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BATLA ENGINEERING COMP (AN INTRODUCTION ) BATLA ENGG. CO. IS A R&D COMPANY,INVOLVED IN THE MANUFACTURING OF AUTOMOBILES AND FILTERS FOR MARUTI AND TATA ) , M/S ELCON INDIA (VOLUME CONTROLS , PRESETS AND SWITCHES FOR SONY AND HITACHI ) M/S PEPSI FOOD LIMITED (COLD DRINK AND PACKED FOODS ) , M/S BRITAX MOTHERSONS (MARUTI ZEN AND MARUTI ESTEEM MIRRORS , FORD AND DCM-CELO MIRRORS ) , M/S ELOFIC (MARUTI FILTERS ) ,M/S ECHLIN (MARUTI BREAK LINEING ) , M/S SHRIRAM NEEDLE BEARING IND. LTD. (NEEDLE BEARINGS FOR AUTOMOBILES ) M/S DIAMOND ELECTRONICS (WIRE WOUND RESISTORS ) ETC. TILL THE NEW INDUSTRIAL POLICY CAME IN , AUTOMATION AND ROBOTICS WERE IRRELEVENT IN INDIA .BUT NOW WITH THE DOORS OPEN FOR FOREIGN INVESTMENT AND ENTRY OF MULTINATIONALS AND RISING COMPETETION WITH GRADUAL INDUSTRSIALISATION IN THE CONUTRY , AUTOMATION HAS BECOME THE NEED OF THE DAY . AND PEOPLE WITH FOREIGN EXPOSURE IN AUTOMATION HAVE BECOME AN ASSET FOR THE COUNTRY AND NON OF THE INDUSTRY IN THIS FIELD IS ABLE TO COUP UP WITH THE GROWING DEMAND FOR INDUSTRIAL AUTOMATION AND ROBOTICS IN THE COUNTRY. NOW PEOPLE IN INDIA KNOW AND USE A LOT OF ROBOTICS FOR AUTOMATION AND IN TIMES TO COME THIS MARKET IS GOING TO SEE A PHENOMIENAL GROWTH AND IT IS WITH THIS IDEA IN MIND THAT WE ARE PLANNING TO ENHANCE OUR OPERATIONS BY SWITCHING OVER OUR OPERATIONS FROM PRESENT LOCATION TO A BIGGER AND WELL ORGANISED INDUSTRIAL AREA . WHERE WE WISH TO ESTABLISH A VERY FUTURISTIC AND STATE OF ART INDUTRIAL UNIT INVOLVED IN INDUSTRIAL AUTOMATION AND ROBOTICS . WE ARE ENCLOSING A PROJECT REPORT WITH AN INTENTION TO GET FINANCE FOR THE PURPOSE OF SETTING UP NEW UNIT FOR INTERESTED AND PROSPECTIVE INVESTORS /PARTNERS. BATLA ENGG. CO. (UNIT-1) BATLA ENGINEERING COMPANY IS STARTED BY A 31 YEARS OLD ENTERPRENURE WHO WAS WORKING WITH MITSUBISHI ELECTRIC CORPORATION IN JAPAN AT THEIR KYOTO WORKS IN THE FIELD OF INDUSTRIAL AUTOMATION AND ROBOTICS . THE BUSINESS IS STARTED ABOUT THREE YEARS BACK , BUT BY THIS TIME WE HAVE DEVELOPED A VERY GOOD REPUTATION WITH ALL OUR CLIENTS AND HAVE RECEIVED NATIONAL AWARD FOR BEST TECHNOLOGY AT INTERNATIONAL TRADE FARE-1996 AT PRAGATI MAIDAN .WE HAVE A VERY GOOD EXPOSURE OF INDIAN INDUSTRY AND HAVE IN DEPTH KNOWLEDGE AND DATA BASE OF RELEVENT SUBJECTS IN THIS FIELD WITH A VERY GOOD AND DEDICATED TEAM OF PROFESSIONALS . WE ARE BASICALLLY INVOLVED IN DESIGNING & DEVELOPMENT OF MACHINES AND TECHNOLOGIES FOR ASSEMBLY AUTOMATION . INVOLVING PNEUMATICS , PRECISION SPOT WELDINGS , LASER WELDINGS , CRIMPINGS , PIN BENDINGS , PRECISION ASSEMBLIES , RIVETTING , PRECISIAN GLASS TUBE CUTTINGS , FEEDINGS THROUGH BOWL FEEDERS & LINEAR FEEDERS , ORIENTATIONS , PICK AND PLACE UNITS , TESTING MACHINES , RECONDITIONING OF OLD MACHINES , DUPLICATION AND MODIFICATION OF PRESENT MACHINES , SYSTEM INTEGRATIONS & DESIGNS .NORMALY WE USE FESTO PNEUMATICS , OMRON OR A/B SENSORONICS , MITSUBISHI OR MESSUNG PLCs . COMPLETE SOLUTION FOR AUTOMATION IS OFFERED UNDER ONE ROOF RIGHT FROM MECHANICAL DESIGNING OF JIGS & FIXTURES TO RELAY / PLC LOGIC DEVELOPMENT , WIRING , SENSORONIC & PNEUMATIC FITTINGS AND TRIALS .VERY HIGH SPEED PENTIUM COMPUTORS ARE BEING USED FOR DESIGNING AND DRAFTING OF MACHINEIS USING THE LATEST SOFTWARES . TIMELY DELIVERY , DESIGNING AND QUALITY OF PRODUCT WITH PROPER AFTER SALES SERVICES, HAVE ALWAYS BEEN THE THRUST AREA OF THE COMPANY .FOR OUR R&D BASED TECNOLOGY DEVELOPMENT IN VARIOUS FIELDS WE HAVE BEEN AWARDED BEST TECHNOLOGY