COLLEGE OF ENGINEERING BHUBANESWAR [CEB]

PLOT -1, SECTOR -B, CNI COMPLEX, PATIA, BHUBANESWAR- 751024

www.coeb.org
This is to certify that the project report entitled Investment Casting of
Lost Wax Type is a bonafde record of work done by the 8
th
semester
students of 4
th
year in partial fulfllment of Bachelor of Technology in
Mechanical Engineering during the academic year of 2005-2009 at
College of Engineering, Bhubaneswar .
Project Guide Er. M. M.
Mohapatra
Er. Samir Mohanty Head of Department
Senior Lecturer in Mech. Engg. Mechanical Engineering
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This is to certify that the following students have
successfully completed the Entrepreneurship Project on
Investment Casting of Lost Wax Type
Praveen Kumar --------------------------------------------------------0501219239
Rashmi Kant Rout-----------------------------------------------------0501219243
Manoj Kumar-----------------------------------------------------------0501219245
Himanshu Sekhar Pradhan-----------------------------------------0501219266
Rajesh Ranjan Samal-------------------------------------------------0501219271
Anand Ratna------------------------------------------------------------0501219272
Namrata Sinha---------------------------------------------------------0501219273
Abhishek Rezi----------------------------------------------------------0501219274
Abhijit Roy--------------------------------------------------------------0501219275
Manish Kumar Singh------------------------------------------------ 0501219276
Piyush Priyadarshi----------------------------------------------------0501219279
Pritpal Singh------------------------------------------------------------0501219280
Project Guide Er. M. M.
Mohapatra
Er. Samir Mohanty Head of Department
Senior Lecturer in Mech. Engg. Mechanical Engineering
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During the fnal semester of B.TECH in MECHANICAL
ENGINEERING a curriculum assignment has to be taken as an
entrepreneurship project. Our Entrepreneurship project is Investment
Casting of Lost Wax Type a complete task of starting from concept
analysis to project preparation; the entire has been done under the
guidance of our project guide Mr. Samir Mohanty (Senior Lecturer in
Mechanical Engineering College of Engineering Bhubaneswar) .
In today's scenario, the Investment Casting is used in the aerospace and
power generation industries to produce turbine blades with complex
shapes or cooling systems. Blades produced by investment casting can
include single-crystal (SX), directionally solidifed (DS), or conventional
equiaxed blades. It is also widely used by frearms manufacturers to
fabricate frearm receivers, triggers, hammers, and other precision parts at
low cost. Other industries that use standard investment-cast parts include
military, medical, commercial and automotive.Investment casting ofers
high production rates, particularly for small or highly complex
components, and extremely good surface fnish with very little machining
The R.K Engineers & Manufacturers ofers Investment Casting Products of
highly complex type.
While preparation of this project every care has been taken to avoid any
mistakes and errors. Some errors might have crept in advertently.
================================
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We gratefully acknowledge the authorities of College of
Engineering Bhubaneswar of the Mechanical Engineering
Department for their wide co-operation in the completion of this
project.
We express our deep sense of gratitude to our project guide Mr.
Samir Mohanty & Mr. Rajesh Kumar Behera (Senior Lecturer in
Mechanical Engineering-College of Engineering Bhubaneswar
[CEB]) who constantly guided & advised us at various levels in the
successful completion of the entrepreneurship project.
We thank the entire staf of Mechanical Department for helping
us in this project.
Last but not the least we want to thank all those who have directly
or indirectly helped us during the course of our entrepreneurship project
work.
