Detailed Project Report on pcb manufacturing plant (automated)

PCB MANUFACTURING PLANT (AUTOMATED)
[CODE NO.3504]


A PCB is a printed circuit board, also known as a printed wiring board. It is used in electronics to build electronic devices. A PCB serves two purposes in the construction of an electronic device; it is a place to mount the components and it provides the means of electrical connection between the components.

Multilayer PCB Is made up of three or more conductive layers (copper foil layer), these layers are pressed together and form multilayer PCB. Copper foil layer is bonded together by PP (prepreg), Multilayer PCB is one of the most complex types in printed circuit board. Because of the complexity in PCB manufacturing process, low yield rate and difficulty of rework, making the price is relatively high.

Due to the packaging density increase in integrated circuit, which bring about interconnect highly concentrated, thus using multilayer PCB become necessary. In the layout of printed circuit boards, sometimes it will have some unforeseen design problems, such as noise, stray capacitance, crosstalk and so on, therefore, when design printed circuit board, it must be committed to make the length of signal wire as short as possible and avoid parallel circuits, etc. Obviously, it is hard to get satisfied solution from single-sided PCB or even double-sided PCB, due to the cross circuit number is limited. In the demand of mass interconnection and interdigitation, if printed circuit board wants to achieve a satisfactory performance, it must be extend to more than two layers, thus the multilayer PCB appeared.

Multilayer PCB at least has three conductive layers, two layers on surface side, and the rest of the layers are synthesized inside the insulation part. The electrical connection between each layer is usually realized by plated through hole. Unless special instructions, both multilayer PCB and double-sided PCB are plated through hole printed circuit boards.

A multilayer board consists of a number of layers of dielectric material that has been impregnated with adhesives, and these layers are used to separate the layers of copper plating. All of these layers are aligned and then bonded into a single board structure under heat and pressure. Multilayer boards with 48 or more layers can be produced with today's technologies.

In a typical four layer board design, the internal layers are often used to provide power and ground connections, such as a +5V plane layer and a Ground plane layer as the two internal layers, with all other circuit and circuit package formats.

In electronics, printed circuit boards, or PCBs, are used to mechanically support electronic components which have their connection leads soldered onto copper pads in surface mount applications or through drilled holes in the board and copper pads for soldering the component leads in thru-hole applications. A board design may have all thru-hole components on the top or component side, a mix of thru-hole and surface mount on the top side only, a mix of thru-hole and surface mount components on the top side and surface mount components on the bottom or circuit side, or surface mount components on the top and bottom sides of the board.

The boards are also used to electrically connect the required leads for each component using conductive copper traces.  The component pads and connection traces are etched from copper sheets laminated onto a non-conductive substrate.  Printed circuit boards are designed as single sided with copper pads and traces on one side of the board only, double sided with copper pads and traces on the top and bottom sides of the board, or multilayer designs with copper pads and traces on top and bottom of board with a variable number of internal copper layers with traces and connections.  

A PCB is found in almost every electronic device. If you have electronic components in a device, they are mounted on a PCB, big or small. Besides keeping the components in place, its purpose of a PCB is to provide electrical connections between the components mounted on it. As electronic devices have become more complex, and require more components, the PCB has become more populated, and dense with wiring and components.


COST ESTIMATION

Plant  Capacity                                              :      89.00 Sq. Mtr. PCB/day               
land & Building  (2000 Sq.Mtr)                    :    Rs.  2.12 Cr
Plant & Machinery                                         :    Rs.  2.92 Cr
Working Capital for 2 Months                     :    Rs.  7.64 Cr
Total Capital Investment                             :    Rs.  13.31 Cr
Rate of Return                                              :    40%
Break Even Point                                         :    38%


INTRODUCTION                                            
USES AND APPLICATION                                    
B.I.S. SPECIFICATIONS                                        
MARKET SURVEY                                            
INDIA DEMAND OF PCB                                    
PCB EXPORT DATA IN INDIA                                    
PCB IMPORT DATA IN INDIA                                    
MANUFACTURER/SUPPLIERS OF PCB                            
MANUFACTURING PROCESS                                    
MULTI-LAYER PCB’S:                                        
PCB MANUFACTURING STEPS                                
PROCESS FLOW CHART                                                  
QUALITY CONTROL                                                       
PLANT AND MACHINERY                                                                   
IT HAS GOT THE FACILITY OF INSPECTION OF PHOTO FILMS AND PCBS UNDER A TABLE LAMP WITH A MICROSCOPE.                                               
SUPPLIERS OF PLANT AND MACHINERY                                                          
AUTOMATED PLOTTER                                                                                     
EXPOSURE SYSTEM                                                                           
ETCHING CENTRE                                                                                      
MULTI SPINDLE DRILLING MACHINE                              
PCB EQUIPMENTS                                                                                     
UV CURING EQUIPMENT                                                                             
SCREEN PRINTING MACHINES                                                                       
DRY FILM LAMINATOR                                                           
COPPER PLATING MACHINE                                                        
PCB ETCHING MACHINE                                                            
COATING THICKNESS GAUGE                                                              
PCB TESTING SYSTEM                                                                     
PCB CUTTING MACHINE                                                                   
AIR POLLUTION CONTROL EQUIPMENTS                                          
OPTICAL INSPECTION SYSTEM                                                   
AIR CONDITIONING EQUIPMENTS                                                   
D.G. SETS                                                                                   
ETP PLANTS                                                                                
SUPPLIERS OF RAW MATERIALS                            
COPPER CLAD PHENOLIC SHEET                            
GLASS EPOXY SHEET                                    
SILK SCREEN                                        
ETCHING CHEMICALS AND CLEANING PCB CHEMICALS            
PRINTING INK                                        
 
        
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