AWARD AT THE INTERNATIONAL TRADE FARE-1996 AT PRAGTI MAIDAN, NEW DELHI . WE HAVE BEEN ON NATIONAL TELEVISION, TWICE . RESUME OF THE PROPRIETOR Name : M K Farshori Address : 335, Batla House 6th. Street , Jamia Nagar OKHLA , New Delhi-110025 India Telephone : 91-11-6834157 , 91-11-6926431 Cellular :9810115530 Telefax : 91-11-6926431 E-MAIL : [email protected] Date Of Birth : 1st. December , 1965 NATIONALITY : INDIAN Passport Number : G-194103 Educational : Mechanical Engineering (with Qualification distinction) , May 1988. (AMU) Professional : Worked in Japan with Mitsubishi Experience Electric Corporation for 2-1/2 years. : Worked in Automation Department of Samtel Electron Devices for 3 years. : Presently engaged in Consultancy , Equipment Building and automation for various firms with foreign collaborations. : Very well exposed and have indepth knowledge of pneumatics,bearings,PLCs, Sensoronics and other control elements used in automation and special purpose machines(SPM) for assembly automation. : Know computers very well and use AUTOCAD for m/c designing application and have a computer at my home as well (AT-486 , 16 MB RAM , 256 MB Hard disk). : Can speak Japanese . Awards :NATIONAL AWARD FOR BEST TECHNOLOGY DISPAL AT INTERNATIONAL TRADE FARE -1996 , PRAGATI MAIDAN NEW DELHI. ********* PRODUCT INTRODUCTION : AUTOMATION, AS DISCUSSED ABOVE, IS THE NEED OF THE DAY . WHERE EVER MASS PRODUCTION OR CONTINUOUS PROCESS TYPE OF PRODUCTION IS GOING ON, PEOPLE WANT TO INCREASE THE SPEED OF PRODUCTION WITH ENHANCED QUALITY AND AT THE SAME TIME, THEY WANT TO REDUCE, EXCESSIVE FATIGUE OF THEIR WORKERS AND THE EXCESSIVE MANPOWER IN THEIR PLANTS, AND THATS, WHERE THE AUTOMATION COMES INTO PICTURE. IN DEVELOPING, SPECIAL PURPOSE MACHINES (SPMs) OR INDUSTRIAL AUTOMATION EQUIPMENTS, THE FIRST STAGE IS TO ANALYSE THE AREAS OF EXCESSIVE MATERIAL, ITS HANDELING, AND THE FATIGUE, THAT IS CAUSING, THE UNBALANCING OF THE LINE . THEN WE TRY TO SUGGEST THE WAYS BASED ON CERTAIN THERBLIC STUDIES (ROBOTIC MOVENMENT OF THE MATERIALS RESEMBLING THE HUMAN MOVEMENTS ) AND BASED ON THAT, WE DEVELOP DESIGNS, USING HIGH POWER COMPUTERS AND THEN, THESE DESIGNS ARE FABRICATED USING CONVENTIONAL TOOL ROOM MACHINES AS WELL AS THE LATEST WIRE CUT EDMs ETC. THEN THESE JIGS AND FIXTURES ARE INTEGRATED INTO ASSEMBLIES AND PNEUMATIC CYLINDERS, WITH PLC (PROGRAMABLE LOGIC CONTROLLERS ) ARE INSTALLED INTO THEM SO THAT THESE MACHINES CAN WORK AUTOMATICALLY, USING VARIOUS MEDIUMS. LIKE COMPRESSED AIR , LIQUIDS OR ELECTRICITY BASED STEPPER MOTOR AND AC-DRIVES, THESE EQUIPMENTS ARE THE RESULT OF HIGHLY R&D BASED WORK. FOR EACH TYPE OF PRODUCTION, THEY ARE DESIGNED AND DEVELOPED INDIVIDUALLY . ONCE THE MACHINES ARE DESIGNED AND DEVELOPED, THEY BECOME, AN STRATEGIC PART OF INCREASING THE, PRODUCTIVITY AND THE PROFIT MARGINS OF THE USER . THEY PRESERVE THESE MACHINES, AS HIGHLY GAURDED SECRETS, AS THESE MACHINES ARE BEING DEVELOPED AT A GREAT COST, DUE TO THE INVOLVEMENT OF PLC , PNEUMATICS , CONTROL SENSORONICS AND COMPUTERISED DESIGNS . PROPERTIES : THE INDUSTRIAL SPECIAL PURPOSE MACHINES ARE TO BE SPECIFIC. THE ROBOTICS, ARE UNIQUE, IN THE SENSE, THAT THEY CAN WORK AT A VERY HIGH SPEED, WHICH COULD NEVER BE ACHIVED BY A NORMAL HUMAN BEING. THEY CAN WORK CONTINEOUSLY WITH OUT BREAKS AND GIVE CONSISTANT QUALITY ALL THRO0UGH THE PRODUCTION SCHEDULES. NORMALY, THESE MACHINES, RUN ON COMPRESSED AIR , LIQUIDS OR EVEN MOTORISED MACHINES CAN BE DEVELOPED. A SINGLE MACHINE CAN WORK WITHOUT ANY PROBLEM, IN HAZARDOUS AREAS . AND THE BEST THING, IS THAT THE MACHINES MAKE OPERATION SO SIMPLE, THAT EVEN A LAY-MAN CAN OPERATE THEM AS LOTS OF SENSERONICS AND FEED BACK CIRCUITS, CONTROLLED BY THE COMPUTORS, KEEP GIVING A CONTINEOUS INFORMATION ABOUT THE PRODUCTION PROCESS . USES, APPLICATIONS & CUSTOMERS : INDUSTRIAL AUTOMATION , ROBOTICS AND SPECIAL PURPOSE MACHINES, ARE IN GREAT DEMAND NOW A DAYS . AS EVERY BODY IS GOING FOR EXPENSIONS. TEHY WANT TO DEVELOP MACHINES, WITH EVEN MORE AUTOMATIC FEATURES AND SENSORONICS . LOTS OF AUTOMATIC MACHNES, THAT IN THE FIRST PHASE, WERE IMPORTED, BY THE COMPANIES, ARE BEING DEVELOPED IN INDIA, DURING EXPANSIONS AND THATS WHERE A LOT OF DEMAND IS CREATED FOR INDUSTRIAL AUTOMATION AND EQUIPMENT MANUFACTURRERS . AS A LOT OF FOREIGN COLLABORATIONS, ARE TAKING PLACE NOW A DAYS , LOTS OF COMPANIES ARE APPROACHING US, WITH THEIR REQUIRMENTS, FOR AUTOMATIC MACHINES BASED ON DESIGNS SUPPLIED BY THEIR COLLABORATORS . OUR MAIN CLIENTS ARE IN THE FIELD OF AUTOMOBILE AND CONSUMER ELECTRONIC SECTOR, THAT HAS SEEN A PHENOMINAL MULTI FOLD GROWTH, IN THE PAST FEW YEARS, DUE TO WHICH A GREAT THRUST, IS BEING DEVELOPED ON AUTOMATION . ENCLOSED IS THE LIST OF FEW OF OUR CLIENTS, FOR WHOM WE HAVE DEVELOPED SOME AUTOMATIC MACHINES . WE HAVE ALSO MENTIONED, THE TYPE OF AUTOMATION DONE FOR THEM ; 1. M/S TIMEX WATCH COMPANY (NOIDA):- PLC BASED MACHINES, FOR AUTOMATIC BACK CASE CODINGS, FOR TIMEX WATCHES WITH ROBOTIC PICK AND PLACE ARMS .THIS MACHINE IS ONLY OF IT'S KIND,, IN THE WORLD. IT IS MANUFACTURED BY US, RIGHT FROM THE CONCEPT STAGE TO THE FINAL ASSEMBLY AND COMMISSIONING . 2. M/S SAMTEL ELECTRON DEVICES , (GHAZIABAD) PLC BASED MACHINES, FOR ELECTRON GUN MANUFACTURING, FOR BLACK AND WHITE PICTURE TUBES. SOME OF THE CHALLANGING MACHINES INCLUDE :- a) FLARING OF A 100 MICRON DISC ITO CATHODE SLEEVE . b) PRECISION SPOT WELDING MACHINE, FOR CATHODE WELDING WITH AN ACCURACY OF 5 MICRONS (1/1000000 MM ) . c) FULLY AUTOMATIC STUD WELDING MACHINE FOR G2-CUPS . (A VERY HIGH SPEED SPOT WELDING MACHINE, FOR VERY SMALL COMPONENTS.) 3 M/S SAMTEL ELECTRON DEVICES , (PARWANU) a) PNEUMATIC SEVEN PNEUMATIC HEAD TYPE MACHINES, FOR CUTTING STEM PINS AT VARIOUS HEIGHTS, USING A SINGLE STROKE. b) MACHINES, FOR STEM PIN CUTTING OF ALL SEVEN PINS, IN A VACCUME VALVE STEM AT THE SAME TIME . (DEVELOPED FOR THE FIRST TIME ) c) ELECTRON GUN CHARACTER STIC CHECKERS. 4. M/S HOTLINE TELETUBE & COMPONENTS LTD.(GAWALIOR ) : a) INFRARED FURNACE FOR DRYING ELECTRONINC COMPONENTS . b) PICTURE TUBE GLASS BULB MAKING MACHINES .FOR MAKING NECK GLASS AND RINGS . EARLIER THIS PRODUCT WAS IMPORTED, FROM USA AND JAPAN . ( THIS TECHNOLOGY, IS DEVELOPED, FOR THE FIRST TIME IN INDIA ) 5. PUROLATOR INDIA LTD. (GURGAON) a) FILTER MAKING MACHINES, FOR AUTOMOBILES FILTERS FOR MARUTI AND TATA SUMO. .b) AUTOMATIC SHRINK WRAPPING MACHINES . c) MACHINES FOR MAKING FLAT FILTERS, INCLUDING INDEXING TYPE OVENS WITH FIFTEEN STATIONS EACH .(PRESENTLY MAKING ) 6. M/S ELCON INDIA (OKHLA INDUSTRIAL AREA): a) COMPLETE LINE FOR VOLUME CONTROLS , PRESETS AND SWITCHES FOR SONY , HITACHI , PANASONIC , VIDEOCON AND BPL CONTROL SWITCHES. b) PLC BASED TESTER, FOR DPDT AND SPDT SWITCHES FOR UL APPROVAL FOR SUPPLY OF SWITCHES, TO EUROPEAN MARKETS. c) TESTERS, FOR FULL RANGE OF MICRO TACK SWITCHES FOR EXPORT MARKET . 7. M/S PEPSI FOOD LIMITED (PUNJAB) a) PLC BASED AUTOMATIC STAPLING PAKAGING MACHINES, FOR POTATO CHIPS, PACKAGING, WITH EIGHT LONG HEAD PNEUMATIC STAPLING HEADS ALL CONTROLLED BY PLC. b) AUTOMATIC HIGH SPEED STICKER DISPENSORS, FOR STICKERS INTO THE PEPSI CHIPS PRODUCED BY PEPSI IN THEIR COLD DRINK CONCENTRATED PLANT, AT CHANNO , ( ( PUNJAB ) 8. M/S BRITAX MOTHERSONS (NOIDA) a) PLC BASED AUTOMATIC MACHINES, FOR ASSEMBLING MARUTI ESTEEM EXTERIOR MIRRORS, FOR RIGHT HAND AND LEFT HAND MIRRORS . b) PLC BASED AUTOMATIC MACHINES, FOR ASSEMBLING MARUTI ZEN EXTERIOR MIRRORS, FOR RIGHT HAND AND LEFT HAND MIRRORS .(UNDER PROCESS ) c) MIRRORS ASSEMBLY MACHINES, FOR FORD AND DCM-CELLO MIRRORS. ( UNDER PROCESS ) 9. M/S ELOFIC (FARIDABAD) a) HIGH SPEED FILTER MAKING MACHINE, FOR MARUTI FILTERS . Z 10. M/S ECHLIN (GURGAON) MACHINES FOR MARUTI BREAK DRUM ASSEMBLY SYSTEMS Z. AND MARKING SYSTEMS . 11. M/S DIAMOND ELECTRONICS (GAZIABAD) AUTOMATIC CAP FIXING MACHINES ON CERAMIC WIRE WOUND RESISTORS . 12.M/S SRI RAM NIDDLE BEARINGS(RANCHI) FULLY AUTOMATIC NIDDLE BEARING MACHINE ( UNDER PROCESS ) APART FROM THIS, WE HAVE A LONG LIST OF CUSTOMERS WHO GET SMALL MACHINES DONE THROUGH US AT VARIOUS TIMES . BUT NOW, DUE TO SPACE CONSTRAINTS AT OUR PRESENT SITE, WE ARE REFUSING THE ORDERS AND NOT BOOKING MANY, EXCEPT FOR OUR QUALITY VENDORS, WITH WHOM, WE WANT TO DEVELOP A LONG TERM ASSOCIATION . IN FACT SOME OF CUSTOMERS, ARE TALKING OF BUYING ALL OUR CAPACITIES, FOR NEXT TWO THREE YEARS, AND ARE TO SOME EXTENT, READY TO HELP US ARRANGE FINANCES ETC. BUT WE DO ANTICIPATE, THAT AS WE MOVE TO A BIGGER FACTORY, WE CAN FURTHER EXPAND OUR OPERATIONS ,AND THEN PROBABLY CATER, MORE COMFORTABLY, TO ALL OUR PRESENT AS WELL AS FUTURE CLIENTS . ISI SPECIFICATIONS AND REQUIREMENTS :- AS SUCH, THESE MACHINES, DO NOT FALL, UNDER ANY, PERTICULAR CATAGORY OF I.S.I. SPECIFICATIONS. BUT VARIOUS PARTS OF IT, LIKE THE CONTROL PANELS , THE MECHANICAL JIGS AND FIXTURES . THE BASIC ELECTRONIC COMPONENTS , VARIOUS HIGH VOLTAGE COMPONENTS, DO FALL, UNDER THEIR SPECIFIC CATAGORIES OF SPECIFICATIONS AND ALL THOSE SPECIFICATIONS ARE BEING FOLLOWED ACCORDINGLY . SPECIAL PRECAUTIONS ARE BEING TAKEN AS REGARDS THE SAFTY OF THE OPERATOR WHILE OPERATING THE MACHINES . ALL THESE MACHINES ARE BEING PROVIDED WITH SPECIAL EMERGENCY CUT-OFF AND OTHER PROTECTIONS FOR THE PURPOSE. ALL THE MACHINES ARE BEING PROVIDED WITH SERVICE CUM MAINTENANCE MANUALS . A REGULAR SCHEDULE OF MAINTENANCE, IS ALSO PROVIDED. THE MANUALS ALSO EXPLAIN THE VARIOUS CAUSES OF ERRORS AND THEIR REMEDIES . ALL NECESSARY TEST CERTIFICATES FOR VARIOUS BOUGHT OUT ITEMS, ARE BEING PROVIDED WITH THE MACHINES . CERTIFICATE OF HIGH VOLTAGE STABILITY , PNEUMATIC LEAKAGES , NOISE AND VIBRATION LEVEL, IS PROVIDED WITH THE MACHINES . ALL PNEUMATIC ARE EITHER FESTO-(GERMANY MAKE) OR SMC (JAPAN) MAKE. NO LOCAL PNEUMATICS OR ANY OTHER LOCAL OR SUB-STANDARD COMPONENT IS USED IN OUR MACHINES AND ALL THE MACHINES ARE GUARANTEED FOR A MINIMUM PERIOD OF SIX MONTHS, AS A COMPULSORY WARRANTY CLAUSE OF OUR DEALS . PRESENT MANUFACTURERS: AS THE FIELD OF AUTOMATION IS RELATIVELY NEW TO INDIA, THERE ARE VERY FEW GOOD MANUFACTURERS OF SPECIAL PURPOSE AUTOMATIC MACHINES (SPMs) IN INDIA . IN FACT ONE CAN COUNT THEM ON FINGERS. ALMOST ALL OF THEM ARE BASED IN SOUTHERN INDIA . ONE OF THE REASON HAS BEEN, A BIT ,LATE INDUSTRIALISATION IN NORTHEN INDIA , WHICH WITH THE ENTRY OF SOME AUTOMOBILE MULTINATIONS, IS NOW, PICKING UP TEMPO . VERY FORTUNATELY, ALL THE GOOD SPM MANUFATURERS IN INDIA, HAVE WORKED IN FOREIGN COUNTRIES AT ONE POINT OF THE TIME OR THE OTHER . THE NAME OF THE PRESENT MANUFACTURERS, WHO ARE IN THIS FIELD ARE :- a) M/s. ELSCINCT AUTOAMTION -PUNE BOWL FEEDERS AND ASSEMBLY AUTOMATION b) M/s. FEED-TECH-BOMBAY. BOWL FEEDERS AND FLUID CONTROL AUTOMATION. c) M/s. ORBITAL SYSTEMS-BANGALORE. GENERAL PURPOSE SPMs. AND RIVETTING MACHINES . d) M/s. MECHLONICS-BOMBAY SPOT WELDING MACHINES AND RELATED AUTOMATION . e) M/s. JAY HIND SCIYAKI-PUNE SPOT WELDING MACHINES AND RELATED AUTOMATION . f) M/s. ECCARD AUTOMATUION .