********************************
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TABLE OF CONTENTS
1. WHAT IS ENTREPRENEURSHIP ?....................................................
2. WHO IS AN ENTREPRENEUR ?.........................................................
3. NEED OF ENTREPRENEURSHIP...
4. TYPES OF ENTREPRENEURSHIP.
5. FACTORS AFFECTING ENTREPRENEURSHIP
6. BASIC PROBLEMS OF MARGINAL ENTERPRENEURSHIP
7. IMPACT OF BIG ENTREPRENEURSHIP ACTIVITY..
8. INVESTMENT CASTING OF LOST WAX TYPE- COMPANY PROFILE
9. WHAT IS INVESTMENT CASTING...
10. BENEFITS OF THE PROCESS.
11. PROCESS CHARACTERISTICS.
12. FUTURE PROCESS AND DEVELOPMENT
13. OVERVIEW OF THE INVESTMENT CASTING PROCESS...
14. SCOPES OF INVESTMENT CASTING..
15. TOTAL COST TO ESTABLISH THE PLANT
16. CONCLUSION.
17. BIBLIOGRAPHY.
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WHA" IS EN"REPRENEURSHIP
Entrepreneurship is the practice of starting new organizations or
revitalizing mature organizations, particularly new businesses generally in
response to identifed opportunities. Entrepreneurship is often a difcult
undertaking, as a vast majority of new businesses fail. Entrepreneurial
activities are substantially diferent depending on the type of organization
that is being started. Entrepreneurship ranges in scale from solo projects
(even involving the entrepreneur only part-time) to major undertakings
creating many job opportunities. Many "high-profle" entrepreneurial
ventures seek venture capital or angel funding in order to raise capital to
build the business. Angel investors generally seek returns of 20-30% and
more extensive involvement in the business. Many kinds of organizations
now exist to support would-be entrepreneurs, including specialized
government agencies, business incubators, science parks, and some NGOs.
Entrepreneurship in a broader sense can be described as a process of action
an entrepreneur undertakes to establish his enterprise. It is a creative and
innovative response to the environment. Entrepreneurship is the inclination
(attitude) of mind to take calculated risk with confdence to a
predetermined business or individual objective. Entrepreneurship means
the function of creating something new, organizing and co-ordinating,
undertaking risk and handling economic uncertainty.
WHO IS AN EN"REPRENEUR #
An entrepreneur is a person who has possession over a new enterprise or
venture and assumes full accountability for the inherent risks and the
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outcomes. The term is a loanword from French and was frst defned by the
Irish economist Richard Cantillon. A female entrepreneur is sometimes
known as an entrepreneuse. However, with the word "entrepreneuse" being
the French feminine form of entrepreneur, its usage in English in
delineating sexes detracts from the meaning of the word "Entrepreneur."
Entrepreneur in English is a term applied to the type of personality who is
willing to take upon her self or himself a new venture or enterprise and
accepts full responsibility for the outcome.
The modern myths about entrepreneurs include the idea that they assume
the risks involved to undertake a business venture, but that interpretation
now appears to be based on a false translation of Cantillon's and Say's
ideas. The research data indicate that successful entrepreneurs are actually
risk averse. They are successful because their passion for an outcome leads
them to organize available resources in new and more valuable ways. In
doing so, they are said to efciently and efectively use the factors of
production. Those factors are now deemed to include at least the following
elements: land (natural resources), labour (human input into production
using available resources), capital (any type of equipment used in
production i.e. machinery), intelligence and knowledge, and creativity. A
person who can efciently manage these factors in pursuit of a real
opportunity to add value in the long-run, may expand (future prospects of
larger frms and businesses) and become successful.
Entrepreneurship is often difcult and tricky, as many new ventures fail.
Entrepreneur is often synonymous with founder. Most commonly, the term
entrepreneur applies to someone who creates value by ofering a product
or service. Entrepreneurs often have strong beliefs about a market
opportunity and organize their resources efectively to accomplish an
outcome that changes existing interactions.
Some observers see them as being willing to accept a high level of personal,
professional or fnancial risk to pursue that opportunity, but the emerging
evidence indicates they are more passionate experts than gamblers.
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Business entrepreneurs are viewed as fundamentally important in the
capitalistic society. Some distinguish business entrepreneurs as either
"political entrepreneurs" or "market entrepreneurs," while social
entrepreneurs' principal objectives include the creation of a social and /or
environmental beneft. Entrepreneurs are men of vision, drive and talent,
who spot our opportunities and promptly grasp them for exploition.
Entrepreneur is an individual who introduces something new into the
economy, a new method of production, a new product with which the
consumers are not familiar, a new source of raw-material or new market
and the alike.
NEE& OF AN EN"REPRENEUR
Entrepreneurs play an important role in developing and contributing to the
economy of a nation. It is all the more in a developing world where are
ample opportunities for innovations to exploit the available resources and
initiate entrepreneurial ventures. But the emergence of entrepreneurship in
all countries and in all parts of any country is not usually even. Commonly
we see more entrepreneurs in comparatively more developed areas.
Another paradox exists in terms of increasing number of unemployed
population, seeking wage earners career and unaware of the wide
opportunities for entrepreneurial career. This is, by and large, because of
lack of education about entrepreneurship.
The business entrepreneur, the archetypal enterprising person, has become
the focus of interest in many nations as an instigator of social and economic
change. The search is on for more and better ways of creating enterprising
people and specially for developing entrepreneurs. For this, the role of
education and training is typically very important. Education is a strong
infuencing media that sets values, develops attitudes and motivation and
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induce people to acquire skills and competencies to achieve goals. The
word education can be linked to the word enterprise in three ways
Education about enterprise in which the role of education is in raising
awareness of enterprise and entrepreneurship as a key change agent in
economic process.
Education through enterprise in which the education process itself can be
enhanced by using pedagogic styles which work in and makes use of
enterprising situations including the student concerned and real world
project driven approaches
Education for enterprise which is aimed at entrepreneurship
development and includes training existing entrepreneurs as well as for
new business start-up.
"(PES OF EN"REPRENEUR
I have made the point that the one trait common to all entrepreneurial
hearts is a drive toward independence, and I added that varying levels of
that independent spirit serve to create a scale on which we could fnd and
defne diferent types of entrepreneurs. Id like to expand on those
thoughts.
The notion of difering types of entrepreneurs is only important if one is
in some way connected to the world of self-employment. And frankly,
unless a person has a direct use for this type of information, the subject is
boring. But guess what? At least 25% of Americans are plugged directly
into the subject as small business owners, employees of those businesses, or
family members of entrepreneurs. As stated before, using a broad brush to
defne the entrepreneurial personality will not work for serious
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entrepreneurs because it leaves too many possibilities to examine, too many
roads to travel that are unnecessary as one decides on their future. In a
nutshell, it is neither forward thinking nor efcient to lump together, all the
players and all the personalities. Making broad assumptions about the
entrepreneurial personality can also lead to danger and business failure.
Over time I have identifed at least fve distinct entrepreneurial types, and
that discovery represents a major step up from the quick fx tests that
claim to evaluate ones entrepreneurial personality in a few minutes time.
You know the tests Im talking about. The ones found in pop magazines.
The multiple choice questionnaires that help puf up the ego and encourage
us to think of ourselves as independent, entrepreneurial leaders with all
the right stuf. Folks, not all of us have the right stuf for the
entrepreneuriallifestyle, but then again, most entrepreneurs do not possess
the right stuf to make it as great corporate stafers at the highest levels.
Why? Because they tend to upset the apple cart and make other staf
uncomfortable.
The question is not whether a test says a person can be or should be an
entrepreneur. The issue is whether or not a person knows in their heart
what type of entrepreneur they are, if any, before the journey begins.
There is little or no value associated with a 15-minute personality test that
gives people a green light to buy a franchise. Could that test possibly
provide better analysis than a system that allows a person to think
through ownership issues on their own? There is little value in those tests,
and there is little value in pursuing an entrepreneurial lifestyle based on
what other people claim to be hot new opportunities. It is the opinion of
the prospective entrepreneur that matters most, but unfortunately we have
been conditioned to accept salesmanship and promotion rather than
thinking for ourselves. The more informed and defnite we become
concerning our traits and objectives, the better choices we are able to make.
