STEEL FABRICATION INDUSTRY (CAP:800 TONS PER MONTH)
[EIRI/EDPR/4835] J.C.: 3056XL
1. Introduction
Fabrication is the process of constructing products by combining typically standardized parts using one or more individual processes. For example, steel fabrication is the production of metal structures using a range of processes such as cutting, bending and assembling. Metal fabrication will often form a complete assembly made from smaller sub-assemblies for use with readily available standard sections. This is achieved with computer-aided designs (CAD) that are often programmed using computer numerical control (CNC) technology which communicates directly with machinery on the factory floor. By using these technologies, the quality standards of production are increased and higher quality assemblies are produced. This ensures a more accurate and quicker steel erection time on site, which is vital in high volume production, reducing cost for the customer through better material utilisation and faster assembly times.
Fabrication and manufacturing are industrial terms linked to the process of production or construction. Often, the two processes are confused, yet they are very different from each other.
The key difference between manufacturing and fabrication is how much of the process a job involves. Fabrication involves the assembly of standard or specialized parts to form parts of a product to be used in the manufacture of the finished piece. Manufacturing, however, is a start to finish movement, from the creation of parts through to the final assembly to produce a finished product, often using areas of fabrication within the manufacturing process.
COST ESTIMATION
Rated Plant capacity = 32 MT/Day
Land & Building (16000 Sq.Mtr) Rs. 1.50 Cr
Plant & Machinery Rs. 4.00 Cr
Working Capital for 2 Month Rs.13.79 Cr
Total Capital Investment Rs. 19.79 Cr
Rate of Return 56%
Break Even Point 34%
CONTENTS
INTRODUCTION
FABRICATION COMPRISES OR OVERLAPS WITH VARIOUS METALWORKING SPECIALTIES:
MARKET OVERVIEW
INCREASING NUMBER OF MANUFACTURING PLANTS
METAL FABRICATION SAFETY
IDENTIFY ANY RISKS BEFOREHAND
PROVIDE PROPER TRAINING FOR YOUR EMPLOYEES
ENSURE THAT GUIDELINES AND HAZARD SIGNS ARE VISIBLE AT ALL TIMES
SUPPLY PERSONAL PROTECTIVE EQUIPMENT
INSTALL FUME EXTRACTION SYSTEMS
CONDUCT REGULAR INSPECTIONS AND MAINTENANCE
PRODUCTION/FABRICATION PROCESS
FABRICATION PROCESS
PROCESS FLOW
SWOT ANALYSIS
INFRASTRUCTURAL FACILITIES
THE FOLLOWING COMMON INFRASTRUCTURAL FACILITIES ARE BEING PROPOSED
LATHE MACHINE:
BENDING MACHINE:
DRILL MACHINE:
SHEET CUTTING MACHINE:
CUT OFF MACHINE:
PLASMA CUTTING MACHINE:
ARC WELDING MACHINE:
POWER PRESS:
ANGLE GRINDER:
SHEET BENDING MACHINE:
PAINTING:
EXPECTED OUTCOME
THE PROJECT WILL BE BENEFICIAL WITH RESPECT TO
RAW MATERIALS SUPPLIERS
DEGREASING CHEMICAL
MIG WELDING WIRE ELECTRODE
CHEMICALS
COATING POWDER
BIS SPECIFICATION
PLANT & MACHINERY SUPPLIERS/CONSULTANT
PLASMA CUTTING MACHINE
CNC PRESS
PUNCHING PRESS
POWER PRESS
SHEARING MACHINE
DRILLING MACHINE
GRINDING MACHINE
PRECISION MEASURING TOOLS
EOT CRANES
D.G. SETS
POWER TRANSFORMERS
ETP PLANTS
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSOR
PLATEFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
ELECTRICAL MEASURING INSTRUMENTS
PRELIMINARY LAYOUT
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
WASTE MANAGEMENT
HEALTH SAFETY AND ENVIRONMENT
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HSE REQUIREMENT
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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