Steel Fabrication Work (40 MT/Day)

STEEL FABRICATION WORK

[EIRI/EDPR/4679] J.C.: 2896XL

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.

As with other manufacturing processes, both human labor and automation are commonly used. A fabricated product may be called a fabrication, and shops specializing in this type of work are called fab shops. The end products of other common types of metalworking, such as machining, metal stamping, forging, and casting, may be similar in shape and function, but those processes are not classified as fabrication.

COST ESTIMATION

Plant Capacity            40 MT/Day

Land & Building (8000 sq.mt.)    Rs. 6.02 Cr

Plant & Machinery                    Rs. 4.25 Cr

Working Capital for 1 Month    Rs. 6.86 Cr

Total Capital Investment          Rs. 17.53 Cr

Rate of Return                          13%

Break Even Point                      70%

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)