First, is the Intrapreneur!! Although tied to the other owned organization
where they are employed, the intrapreneur enjoys independent
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responsibilities where risk and reputation are part of the assignment. What
kinds of assignments would those be? Heading up a take-over or merger.
Implementation of a new business development plan.
Finally, the Practical Visionary (?) with the question mark following the
term grabs for the greatest measure of independence. This person follows
their heart and their dream with great gusto, but the question mark is
attached because until the vision is proven, its practical value and
acceptance by the marketplace remains a question.
FAC"ORS AFFEC"ING EN"REPRENEURSHIP
Psychology
Human Capital
Life Course Stage
Environment
Social Networks (Gender)
Ethnic
Resources
Culture and Entrepreneurship
Culture: shared cognitions, values, norms and expressive symbols of a
society or Subgroup
Culture as a Socialization Agent
Supply-side Mechanism: Individuals are socialized into a societys or
groups culture which encourages entrepreneurship
Examples:
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Protestant Ethic and Capitalism (Weber)
Soviet / communist culture and efect on
Entrepreneurship Culture as Legitimating Agent
Demand-side Mechanism: Environmental factors (widely-held rules and
beliefs) afect the demand for entrepreneurial activity.
Individuals, organizations, products, and markets conform to these rules
and beliefs in order to gain legitimacy and gain access to resources in order
to survive.
To gain legitimacy new ventures must present themselves within societal
norms, so others can believe in their future success as a business
Rationalized Environments
Institutional Theory in Sociology
Focuses on cognitive, normative, and regulatory structures
that provide meaning to social behavior
Main Thesis
Environments in which organizations must operate have
become rationalized, i.e., organizations are subject to prescribed rules
and ideologies regarding proper organizational practices or forms;
Rationalization leads to a world society, an orderly society
Loci of Rationalization
Elite Organizations
Provide models for successful organizing
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Nation-State
Constructs laws and policies for the public good
Sciences and Professions
Knowledge system as demystifying nature; truths about how the social
system works
BASIC PROBLE+S OF S+ALL EN"REPRENEURSHIP
Probably the most uncomfortable are the political and ethnical
ones.
According to diferent surveys, the most frequent complaints
concern constantly changing laws, high tax rates, lack of capital,
complicated access to credit, lack of working capital, high competition, and
bureaucracy.
The basic problem is the huge and constantly growing amount of
administrative costs, the extraction of extra-legal fees for permissions and
approvals, and the high pressure of corruption. The state's participation in
business, its interference in competition and its violation of the rights of
entrepreneurs are serious barriers. Currently, the pressure on leu,
Romanian national currency. After 15 years of constant depreciation of the
leu, since last autumn we have been witnessing the opposite situation.
Entrepreneursare having a hard time to adapt, especially the ones who
export in Europe. Access to capital, a labor code that is very much in favor
of the employees, and competition from China and other Asian countries
are other constraints to developing entrepreneurship.
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I+PAC" OF BIG EN"REPNUERSHIP AC"I,I"(
The importance of entrepreneurship for achieving economic growth in
contemporary economies is widely recognized, both by policy makers and
economists. However, empirical evidence linking entrepreneurship to
economic growth is scarce. This paper investigates the relation between
entrepreneurship and economic growth at the country and regional level. It
contributes to the understanding of how entrepreneurship may afect
economic growth. It is investigated whether the impact of entrepreneurship
on economic growth varies with the development level of an economy, with
the sector of economic activity, and with the quantity and quality of
entrepreneurial supply.
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I-.e/01e-0 Ca/02-g o3 Lo/0 Wa4 "56e
CO+PAN( PROFILE
Investment casting is used in the aerospace and power generation
industries to produce turbine blades with complex shapes or cooling
systems. Blades produced by investment casting can include single-crystal
(SX), directionally solidifed (DS), or conventional equiaxed blades. It is also
widely used by frearms manufacturers to fabricate frearm receivers,
triggers, hammers, and other precision parts at low cost. Other industries
that use standard investment-cast parts include military, medical,
commercial and automotive.
Investment casting ofers high production rates, particularly for small or
highly complex components, and extremely good surface fnish with very
little machining.