(PUNE) BOWL FEEDERS AND SPMs. PROCESS OF MANUFACTURING : AS AUTOMATION IS NOT A REGULAR MASS PRODUTION TYPE OF JOB AND IT IS HIGHLY R&D BASED ACTIVITY, IT CAN NOT HAVE A HARD AND FAST RULE FOR THE PROCESS OF MANUFACTURING, BUT EVEN THEN, WE HAVE, A GENERAL OUT LINE OF THE WAY, THE AUTOMATION IS DONE OR RATHER THE WAY AN SPM (SPECIAL PURPOSE MACHINE IS DEVELOPED). THE PROCESS IS AS FOLLOWS :- FIRST OF ALL, THE CUSTOMER IDENTIFIES THE PROCESS AREA WHERE HE WANTS AUTOMATION OR FOR WHICH AREA HE WANTS SPM (SPECIAL PURPOSE MACHINE ) THEN WE VISIT THE SITE AND PERFORM THE TIME STUDIES, IF IT IS A MASS PRODUCTION PROBLEM . OR OTHER WISE JUST RECORD THE SEQUENCE OF OPERATION USING CAMERAS AND TIME RECORDING DEVICES . NEXT WE TAKE THESE READING AND THE COMPONENTS AND MAKE THEIR COMPONENT DRAWINGS ON HIGH SPEED PENTIUM COMPUTORS . THEN WE TRY VARIOUS LAY OUT ON COMPUTORS FOR THE EQUIPMENTS TO BE MANUFACTURED . OUT OF ALL THE POSSIBLE OPTIONS, WE SELECT A FEW AFTER DISCUSSIONS WITH OUR ENGINEERS AND DESIGNERS . IF REQUIRED, SOME TRIALS ARE ALSO BEING DONE . NEXT WITH OUR SOLUTION ON COMPUTORS, WE AGAIN, SIT WITH OUR CUSTOMER AND TELL THEM THE VARIOUS POSSIBLE WAYS OF DOING THE CONCERNED OPERATION ALONG WITH THE PRICE TAG FOR EACH TYPE . NOW CUSTOMER, BASED ON HIS CHOICE AND ROI ANALYSIS (RETURN ON INVESTMENT ANALYSIS ) GIVES US A GO AHED ON THE TYPE OF MACHINE, HE WANTS TO GET DEVELOPED, BASED ON VARIOUS OPTIONS SUGGESTED BY US . NEXT WE SIT ON THE COMPUTOR AND DESIGN A DETALED MACHINE ON COMPUTOR BEFORE STARTING ANY FABRICATION . THEN ONCE THE DESIGNES ARE COMPLETE, VARIOUS TOOLINGS ARE STARTED . AT THE SAME TIME, THE ORDER FOR STANDARD BOUGHT OUT ITEMS LIKE PNEUMATIC , MAOTORS , BEARINGS , PLCs (PROGRAM-ABLE LOGICAL CONTROLERS ) , RELAYS , SWITCHES AND OTHER PERIFERLA ITEMSARE LOADED . A BAR CAHRT IS, ALSO, MADE FOR EACH MACHINE, TO KEEP A TRACK OF TIME BASED, ON CPM AND PERT TECHNIQUES AND TO ENSURE TIMELY DELIVERIES, KEEPING IN MIND ALL CRITICAL ACTIVITIES . A JOB CARD OF EACH MACHINE, IS ALSO MADE RIGHT IN THE BEGINING FOR OPTIMUM UTILISATION OF THE WORK FORCE . THEN, AS THE JIGS AND FIXTURES, START REACHING COMPLETION, WE START ASSEMBLING THE VARIOUS SUB ASSEMBLIES , THE SENSORONIC PART AND THE CONTROL CIRCUITS, ARE ALSO BEING PREPARED IN THE MEAN TIME . NEXT, ON ARRIVAL OF THE PNEUMATIC, THEY ARE FIXED ON TO THE SUB ASSEMBLIES AND THEY ARE BEING TRIED AS A HOLE . IF ANY CHANGES ARE REQUIRED, THEY ARE BEING DONE. NOW, DURING THE FIRST TRIAL OF THE MACHINE . AFTER WHICH A SECOND TRIAL IS DONE IN THE PRESENCE OF THE CUSTOMER . ON APPROVAL OF THE CUSTOMER, THE WHOLE MACHINE, IS OPENED AGAIN AND THEN, VARIOUS COMPONENTS OF THE MACHINE, ARE SENT, FOR VARIOUS SURFACE COATINGS AND TREATMENTS . THE CONTROL PANEL PART OF THE MACHINE, IS NOT OPENED AND IT IS PAINTED RIGHT IN THE BEGINING AS IT WILL BE VERY DIFFICULT TO OPEN AND AGAIN DO LONG WIRINGS. IF ANY CHANGES ARE REQUIRED BY THE CUSTOMER, THEY ARE BEING DONE BY US DURING THE SECOND TRIAL ONLY . AFTER THE SURFACE FINISHES ARE COMPLETE , THE MACHINE IS RE-ASSEMBLED AND THEN, THE THIRD TRIAL IS BEING PERFORMED AT OUR END IN WHICH CUSTOMER'S ACTUAL OPERATORS MAKE A TRIAL PRODUCTION ON THE MACHINE TO CROSS CHECK THE DESIRED OUT-PUT OF THE MACHINE AS SPECIFIED BY US . AFTER THE APPROVAL OF THE OPERATOR, THE MACHINE IS PACKED IN PROPER WOODEN BOXS AND ARE TRANSPORTED TO THE CUSTOMER'S FACTORY. .IN CASE, THE MAHINE, IS TOO LARGE, IT IS SENT TO CUSTOMER IN PART-ASSEMBLY SHAPE AND WE DO REASSEMBLY AND COMMISSIONING OF THE MACHINES AT THEIR SITES. FLOW SHEET DIAGRAM: FOLLOWING IS THE FLOW SHEET DIAGRAM FOR THE MANUFACTURING PROCESS OF AUTOMATIC MACHINES, FROM THE CONCEPT STAGE TO THE FINAL STAGE OF COMMISSIONING AT THE ACTUAL OPERATOR'S END; -UNDERSTANDING OF THE VENDOR'S REQUIREMENT -TIME AND MOTION STUDIES AT VENDOR'S END. -COMPONENT STUDY -FEED COMPONENT DRAWINGS ON AUTO CAD -IDEA GENERATION FOR VARIOUS POSSIBILITIES TO REACH TEH DESIRED RESULTS . -TRIALS FOR CERTAIN CRITICAL PARTS (IF REQUIRED ) -FINAL SELECTION OF OPTIONS TO BE DISCUSSED WITH THE CUSTOMER. -PRESENTATION OF VARIOUS IDEAS BEFORE CUSTOMER AND QUOTATIONS FOR THE SAME . -BAR CHART PREPARATION ON CONFIRMATION OF ORDER . - DESIGNING OF THE MACHINE . -FINALISATION AND ORDER OF STANDARDS BOUGHT OUT ITEMS LIKE PLC , PNEUMATICS , AND OTHER SENSSORONIC ETC. -FABRICATION OF VARIOUS JIGS AND FIXTUIRES AS PER DESIGNS DEVELOPED ON COMPUTORS . -ASSEMBLY OF VARIOUS COMPONENTS . -FIRST TRIAL OF THE MACHINE . -CHANGES, IF REQUIRED . - SECOND TRIAL OF THE MACHINE IN THE PRESENCE OF THE CUSTOMER. -CHANGES, IF SO DESIRED, BY THE CUSTOMER . -DISMANTELING OF THE MACHINE, FOR SURFACE TREATMENTS LIKE POWDER COATINGS , BLAKENINGS , ZINK PLATING AND CHROME PLATING ETC. RE-ASSEMBLY OF THE MACHINE. -THIRD TRIAL OF THE MACHINE BY CUSTOMER'S OPERATORS . -PREPARATION OF SERVICE MANUAL AND TRAINING OF THE OPERATORS . -PACKAGING OF THE MACHINE AND FORWARDING IT TO THE CUSTOMER'S SITE. -COMISSIONING OF THE MACHINE, AT THE CUSTOMER'S SITE . -TIME TO TIME, MONITORING OF THE MACHINE, AT CUSTOMER'S END FOR THE FIRST MONTH, TILL THE OPERATORS ARE USED TO THE MACHINE . ( THUS, THE PROJECT IS COMPLETE) PRODUTION CAPACITY: AN AVRAGE MACHINE, USING 5 TO 6 PNEUMATIC ELEMENTS AND PLC BASED LOGICS AND PRICE WISE, IN THE RANGE OF RS. 2.5 TO 3 LACS, TAKE 1-1/2 TO 2 MONTHS, DEPENDING ON THE COMPLEXITY OF THE PROBLEM . BUT WITH ENHANCED CAPACITY OF MACHINE TOOLS , MANPOWER AND SPACE TO KEEP MACHINE S, WE DO ANTICIPATE, THAT WE WILL BE ABLE TO ROLL OVER 2 TO 3 MACHINES PER MONTH ON AN AVERAGE .THIS CAPACITY , WILL FURTHER IMPROVE, TO 3 TO 4 PER MONTH WITH FUTURE EXPANSIONS . IN CASE, REPEAT ORDEDRS FOR THESE MACHINES, THEY CAN BE MADE VERY FAST AS ALL THE DESIGNING AND TOOLING HAS ALREADY BEEN DONE. IN THAT CASE, WE CAN OFF LOAD THE COMPONENTS MANUFACTURING, TO OTHERS, ON JOB WORK BASIS, AND CAN CONCENTRATE JUST ON ASSEMBLING AND INTEGRATION PART OF THE SAME. LAND AND BUILT UP AREA REQUIRED : THE PRODUCTION OF AUTOMATIC ASSEMBLY MACHINES AND SPMs INVOLVE, INITIAL DESIGNING OF MACHINE ON COMPUTORS , THEN PRODUCTION OF VARIOUS SUBASSEMBLIES AND LATER THEIR ASSIMILATION AT FABRICATION SHOP TO GIVE IT A FINAL SHAPE . IN AUTOMATION AND SPM BUILDING, WE ARE GOING TO DEAL WITH DESIGN OF MACHNES ON COMPUTORS , PRODUCTION OF SUB ASSEMBLIES, AT VARIOUS SHOPS , AND LATER, ALL THESE SUBCOMPONENTS, ALONG WITH PLCS AND PNEUMATICS, WILL BE ASSEMBLED IN ASSEMBLY AREA . DESIGN SECTION : HERE VARIOUS MACHINES, WILL BE DESIGNED ON COMPUTORS . WE WILL START, WITH TWO IBM PENTIUM 166 MHZ. COMPUTORS , AND ONE AT-486 COMPUTOR .PRINTERS AND THE OTHER PERIFERALS, WILL ALSO, BE INSTALLED IN THIS SECTION . THIS SECTION WILL BE A CLEAN ROOM AREA WITH AIR CONDITIONING PROVIDED FOR PROPER WORKING OF THE HIGH SPEED PENTIUM COMPUTORS . AN INTERNET CONNECTION AND E-MAIL SERVIEC THROUGH A MODEM WILL ALSO BE PROVIDED IN THIS SECTION . THE AREA WILL BE DESIGNED, WITH A SCOPE, TO INSTALL ATLEAST FIVE TO SIX MORE COMPUTORS AND A PLOTTER IN FUTURE. THIS SECTION, WILL BE HANDELED BY DESIGN ENGINEERS, WHO WILL BE WELL VERSED WITH LATEST CAD CAM DESIGNING TECHNIQUES AND HAVE THROUGH KNOWLEDGE OF DESIGNING AND AUTO CAD PRODUCTS . TO START WITH ,TWO ENGINEERS WILL BE WORKING IN THIS AREA .TAH T WILL BE LATER RAISED TO FOUR TO FIVE IN FUTURE EXPANSION . AS OUR MAIN THRUST IS ON DESIGNING AND R&D FOR DEVELOPMENT OF TECHNOLOGIES , COMPUTOR DESIGN SECTION, WILL BE HEART OF OUR OPERATIONS . ELECTRONIC COMPONENT SHOP. IN THIS AREA, WE WILL MAKE CONTROL PANELS FOR MACHINES THAT INVOLVE WIRINGS , CIRCUIT DEVELOPMENTS , INSTALLATION AND PROGRAMMING OF THE PLCs , RELAY BASED LOGICS DESIGN AND THE WIRING FOR SAME . DEVELOPMENT OF SENSORONIC BASED FEED BACK LOOPS TO BE INSTALLED ON AUTOMATIC MACHINES . ONE AT-486 COMPUTOR, WILL BE INSTALLED HERE AS WELL, FOR DEVELOPMENT OF SOFTWARES AND THEN THE FEEDING OF THE SAME TO THE PLC.. THERE WILL BE ONE ELECTRICAL ENGINEER AND ONE TO TWO SKILLED ELECTTRONIC CERTIFICATE HOLDERS IN THIS AREA . FITTING AND WELDING SHOP AND FABRICATION SHOP: HERE, ALL THE FRAME AND TUBLAR STRUCTURES, FOR THE MACHINES INCLUDING CONTROL PANELS AND OTHER SHEET MEATAL FABRICATION EQUIPMETS WILL BE INSTALLED. ONE LIGHT WELDING MACHIEN . ONE HEAVY ELECTRIC WELDING MACHINE . ONE 10 TO 20 KWA SPOT WELDING MACHNE . ONE C-FRAME TYPE 8 TO 10 TON PRESS , ONE SHARE CUTTER , ONE GAS WELDING SET , HAND GRINDER AND BASIC HAND TOOLS WILL BE KEPT . THIS AREA WILL HAVE ONE WELDER , ONE FABRICATOR OF SHEET METAL AND ONE HELPER . AN OPEN CHANNEL TYPE STORE FOR STORING CHANNELS AND ANGLE IRON SECTIONS WILL ALSO BE BUILT UP IN THIS AREA . PAINTING SHOP : THIS WILL BE A SMALL SECTION, WHERE SPRAY PAINTS AND SURFACE TREATEMENT SECTION WILL BE THERE . VARIOUS MATERIALS FOR SPRAY PAINTS AND SURFACE TREATMENTS WILL BE STORED HERE, AND A SKILLED PAINT OPERATOR, WILL BE DOING SPRAY PAINT ON JOB WORK BASIS USING OUR EQUIPMENTS AS AND WHEN REQUIRED . MACHINE SHOP : THIS WILL BE ANOTHER OF OUR THRUST AREA ,AS WE WILL HAVE FOUR LATHE MACHINES , ONE UNIVERSAL MILLING MACHINE , ONE VERTICAL (SMALL ) MILLING MACHNE , THREE SURFACE GRINDERS AND , TWO DRILL MACHINES , ONE SHAPPER , ONE POWER HACK SAW AND TWO TOOL GRINDERS WILL ALSO BE THERE IN THIS SECTION . SCOPE FOR ADDITIONAL MACHINES, WILL BE THERE FOR FUTURE EXPANSION . ALL HAND TOOLS AND PRECEISION MARKING AND MEASURING EQUIPMENTS, LIKE PRECISION HEIGHT GAUGES , VERNIERS , MICROMETERS AND OTHER MEASURING INSTRUMENTS WILL BE KEPT IN THIS AREA . AT ANY PERTICUALR TIME , ATLEAST, TWO TURNERS , TWO DIE FITTERS , ONE FOREMAN , AND TWO TO THREE WORKERS WILL BE THERE IN THIS SHOP . PROPER CARE WILL BE TAKEN OF GOOD LIGHT AND VENTILATIONS, BY PROVIDING LOTS OF OPEN EXHAUST VENTS AND WINDOWS IN THE MACHIHNE SHOP AREA. .A GOOD CARE WILL BE TAKEN FOR REMOVING THE POWDER GENERATED BY SURFACE GRINDERS . FOR THIS PURPOSE, VERY HIGH POWER FANS AND CYCLONES, WILL BE USED . PROPER LIGHTING AND ELECTRICAL SWITHCING, WILL BE DONE IN THIS SHOP SO THAT IN CASE OF EMERGENCY ., THE POWER ISOLATION AND SWITCHING IS POSSIBLE COVENIENTLY . TWO WORKING TABLES, WITH BENCH WISE MOUNTED ON ALL FOUR SIDES . COMPRESSED AIR