Detailed Project Report on electric bus building plant

ELECTRIC BUS BUILDING PLANT
[CODE NO.3305]


Over the past decade, India’s cities have been witnessing an increasing trend in motorization with deteriorating air quality, and there have been calls to promote public transport as a way out of this gridlock. It is in this context that electric buses can play a positive role, as there are several benefits associated with the shift from conventional diesel buses to electric buses in terms of reduction in local pollution, noise, and fuel consumption.

In spite of the many positive benefits related to the electric bus technology, certain challenges remain. Primary among these are costs and safety concerns. Currently, the Electric Vehicle (EV) technology is associated with significant capital costs, with the battery component constituting about half of the total manufacturing costs. Safety is yet another important parameter, and the biggest concern is that of a fire hazard. However, with a good Battery Management System (BMS), rigorous implementation of standard operating procedures, and customization of bus fleet, both safety and cost aspects can be effectively addressed. Electric buses have already been deployed on a large scale globally, and the technology is mature and evolving continuously.

COST ESTIMATION

Plant  Capacity                                                :     24.00 Nos/day
land & Building (20000 Sq.Mtrs)                  :    Rs. 10.48 Cr
Plant & Machinery                                           :    Rs. 5.10  Cr
Working Capital for 2 Months                       :    Rs. 67.66 Cr
Total Capital Investment                               :    Rs. 83.93 Cr
Rate of Return                                                 :    56%
Break Even Point                                            :    35%

INTRODUCTION    
CATEGORISATION OF BUSES    
(A) SCHOOL BUS:
(B) SLEEPER COACHES:    
(C) TOURIST BUS:    
LOW CAPACITY BUS INCLUDE –    
MEDIUM CAPACITY BUSINCLUDE -    
HIGH CAPACITY BUS    
BUS BODY    
COMPONENTS OF BUS BODY    
(A) CROSS BEARERS    
(B) VERTICAL PILLARS    
(C) ROOF ARCH MEMBERS    
(D) CANT RAILS    
(E) WAIST RAILS    
(F) SOLE BARS    
(G) SEAT RAILS    
(H) FLOOR RUNNERS    
(I) ROOF RUNNERS    
(J) OUT-RIGGER BRACKETS    
(K) U” BOLTS    
(L) A PILLAR    
(M) FRONT OUTRIGGER MEMBERS    
TYPES OF BUS BODY    
1. NORMAL CONTROL BUS    
2. SINGLE DUCKER    
3. SPLIT LEVEL    
4. DOUBLE DECKER    
5. TWO LEVEL SINGLE DECKER    
6. ARTICULATED BUS BODIES    
PART NAME & LOCATIONS:    
TYPES OF BUS BODY CONSTRUCTION    
1. FRAME CONSTRUCTIONAL DETAILS:    
2. DOUBLE SKIN CONSTRUCTIONAL DETAILS:    
(A) INTERIOR PANELING:    
(B) EXTERIOR PANELING:    
TYPES OF BUS CONSTRUCTION    
(1) CONVENTIONAL TYPE CONSTRUCTION:    
THE FRAME SECTIONS ARE GENERALLY, USED    
ADVANTAGE:    
DISADVANTAGE:    
(2) INTEGRAL BUS BODY (MONOCOQUE/UNIBODY) CONSTRUCTION    
ADVANTAGES:    
DISADVANTAGES:    
USES AND APPLICATION    
(1) PUBLIC TRANSPORT    
(2) TOURISM    
(3) STUDENT TRANSPORT    
(4) PRIVATE CHARTER    
(5) PRIVATE OWNERSHIP    
(6) PROMOTION    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
(1) FABRICATION PROCESS OF STRUCTUE OF BUS BODY    
STRUCTRE SECTION    
STRUCTURE ASSEMBLY    
(2) SIDE PAENLING & ROOF PANELING    
(3) INTERNAL PANELING    
4. PROTECTION TREATMENT AND PAINTINGS    
PAINTING PROCESS    
5. FITTING OF INTERIOR AND EXTERIOR COMPONENTS    
6. MOUNTING OF BUS BODY TO CHASSIS    
QUALITY CONTROL    
(A)METAL TEATMENT    
(B) BODY MOUNTING:    
(C) FLOOR:    
(D) ROOF STRUCTURE:    
(E) SIDE STRUCTURE:    
(F) PANELLING:    
(G) CANT RAIL:    
(H) STEP WELL:    
7. TESTING:    
TEST CONDITIONS    
TEST PROCEDURE    
FACTORS AFFECTING ROLLOVER:    
(2) STABILITY TEST    
(3) JOINT STRENGTH TEST
(4) WATER LEAK PROOFING TEST    
(5) PREPARATION OF THE VEHICLE    
(6) TEST PROCEDURE    
(7) ACCEPTANCE CRITERIA    
(8) PDI (PRE DISPATCH INSPECTION)    
MARKET SURVEY    
MARKET DYNAMICS    
TRENDS    
GROWTH DRIVERS    
OPPORTUNITIES    
GLOBAL BUS MANUFACTURING INDUSTRY 2012-2017    
THE WORLD OF BUSES AND COACHES FOR 2012    
GLOBAL BIGGIE’S LINE UP FOR INDIAN BUS MARKET    
GLOBAL DEMAND FOR BUSES TO 632,000 UNITS IN 2016    
MANUFACTURERS/SUPPLIERS    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
M.S. CHANNELS AND ANGLES    
SUPPLIERS OF M.S. FLAT    
SUPPLIERS OF M.S PLATE    
M.S. PIPE    
CR/BP SHEET    
ALUMINIUM CHEQURED PLATE    
DEGREASING CHEMICAL    
PHOSPHATING CHEMICALS    
METAL PRIMER    
PAINT THINNER    
COATING POWDER    
ELECTRICAL HARNESS    
SUPPLIERS OF AUTO LIGHT    
MIG WELDING WIRE ELECTRODE    
FIRE EXTINGUISHERS    
AIR CONDITIONER    
SUPPLIERS OF SEAT    
SUPPLIERS OF SPEAKER    
SUPPLIERS OF PLANT AND MACHINERIES    
PUNCHING PRESS    
POWER PRESS    
SHEARING MACHINE    
ROLLING MACHINE    
BENDING MACHINE    
CNC PLASMA CUTTING MACHINE    
PNEUMATIC RIVETING MACHINE    
SUPPLIERS OF JIGS AND FIXTURE    
WELDING MACHINE    
MIG WELDING MACHINE    
PAINTING BOOTH    
CHROME PLATING PLANT    
PHOSPHATING PLANT    
POWDER COATING MACHINE    
METAL TESTING MACHINE    
PRECISION MEASURING TOOLS    
ELECTRICAL MEASURING INSTRUMENTS    
EOT CRANES    
POWER TRANSFORMERS    
ELECTRICAL PANEL    
COOLING TOWER    
EFFLUENT TREATMENT PLANT    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
AIR COMPRESSORS    
MATERIAL HANDLING EQUIPMENTS    
FIRE FIGHTING EQUIPMENTS    
SHOT BLASTING MACHINE    

        
APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET