Detailed Project Report (DPR) on wooden doors external, internal for residential (capacity 100 doors per day)

WOODEN DOORS EXTERNAL, INTERNAL FOR RESIDENTIAL [3582]

Wood door is a door made of wood. It is very commonly used in constructions and known for its good machinability, strength and durability along with a lot of other abilities. Wood doors can be categorized in many ways. By the different manufacturing method due to the structure, the doors can be divided into three categories. Each category of doors has a very different structure from each other. • Real wooden tenon-joint door, • Wood composite door, • Veneer and wooden frame core door. Doors are different in design, structure and external finish. Wooden door structures may be of different types and different technologies: solid wood, blockboard or double-panel. Solid wood: veneered or laminated solid wood for long-lasting stability. This technology is used to produce Antikè and Rodi. Blockboard wood: perpendicularly-glued wooden strips for long-lasting stability. This technology is used to produce Baltimora and Baltimora New. Double-panel wood: sandwich structure with light interior. This technology is used to produce Fashion, Natura, Costellazioni, Casa Zen, Venezia. The external wooden finish is made using fine wood veneer to cover door elements with different materials, colours and finishing. Carpentry  and joinery are common terms used with any  class of  work with wood.  Strictly speaking carpentry deals  with  all works of a carpentry such as roofs, floors, partitions etc. of  a building, while joinery deals with the making of doors  windows, cupboards,  dressers, stairs and all the interior fitments  for a building. Timber  is  the basic material used for any  class  of  wood working.   The term timber is applied to the trees which  provide us with wood.  Furniture and fixture are essential for a family. Furniture and fixtures proposed to be manufactured in this scheme are made out of wood specially from CP teak, chap, haldu, Jack or similar  good quality wood.  With the modern life  furniture  and fixture  used in a family are wide and varied in nature  starting from  plank,  almirah, table, chair, rack, etc. Apart  from  this utility  furniture  is made out of good quality wood  and  highly finished adds beauty to   the room. Wood  with moisture content brought down to the extent  that it  does  not  further shrink under normal conditions by  way  of evaporation of moisture from it is called seasoned wood. Generally timber  with moisture content less than 15% does not  appreciably shrink and can be called as seasoned timber. It is desirable that in  carpentry and joinery work wood does not shrink after  it  is joined  and  finished .  But if unseasoned wood is used  it  will give out moisture to further dry and shrink after work is done. This  will  obviously  weaken the joints  and  give  clauses between  the  pieces for a bad finish.  When seasoned  timber  is used to joints remain understored and no gap develops between the pieces  of  timber after finishing.  Hence for  making  door  and window  shutters, furniture, interior decoration and  such  other work  where strength and finish matter use of seasoned timber  is advisable.  Since use of seasoned timber is  advisable.   Since use  of  seasoned  timber gives longer life  and  better  finish. there   is  growing  trend  to  used  seasoned  timber  in   wood industries. Various govt. departments including defense department are now  including use of  seasoned  timber  in  the specification for various work involving use of timber. STRUCTURE OF WOOD- The trees are known as growers, due to the  fact that each year a new layer of tissue is formed  on  the outside  of  previous  layers.   The  layers  are  termed  annual i\rings,  because  most trees produce one ring each  year.   Each annual  ring  is  composed  of an  open  porous  layer  known  as springwood, due to the rapid growth in spring, and thinner denser layer  called  autumn wood, due to the outer rings  of  the  tree known  as sapwood convey the watery sap from the roots up to  the leaves.   Here it undergoes certain chemical changes, and on  its return journey to the roots in autumn , this perfected gap leaves behind  various starchy secretions, gums or resins, according  to the type of tree.  These substances fill up the tissues, feed the tree,  and  help  to  form a denser  wood  known  as  doorman  or heartwood.   The cambium layer situated between the  sapwood  and the bark is responsible for the formation of new wood each  year. It divides up forming layer of new wood cells on the inside and a soft  layer  on the outside which becomes bark.   Each  year  the innermost layer of sapwood becomes transformed into heartwood. It is generally  understood that heartwood is the only  part of the tree which should be converted for use, as sapwood is more prone  to attack from wood-destroying organisms.  If  sapwood  is properly treated with an effective preservative, it is as durable as  harrowed,  similarly  treated,  when  used  under  conditions favorable to decay. The difference in colour   between  sapwood and  heartwood is most important when choosing wood for  joinery, the  decorative  value of which depends on the  dark  colour  and grain  of the heartwood.  Treating with preservatives is  useless and  staining is very difficult. as sapwood  absorbs  stains more readily  than heartwood and takes on a much darker shade. There fore,  for  all  joinery  work  it  is  better  that  sapwood  be eliminated altogether. Wood is generally used to manufacture so many things starting from furniture to industrial products. But mainly used to  manufacture wooden doors, windows, shutters etc. Besides these the other uses are to manufacture T.V. cabinets. Wooden TV cabinets are cheap and durable.  The rapid expansion of the TV network  in  India  has given a tremendous thrust to the TV manufacturing industries  and which in turn has generated a great demand for the various  parts and  accessories  in  the manufacture of TV  set  out  of  which, cabinet is an important component.

COST ESTIMATION

Plant Capacity                           100 Doors/Day  
Land & Building (1000 sq.mt)     Rs. 1.27 Cr
Plant & Machinery                    Rs. 35 Lac
Working Capital for 2 Months   Rs. 82 Lac
Total Capital Investment          Rs. 2.54 Cr
Rate of Return                         25%
Break Even Point                     61%


INTRODUCTION    
CLASSIFICATION OF WOOD -    
COMMON VARIETIES OF INDIAN TIMBER    
USES OF SEASONED WOOD    
INSTRUMENT INDUSTRIES    
B.I.S. SPECIFICATION    
SPECIFICATION OF WOODEN DOOR    
TIMBER DOOR, WINDOW AND VENTILATOR FRAMES — SPECIFICATION    
(THIRD REVISION)    
1 SCOPE    
2 REFERENCES    
4 MATERIALS    
5 CONSTRUCTIONS AND WORKMANSHIP    
6 DIMENSIONS, SIZES AND TOLERANCES    
EXAMPLE 1    
EXAMPLE 2    
7 LOCATIONS OF HOLDFASTS    
8 FINLSH    
NOTES    
9 SAMPLING    
10 MARKING    
MARKET SURVEY    
DOOR AND WINDOW FOR RESIDENTIAL BUILDING    
TABLE– RECOMMENDED OPENING SIZES – DOORS    
WOODEN DOOR ELEVATION    
FIG. ELEVATION OF WOODEN DOOR    
TYPICAL DOOR DETAIL – WOOD    
FIG. ELEVATION OF WOODEN DOOR    
BOTTOM RAIL    
KITCHEN DOOR ELEVATION    
FIG. ELEVATION OF KITCHEN DOOR    
DETAILED EXPORT DATA OF WOODEN DOOR SIZE    
MANUFACTURERS OF WOODEN DOORS    
MANUFACTURING PROCESS    
PROCESS FLOW DIAGRAM    
PROCESS IN DETAILS    
PROCESS INVOLVE MAINLY IN FIVE GROUPS-    
SUMMARY OF THE MANUFACTURING PROCESS    
INSPECTION AND QUALITY CONTROL    
PLANT LAYOUT    
SUPPLIER OF RAW MATERIALS    
SUPPLIERS OF PLANT AND MACHINERY    
VERTICAL SAW MACHINE    
WOOD CUTTING MACHINE    


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)