R.K Engineers & Manufacturers is a quality manufacturer of Investment
Casting & Precision Investment Castings by lost wax process. R.K
Engineers & Manufacturers ofers highest quality of engineering by its ultra
modern plant equipped with all latest Investment Casting Equipmentsand
high tech laboratory.
R.K Engineers & Manufacturers is an Investment casting company in India
producing Ferrous & Non Ferrous castings. We are involved in Producing
Cheap and very high Quality Investment castings as on customized
requirements for Auto, Engineering, Pumps, Valves, Medical Equipments,
and Chemical Industry etc.
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W7a0 I/ I-.e/01e-0 Ca/02-g #
Investment casting converts molten metal in a single operation to precision
engineered components with a minimum wastage of material and energy
and subsequent machining. It has a versatility approached by few other
metal forming processes. Intricate or re-entrant contours can be
incorporated. These features ofer great freedom of design with the
process. The versatility of the technique extends to materials, since virtually
any alloy can be cast. Castings of over 250 kg and an envelope of 1 cubic
metre are common place.
The IC process is distinguished by the use of an expendable pattern. A
metal die is usually used to produce the pattern, now almost universally of
wax. These injection dies are normally made of duralumin or brass.
Preformed ceramic or water soluble cores may be used to give precision
internal cavities and these are located in the wax die prior to injection.
Patterns can be mounted onto a runner system to give an assembly ready
for subsequent coating with refractory.
Industrial investment casting is based on the ceramic shell process where
the wax assembly is dipped into thin refractory slurry and after draining,
fne grains of refractory are deposited onto the damp surface, providing a
primary refractory coating. The primary coat typically contains a zircon
based refractory while the binders used are either alcohol based (ethyl
silicate) or water based (silica sol) or a hybrid of these. When the primary
coat has hardened or set, subsequent cycles of wet dipping and dry
sanding build up the thickness of the invested material to provide a
refractory shell that, when fully hardened, is sufciently strong to hold the
liquid metal during casting.
At the end of the investing process, the wax pattern material is removed by
thermal means, steam autoclaving being usual. The mould is heated to a
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high temperature to eliminate any residual wax and to induce chemical and
physical change in the refractory that will ensure maximum strength and
stability combined with minimal reaction between the mould surface and
the liquid metal to be poured into the investment casting for lost wax type.
The majority of investment casting foundries has air melting facilities and
cast a wide range of materials. Steel casting furnaces tend to be of the roll
over or tilt induction melting type, whilst for many of the more advanced
nickel super alloys, vacuum melting / casting is essential. In the case of
aluminum investment castings, melting may be by gas or electricity, while
various methods of pouring the molten metal are in use (e.g. it may be
gravity vacuum or pressure assisted) These are the methods of pouring.
When the mould has cooled sufciently, the mould material is removed to
leave the castings which are then separated from the running system.
Various postcasting operations may be carried out to meet customer
requirements.
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Be-e80/ o3 07e Proce//
The benefts of the investment casting process may be summed up by the
four words accuracy, versatility, integrity and fnish. Few if any alternative
metal forming methods can ofer such a unique and broad spectrum of
advantages. Accuracy and versatility stem from the use of a one piece
mould without a joint line or the need for draft angles. These features not
only give rise to a component shape that is aesthetic and uniform; they also
allow the process to give, on a regular basis, consistent and repetitive close
tolerances, intricate and re-entrant contours (many impossible to create
economically by alternative manufacturing techniques) and competitive
cost ratios. Versatility extends to the choice of materials since virtually all
alloys can be investment cast.
Utilising the aluminum die form ensures tooling is relatively cheap and is
adaptable should design changes be necessary. It also enables relatively
small quantities, typically for research and development trials, to be
produced prior to commitment to production quantities.
