt.)    :    US$. 2.76  Lacs
Plant & Machinery                         :    US$. 66.00 Thousand
Working Capital for 2 Months    :    US$. 79.00 Thousand
Total Capital Investment             :    US$. 4.38 Lacs
Rate of Return                              :    30%
Break Even Point                         :    56%


INTRODUCTION    
USES AND APPLICATIONS    
CLASSIFICATION OF SAFETY SHOES    
SAFETY-TOE SHOES    
CONDUCTIVE SHOES    
FOUNDRY SHOES    
EXPLOSIVE - OPERATIONS (NON-SPARKING) SHOES    
ELECTRICAL HAZARD SHOES    
OTHER TYPES OF SAFETY SHOES    
CARE OF FOOT AND LEG PROTECTION EQUIPMENT    
SPECIFICATIONS FOR DIFFERENT    
TYPES OF SAFETY SHOES    
LEATHER SAFETY BOOTS AND SHOES [IS: 1989 (PART-1 & 2)-1986]:    
FIREMAN’S LEATHER BOOTS (IS: 4128-1980):    
ELECTRICAL SAFETY SHOES:    
CHEMICAL SAFETY SHOES:    
ELECTRICAL-CUM-CHEMICAL GUM BOOTS:    
SHOES SUITABLE FOR MINING OPERATIONS:    
MARKET SURVEY OF INDUSTRIAL SAFETY BOOTS    
INDUSTRIAL PROTECTIVE FOOTWEAR MARKET: BY TYPE    
INDUSTRIAL PROTECTIVE FOOTWEAR MARKET: BY APPLICATION    
OVERVIEW OF GLOBAL FOOTWEAR MARKET    
ASIA-PACIFIC FOOTWEAR MARKET SCENARIO    
VALUE CHAIN ANALYSIS    
B.I.S. SPECIFICATION    
RUBBER SOLE RAW MATERIAL    
THICKNESS    
MANUFACTURE OF SCHOOL SHOES    
THE PROCESS IS DIVIDED IN FOUR DEPARTMENTS VIZ;    
PROCESS FLOW DIAGRAM    
PROCESS OF MANUFACTURE FOR CANVAS SHOES FOR COAL MINES    
THE OUTLINE OF PROCESS OF MANUFACTURE IS AS FOLLOWS    
HOWEVER, THE COMPLETE PROCESS OF MANUFACTURE CAN
BE SPLIT INTO FOLLOWING MAJOR STEPS I.E.    
THE DETAILED STEPWISE PROCESS IS AS FOLLOWS    
ADHESIVE ATTACHMENT    
MOULDING PROCESS CAN BE CLASSIFIED INTO TWO TYPES.    
PROCESS FLOW SHEET FOR THE MANUFACTURE OF CANVAS SHOES
FOR COAL MINES    
PROPERTIES OF SHOE FABRICS (CANVAS) FOR COAL MINES    
PHYSICAL PROPERTIES:    
STRENGTH:    
TENSILE STRENGTH:    
TEAR STRENGTH    
STRECH:    
BALANCE OF STRENGTH & STRETCH:    
SHOE FABRIC SPECIFICATION    
TYPICAL SPECIFICATIONS OF SHOE LINING FABRICS    
SAME STANDARD SPECIFICATIONS OF SHOE LINING FABRICS    
RUBBER SOLE: ANCILLARY ITEM FOR CANVAS SHOE    
USES OF RUBBER IN FOOTWEAR TRADE    
USE OF VULCANISED SOLES AND HEELS    
FORMULATION OF SAFETY BOOTS (UPPER)    
FORMULATION OF SAFETY BOOTS (SOLE)    
FORMULATION OF SOLE FOR SCHOOL SHOES    
FORMULATION OF SOLE MAKING    
A. BLACK SOLE MIX    
B. BROWN SOLE MIX    
IMPLEMENTS & TYPES OF MACHINERIES SHOE LASTS    
COMPRESSION MOULDED FOOTWEAR    
MOULDING PRESSES CAN BE CLASSIFIED INTO TWO TYPES    
INJECTION MOULDING OF SOLES & HEELS    
RUBBER SOLE MANUFACTURING    
PLASTICIZING    
INJECTIONS    
AFTER FILLING    
COOLING AND MOULD RELEASE    
MANUFACTUREING PROCESS OF SAFETY BOOTS    
THE PROCESSING IS DIVIDED IN DEPARTMENTS VIZ.    
1. RUBBER SECTION    
2. COMPRESSION MOULDED INDUSTRIA
4. ASSEMBLY SECTION     
5. FINISHING & PACKING SECTION     
PREPARATION OF RUBBER MIX    
VULCANISATION OF SOLES    
PROCESS FLOWSHEET FOR MANUFACTURE OF SAFETY BOOTS    
MANUFACTURING PROCESS OF NITRITE BOOTS    
PROCESS OF SHOE MAKING    
CLICKING OR CUTTING DEPARTMENT    
CLOSING OR MACHINING DEPARTMENT    
LASTING & MAKING DEPARTMENT    
FINISHING DEPARTMENT AND THE SHOE ROOM    
TESTING AND INSPECTION OF SAFETY BOOTS    
INSPECTION OF FINISHED PRODUCT    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT AND MACHINERY    


APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET