Detailed Project Report on led light (home and street lights) assembly/manufacturing plant

LED LIGHTS (HOME AND STREET LIGHTS) ASSEMBLY/MANUFACTURING PLANT
[CODE NO. 3231]  

Light emitting diode (LED) is a semiconducting device that emits light when electrical current is applied to the device. LEDs are said to be the future light source because of their low energy usage and efficiency. The advantages of LEDs are that they are very robust, have a very long lifetime or up to 50,000 hours, they are easily dimmable and fail by dimming over time, rather than burn off like incandescent light bulbs. LEDs cause less glare irritation because of the smaller beam angle of the luminaire. LEDs are very common as indicator lights in electrical equipment and recently in higher power applications such as flashlights and artificial lighting. The colour of the light depends on the composition and condition of the semiconducting material used. It can be infrared, visible or ultraviolet. Blue, green and red LEDs can be used to produce most perceptible colours, including white.

Today, after many years of development, the LEDs on the market are now emitting white light in different colour temperatures as well as an advanced RGB control to produce coloured light to capture different moods for various aspects. Because of the huge potential of LED technology and the constant improvements in the quality (e.g. colour rendering), it can be predicted that the use of LEDs will become more common in both homes and offices with the advantage of energy savings due to their efficiency and long lifetime. Another advantage of using LED is it does not contain Hg, which is not an eco-friendly chemical and has adverse effect on human body.


COST ESTIMATION

Plant  Capacity                                          :    1623.00 Nos./day
land & Building (600 sq.mtrs)                :    Rs. 43.50 Lacs
Plant & Machinery                                     :    Rs. 2.93  Lacs
Working Capital for 2 Months                 :    Rs. 1.95  Cr
Total Capital Investment                          :    Rs. 2.54  Cr
Rate of Return                                           :    107%
Break Even Point                                      :    24%



INTRODUCTION    
WHAT IS LIGHT EMITTING DIODE?    
WORKING PRINCIPLE OF LIGHT EMITTING DIODE    
ADVANTAGES OF LED OR LIGHT EMITTING DIODE    
LED LIGHT    
TYPES OF LED LIGHTING    
LED LAMPS    
LED FIXTURES    
LED HOME LIGHT    
OTHER BENEFITS OF LED LIGHT BULBS:    
TYPES OF LED BULB    
LED TUBE LIGHT    
BENEFITS:    
LED STREET LIGHT    
ADVANTAGES    
DISADVANTAGES    
PARTS OF LED STREET LIGHT    
LED LIGHT PANEL
DRIVER    
SPECIFICATIONS OF THE DRIVER GIVEN BELOW:    
STREET LIGHT LENS    
KEY FEATURES OF A LENS:    
GENERAL INFORMATION:    
GLASS COVER    
ADVANTAGES OF LED LIGHTING    
REDUCED HEAT OUTPUT    
LIFETIME OF LED LIGHTING    
DURABILITY OF LED LIGHTS    
LED LIGHTING EFFICIENCY    
LIGHT OUTPUT    
DISPOSING OF LED LIGHTS    
RANGE OF USES    
INSTANT LIGHTING    
LESS WIRING REQUIRED
HEALTH BENEFITS    
LOWER MAINTENANCE COSTS    
TOP 10 BENEFITS OF LED LIGHTING    
DRAW BACK OF LED LIGHT    
USES AND APPLICATION    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
MANUFACTURING PROCES    
RAW MATERIAL    
PRINTED CIRCUIT BOARD    
DRIVER - IT CONSISTS OF TRANSFORMER, DIODE, RECTIFIER ETC.    
HEAT SINK - MADE OF ACRYLIC, SILVER, ALUMINIUM, CERAMICS,
SS, FR4 AND COPPER    
DIFFUSER    
BODY - MADE OF ALUMINIUM ALLOY    
CAP OR HOLER    
ASSEMBLING PROCESS    
INCOMING RAW MATERIAL INSPECTION    
CLEANING AND RE-ASSORTING BEFORE PRODUCTION    
CABLE CUTTING AND ASSORTING    
SOLDERING AND ASSORTING    
ASSEMBLY    
AGING TEST    
CLEANING AND LABELING    
RANDOM INSPECTION    
PACKAGING    
LOADING FOR SHIPMENT.    
QUALITY CONTROL    
FOR INDOOR LIGHT    
(A) WORK AREA LIKE CABIN AND WORK STAATION    
(B) CORRIDORS    
TESTS:    
TYPE TEST    
ACCEPTANCE TESTS:    
SAMPLE SIZE AND CRITERIA FOR CONFORMITY:    
ROUTINE TESTS:
TESTING METHODS
VISUAL AND DIMENSIONAL CHECK:    
CHECKING OF DOCUMENTS OF PURCHASE OF LED:    
RESISTANCE TO HUMIDITY TEST:    
INSULATION RESISTANCE TEST:    
HV TEST:    
OVER VOLTAGE PROTECTION:    
SURGE PROTECTION:    
REVERSE POLARITY:    
TEMPERATURE RISE TEST:    
RA (COLOUR RENDERING INDEX) MEASUREMENT TEST:    
(11) LUX MEASUREMENT:    
(12) FIRE RETARDANT TEST    
(13) TEST FOR IP20 PROTECTION    
(14) ENVIRONMENTAL TESTS    
(15) RELIABILITY TEST    
(16) LIFE TEST    
(17) ENDURANCE TEST    
(18) SAFETY:    
MARKET SURVEY    
PLANT LAYOUT    
PRINCIPLES OF PLANT LAYOUT    
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE
SERVICE ARE:    
PLANT LOCATION FACTORS    
PRIMARY FACTORS    
SPECIFIC FACTORS    
EXPLANATION OF TERMS USED    
IN THE PROJECT REPORT    
PROJECT IMPLEMENTATION SCHEDULES    
INTRODUCTION    
PROJECT HANDLING    
PROJECT SCHEDULING    
PROJECT CONSTRUCTION SCHEDULE    
TIME SCHEDULE    
PRESENT MANUFACTURERS/SUPPLIERS    
MANUFACTURERS/EXPORTERS/SUPPLIERS OF LED HOME
AND STREET LIGHT    
SUPPLIERS OF RAW MATERIALS    
PCB    
TRANSFORMER    
TRANSISTERS    
RESISTOR    
CAPACITOR    
SUPPLIERS OF RAW MATERIAL FOR LED LIGHT    
LED DIODES    
ALUMINIUM LED PCB    
LED BULB HOUSING    
LED BULB CAP    
LED LIGHT CASING    
SUPPLIERS OF PLANT AND MACHINERY    
       
                            
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