Casting integrity is an important feature of the process and investment
casting has a long history of serving the most demanding sectors of
industry. This has promoted a tradition of quality and reliability, an aspect
that by recent work to develop production methods of guaranteed integrity
has resulted in fatigue performances equal to that given by forgings
measured longitudinally. Based on this work, investment castings are now
beginning to replace forgings and machined components in fatigue related
environments.
Other advantages arise from the high degree of dimensional accuracy, + or
- 0.13 mm per 25 mm with improvements up to + or - 0.08 mm per 25 mm
and the excellent surface fnish that can be routinely achieved, typically 1.5
to 3.2 microns with improvements up to 0.8 microns.
Typical minimum wall thickness of 1.5 mm with thinner sections of 1 mm
is possible. Tolerances quoted should be taken as a guide, as they may vary
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depending on the complexity and confguration of the component.
Consistency from casting to casting will generally be within the tolerances
indicated with individual foundries being able to advice on this point.
These characteristics minimize the requirements for machining, in some
cases eliminating it entirely, and this leads to substantial savings in raw
materials, labour costs and capital expenditure, reduces and simplifes
production control and simplifes assembly operations.
These benefts individually ofer great competitive advantages; collectively
they suggest an overwhelming case for the consideration of investment
casting as the most economic method of forming for a wide range of metal
components.
Pro!"" C#$r$%!r&"%&"
FREEDOM OF DESIGN
HIGH PRODUCTION RATES
HIGH DIMENSIONAL
ACCURACY
HIGH DIMENSIONAL
CONSISTENCY
HIGH INTEGRITY CASTINGS
EXTREMELY GOOD SURFACE
FINISH CAN BE OBTAINED
COMPLEX SHAPES CAN BE
CAST
LONG/SHORT RUNS CAN BE
ACCOMMODATED
MACHINING CAN BE
REDUCED OR ELIMINATED
MINIMUM FINISHING OF
CASTINGS REQUIRED
ALMOST ANY ALLOY CAN
BE CAST
ENVIRONMENTALLY
FRIENDLY PROCESS
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Most industries requiring castings are catered for but investment castings
are admirably suited for high technology, high volume orders especially in
respect of the aeronautical industry. The petroleum, chemical, electronic,
defence, prosthetic and automobile industries are also large users of
castings produced by the process.
F'%'r! Po%!(%&$) *
+!,!)o-.!(%
Withthe development of rapid prototyping techniques for the production
of patterns and shells it is now possible to produce investment castings
quickly with lead times reduced to less than two weeks.
Work done in BICTA Committees on high integrity castings utilizing
vacuum produced ingot and melting and Hipping will ensure the process
will further replace welded and forged components extending the feld of
use of investment castings in the forming of the lost wax type.
Casting size and weight will increase with 1 cubic metre plus envelopes
and 500Kg castings becoming commonplace in steel. With the use of
improved melting techniques and larger melting and casting facilities
investment castings can be shown to be the fastest growing metal forming
technique and investment casting now represents some 15% of all metal
cast in the UK.
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O/ER/IEW OF THE IN/ESTMENT CASTIN0
PROCESS
Investment casting, often called lost wax casting, is regarded as a precision
casting process to fabricate near-net-shaped metal parts from almost any
alloy. Although its history lies to a great extent in the production of art, the
most common use of investment casting in more recent history has been the
production of components requiring complex, often thin-wall castings.
While a complete description of the process is beyond the scope of the
discussion here, the sequential steps of the investment casting process will
be briefy described, with emphasis on casting from rapid prototyping
patterns.
The investment casting process begins with fabrication of a sacrifcial
pattern with the same basic geometrical shape as the fnished cast part.
Patterns are normally made of investment casting wax that is injected into a
metal wax injection die. Fabricating the injection die often costs tens of
thousands of dollars and can require several months of lead time. Once a
wax pattern is produced, it is assembled with other wax components to
form a metal delivery system, called the gate and runner system. The entire
wax assembly is then dipped in ceramic slurry, covered with sand stucco,
and allowed to dry. The dipping and stuccoing process is repeated until a
shell of ~6-8 mm (1/4-3/8 in) is applied.