CONNECTIONS WILL BE PROVIDED ON ALL MACHNE POINTS FOR EASY CLEANING OF MACHINES AND JOB PIECES . ASLIDING TYPE CHAIN -PULLY MATERIAL HANDELING SYSTEM WILL ALSO BE PROVIDED IN THE MACHINE SHOP AND THE ASSEMBLY AREA, WILL ALSO BE, IN THE SAME LINE . ASSEMBLY SHOP : THIS WILL BE, JUST, NEXT TO THE MACHINE SHOP AND WILL HAVE A COMMON ROOF AND WILL HAVE AN OVER ROOF MATERIAL HANDELING SYSTEM THAT COULD BRING THE MATERIAL FROM MACHINE SHOP DIRECTLY TO THE ASSEMBLY SHOP . THE MATERIAL HANDELING SYSTEM WILL BE EXTENDED UP TO THE GATE FOR LOADING THE MACHINES ON THE TRUCKS . THE ASSEMBLY AREA WILL BE HAVING ASSEMBLY TABLES IN THE SIDES AND THE CENTER AREA WILL BE FREE FOR ASSEMBLING VARIOUS MACHINES. . PLANTY OF LIGHT AND ELECTRICAL SOCKETS, AS WELL AS, CLEAN COMPRESSED AIR CONNECTIONS WILL BE AVAILABLE ALL THROUGH THE ASSEMBLY AREA . AS WE ARE, NOT A PROCESS AND CONTINEOUS INDUSTRY, WE CAN NOT HAVE A PROPER FIXED LAYOUT FOR THE AREA . AS WITH EACH MACHINE, THE LAYOUT KEEPS CHANGING . EASY ELECTRICITY, . ONE FITTER FROM MACHINE SHOP , ONE ELECTRONIC SUPERVISOR , ONE FOUR MAN , ONE DIE FITTER AND TWO HELPERS WILL BE WORKING IN THIS AREA . ADMINISTRATIVE BLOCK: THIS WILL HAVE ONE CHAMBER FOR DIRCETORS OF THE COMPANY . ONE CONFERENCE CUM MEETING ROOM FOR REVIEW MEETING AND MEETING THE CUSTOMERS AND ONE ADMINISTRATIVE BLOCK FOR OFFICE CLERK , LAISEN OFFICERS , AND COMMERCIAL OFFICERS . AND THE OFFICE BOY . A SMALL CANTEEN, WILL ALSO BE THERE IN THE ADMISNISTRATIVE AREA, FOR PANTRY REQUIREMENTS ETC.. THIS AREA, WILL HAVE 5 PERSONS WORKING IN THE AREA, EXCLUDING THE DIRECTORS. STORES: STORE WILL BE A CLOSED ROOM TYPE STRUCTURE WITH PROPER SECURITY ARRANGEMENTS. A IN THIS AREA, ALL THE PNEUMATICS , ELECTRICAL ITEMS , PLCs, CONTROL SENSORONICS , BEARINGS , NUTS & WASHERS , ALLOY MATERIALS AND SPARES FOR VARIOUS MACHINES , GENERATOR AND OTHER UTILITIES, WILL BE STORED . THE AREA WILL BE MANNED BY A PERSON FROM THE ADMINISTRATIVE BLOCK . HELPERS FROM ASSEMBLY AREA, WILL BE USED AS AND WHEN REQUIRED . UTILITIES : IN UTILITIES AREA, WE WILL HAVE TWO DIESEL GENERATORS . ONE OF THEM, ALREADY THERE . ONE GENERATOR WILL BE OF 12.5 KW RATING AND THE OTHER WILL BE 20 KW RATING . ONE 300 LBS. TANK CAPACITY COMPRESSOR WILL ALSO BE INSTALLED IN THIS AREA . THE AREA WILL BE LOOKED AFTER BY PERSONS FOREMAN FROM SHOP FLOOR AND A HELPER DEDICATED FOR THE UTILITIES . A DRY AIR PLANT, WILL ALSO BE INSTALLED, AT A LATER STAGE . AN OVER HEAD TANK OF 1,500 CAPACITY (SYNTAX TYPE) AND A FUEL TANK FOR THE GENERATOR WILL ALSO BE INSTALLED IN THIS AREA . A NOISE CUM POLUTION FILTER FOR THE GENERATORS WILL ALSO BE INSTALLED . PLANT LAY-OUTS & COVERED AREA : AS THE ENVIRMENTAL DETERIORATION IS FAST TAKING PLACE IN THE THIRD WORLD COUNTRIES, IT IS THE MORAL RESPONSIBILITY OF EVERY CITIZEN OF THESE COUNTRIES, SPECIALLY, THOSE, WHO HAVE RESOURCES, TO HELP REBUILT A HEALTHY ENVIRONMENT . WITH THIS CONSIDERATION IN MIND, THAT WE PROPOSE, TO KEEP A PERMANENT GREEN AREA ,WITH GOOD TEAK OR NEAM TREES IN OUR FACTORY AT THE FRONT AND ALL AROUND. THE PERFERY OF THE FACTORY, WHICH WILL NOT ONLY HELP IN IMPROVING THE ENVIRONMENT BUT ALSO GIVE A VERY PLAESENT AND REFRESHING LOOK TO OUR FACTORY AND WILL OBVIOUSLY, ENHANCE THE BEAUTY OF THE AREA . WE PROPOSE TO KEEP 60 TO 65% AREA COVERED AND REST WE WANT TO KEEP OPEN AS PER THE ATTACHED LAYOUTS . IN THE Lsize=+2 color="#ffff00">batla on 2nd Jan 1999 I'm 37 years old, from India. | |||||||||||||||||||||||
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