Once the ceramic has dried, the entire assembly is placed in a steam
autoclave to remove most of the wax. After autoclaving, the remaining
amount of wax that soaked into the ceramic shell is burned out in a
furnace. At this point, all of the residual pattern and gating material is
removed, and the ceramic mold remains. The mold is then preheated to a
specifc temperature and flled with molten metal, creating the metal
casting. Once the casting has cooled sufciently, the mold shell is chipped
away from the casting. Next, the gates and runners are cut from the casting,
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and fnal post processing (sandblasting, machining) is done to fnish the
casting.
Investment Casting Process Description
Investment Casting Process Description
22 | P a g e
Investment Casting Process Description
So-!" o1 I(,!"%.!(% C$"%&(2
Design flexibility
Investment casting produces near-net-shape confgurations, ofering
designers and engineers freedom of design in a wide range of alloys. The
process is capable of producing precise detail and dimensional accuracy in
parts weighing many pounds or just a few ounces.
Wide choice of alloys
More than 120 ferrous and nonferrous metals are routinely cast at
Hitchiner.
Elimination of tooling setup
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By ofering near-net-shape confguration, fxturing costs are substantially
reduced or eliminated.
Reduction of production costs
Costly machining operations are reduced and often eliminated. No capital
equipment investment is needed to produce parts in-house.
Reduction of assembly operations
Several parts can be made as one casting, reducing handling, assembly and
inspection costs.
Reproduction of fine details
Splines, holes, bosses, lettering, serrations and even some threads can be
cast.
Process Comparison Chart
Process
Tool
Cost
Unit
Cost
Metal
Options
Design
Freedom
Volume
Capabil.
Draft
Req'd
Tolerance
Control
Size
Range
Surface
Finis
!all
Min.
"ormal
Deli#er$
%n#estment
Cast
&#g. 'ig Most Most &ll "o &#g. &#g. &#g. Small( &#g.
Die Cast 'ig *o+ Fe+ *east 'ig ,es &#g. &#g. &#g. &#g. &#g.
Forging 'ig &#g. &#g. *east 'ig ,es -oor &#g. -oor *arge *ong
-ermanent
Mold
&#g. &#g. &#g. &#g. &ll ,es &#g. &#g. &#g. *arge &#g.
-laster
Mold
*o+ 'ig Fe+ &#g. *o+ ,es &#g. &#g. &#g. *arge Sort
-o+der
Metal
&#g. *o+ &#g. *east 'ig "o .est Small .est Small &#g.
Resin Sell
Mold
&#g. &#g. &#g. &#g. &ll ,es &#g. &#g. -oor *arge &#g.
Sand Cast *o+ &#g. Most &#g. &ll ,es -oor *arge -oor *arge Sort
2 | P a g e
R&2#%" o1 L$(3
We are on the process of submitting a memorandum for acquiring 30,000
sq. meters of land at Adityapur Industrial Area Development (AIDA),
Jamshedpur. This will be completed after the state government sanctions
us a plot to set up our manufacturing unit.
R!4'&r!3 A--ro,$)" * L&!("&(2
NOC for acquiring land.
NOC from the inspector for factories and boilers.
Clearance from the state pollution control board (OSPCB).
PRO5ECT IMPLEMENTATION AN+
OR0ANISATIONAL ASPECTS
Basis and Presumptions
i) The basis for calculation of production capacity has been taken on single
shift basis on 75% efciency.
ii) The maximum capacity utilization on single shift basis for 300 days a
year. During frst year and second year of operations the utilizationis 60%
and 80% respectively. The unit is expected to achieve full capacity
utilization from the third year onwards.
iii) The salaries and wages, cost of raw materials, utilities, rents, etc. are
based on the prevailing rates in and around Bhubaneswar. These cost
factors are likely to vary with time and location.
iv) Interest on term loan and working capital loan has been taken at the rate
of 16% on an average. This rate may vary depending upon the policy of the
fnancial institutions/agencies from time to time.
2! | P a g e
v) The cost of machinery and equipments refer to a particular make/model
and prices are approximate.
vi) The break-even point percentage indicated is of full capacity utilization.
vii) The project preparation cost etc. whenever required could be
considered under pre-operative expenses.
ANNEXURE- 2
Implementation Schedule
The major activities in the implementation of the project have been listed
and the average time for implementation of the project is estimated at 12
months:
Sl.No. Name of Activity
Period in
Months
(Estimated)
1. Preparation of project report 1
2. Registration and other formalities 1
3. Sanction of loan by fnancial institutions 3
4. Plant and Machinery:


(a) Placement of orders 1
2$ | P a g e

(b) Procurement 2

(c) Power connection/ Electrifcation 2

d) Installation/Erection of machinery/Test
Equipment
2
5. Procurement of raw materials 2
6.
Recruitment of Technical
Personnel etc.
2
7. Trial production 11
8. Commercial production 12
A--)&$%&o( Ar!$"
Idol
Ornaments
Jewellery
Blade of Turbine
Blade of Jet
2% | P a g e
Co"% R!4'&r!3 1or %#! E"%$6)&"#.!(% o1 %#!
P)$(%
F24e9 co/0
Co/0 o3 e:;261e-0/ re:;2re9
Items Numbers Cost/item (in
Rs.)
Total Cost (in Rs)
Shovel 50 500 25,000
Riddle 50 500 25,000
Floor rammer 50 1000 50,000
Bench rammer 50 800 40,000
Swab 150 750 1,12,500
Gate cutter 150 150 22,500
Inside square 500 250 1,25,000
2' | P a g e
Box fask 50 2000 1,00,000
Trowel 50 5000 2,50,000
Lifter 150 115 17,250
Sand cutter 150 150 22,500
Furnace 1 1,000,000 10,00,000
Moulding fask 500 5000 25,00,000
Land 1,00,000 sq. feet 400 4,00,00,000
Cost of const. of
line
35,00,000
2) | P a g e
,ar2ab<e Co/0
Items Numbers Cost/Item (in Rs)Total Cost (in Rs)
Labour Cost 50 5,00,000
Electricity 7,00,000
Water Bill 50,000
Stationary 25,000
Sand 50 TR 1500/TR 75,000
Wax 1 TR 8,00,000
Misc. 2,00,000
"o0a< Ca620a< Re:;2re9 0o E/0ab<2/7 07e Co16a-5
=
F24e9 Co/0 > ,ar2ab<e Co/0
=
R/. !? *1? 3)?%!*
3* | P a g e
Brea@e.e- A-a<5/2/ o3 Pro9;c0 A";rb2-e B<a9eB
What Is Breakeven analysis/ 0 The break-even point for a product is the point
where total revenue received equals the total costs associated with the sale
of the product (TR=TC) Break-even point is typically calculated in order for
businesses to determine if it would be proftable to sell a proposed product,
as opposed to attempting to modify an existing product instead so it can be
made lucrative. Break-Even Analysis can also be used to analyze the
potential proftability of an expenditure in a sales-based business.
Ca<c;<a02o- O3 brea@e.e- Po2-0 O3 "7e Pro9;c0CD
Cost Of Per Turbine Blade = Rs.50, 0000
Total Cost =Fixed Cost+Variable Cost
=Rs5, 01, 39,750
Break even point 5, 01, 39,750/50,000 =1003 No of turbine blade.
31 | P a g e
The project is prepared through the collection of diferent
departmental policies of government as well as technical
consultancy from various organizations and during these project
fnancial policies of diferent fnancial institute and banks.
This project is an analytical representation of data collected from
various sources so that during real time implementation further
clarifcations must be done to make the project a success. Hence,
after going through a detailed study we fnd that the location is
suitable for the fructifcation of our project.
============================
32 | P a g e
1. Industrial Engineering & Management, O.P. Khanna.
2. Entrepreneurship of Electronic Industries, M.V. Deshpande ,
Deep & Deep Publications
3. www.techno-preneur.com
33 | P a g e