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Technology Study Report On Bearing Industry: MSME - Development Institute
Technology Study Report On Bearing Industry: MSME - Development Institute
- : Prepared By : -
MSME - Development Institute, Government of India
Ministry of Micro Small and Medium Enterprises
Bais Godam, Jaipur 302 006 (Raj.)
Ph. 0141-2212098, 2213099, Fax. 2210553
e mail- dcdi-jaipur@dcmsme.gov.in
web- dcmsme.gov.in
2
CONTENTS
Page
METHODOLOGY
1.1 Introduction
1.2 Industry Overview
1.3 Global Collaboration
1.4 Status of Bearing and Bearing Component Cluster at Jaipur
1.5 Raw Material
1.6 Plant and Machinery in SME Sector
1.7 Manufacturing Process
5 PROJECT PROFILE 40 - 49
Annexures
a. Technology Providers
b. Quality Standards (BIS)
c. Chemical Composition of Through-Hardening Bearing Steels Composition
(%)
3
METHODOLOGY
Technology Study Report is prepared as per guide line given by DC(MSME). The
interaction with following prominent Bearing & Bearing component Manufacturers were
carried out to know more about present status as well as latest proven technology has
been adopted by MSME & Large Bearing Manufacturers. Some advance plant &
machinery suppliers were also contacted over phone or through internet.
Chapter - 1
1.1 INTRODUCTION
The Product
Bimetal
Antifriction Bearings
Bimetal bearings (also known as engine bearings) are primarily used in engines
of automobiles or machines. The bearings are meant to reduce the friction
8
between the moving parts of the engine crankshaft or crank shaft or associated
support surfaces.
Antifriction Bearings include Ball Bearings and Roller Bearings. Roller bearings
can further be subdivided into tapered roller. Cylindrical roller, Needle roller, thrust
bearings and other special application bearings. The main components of an
antifriction bearing are the inner race (ring), the other race (ring) the rolling
elements, cages (retainers) and seals. The following are the major types of
bearing.
a. Ball bearing
Ball Bearings
Roller Bearings
The bearing Industry in India can be divided into three segments; the
organized sector, comprising 12 leading manufacturers, located at Rajasthan,
Gujarat, Maharastra, Andhra Pradesh, Karnataka, Tamil Nadu, West Bengal and
Jharkhand primarily cater to the OEM Segment which are predominantly
automotive, Railway and other Industrial users. The unorganized sector includes
the small scale manufacturers and manufacturers of spurious bearings. The
unorganized sector contributes to about 18% of the total Industry turn over. The
unorganized sector players have a strong regional presence and mainly cater to
the needs of the replacement markets. The Indian bearing Industry is estimated at
Rs. 100 billion. The domestic Industry caters to the 74 % of total demand for
common varieties & sizes. The organized sector units contribute around 53% of
the Industry sales. The imports are about 26% of the total demand of the industry,
10
while about 18% import comes through official channels. There is also estimated
8% illegal imports. Legal imports generally represent the specialized / super
precision bearings not manufactured in India. Illegal imports generally represent
the entry of spurious imports of bearings. The legal imports are about Rs.1 8.00
billion while the spurious imports is about Rs. 8.00 billion.
- NSK Japan
- NTN Japan
- FAG Germany
- SKF Sweden
- NRB France
- Timken USA
11
All the manufacturers in the organised sector have entered into collaboration
agreements for supply of complete process know how as well as supply of major
manufacturing machinery. The collaboration agreements are still valid and the industry
gets all assistance for process, know-how product development,customer development,
tool design, production control techniques etc from them. Most of the big player are
having either technical or financial Collaboration with leading Auto Manufacturer.
International Collaboration gives Access to best technology in the world.
GLOBAL COLLABORATION
COMPANY COLLABORATION
NEI NTN
The Indian Bearing Industry, especially the companies having technical and
financial collaboration with Global player are expected to garner higher price in
export market
In view of the growing industrial and automobile sector, the growth in this
industry is going to be substantial . The requirement of bearings increasing day by
day in India in both the OEM and replacement market and increasing number of
small manufacturing industries developing in Jaipur (Rajasthan) Rajkot and
Surrender Nagar (Gujarat) and Punjab have come up in unorganized sector.
These industries are manufacturing from complete bearings to components and
supplying to leading players.
30.00
26.00
25.00 21.40
20.00
Market share in %
15.70
15.00
10.00 8.45
7.04
5.00 3.16
2.90 2.60
1.60 1.50
1.34 1.30 1.25 1.19 0.96 0.93 0.77 0.73 0.63 0.55
0.00
SKF Bearings India
Timken India
NRB Bearings
Tata bearings
HMT Bearings
Harsha
Sujana Industries
Bimtel bearings
ARB Bearings
Austin
Asian
SBL
Texspin
Others
Imports
Name of Companies
14
In the Jaipur Cluster, There are Approx 11 No. of SSI Bearing Manufacturing
Unit, about 90 No. of Outer & Inner Soft Races Manufacturing SSI Units and about
2000 No. of outer /Inner Races turning Tiny/Artisan units. Apart from above there
is one large scale bearing manufacturing unit at JAIPUR namely M/s. NEI Ltd.
owned by Birla Group.
the Cluster. The Bearing and Bearing components units at Jaipur Cluster are
engaged in manufacturing of outer & Inner Races, Cages Dust shield, Balls, & Ball
Bearing.
. The raw material used in the Manufacturing of bearing Races is SAE 52100 high
Carbon Chrome bearing steel, which has composition similar to EN-31 (100 CR 6
As per BIS specification). The raw material for Bearing Races is in the form of
Rods & Seamless Hollow Tubes. This is a Spherodised Annealed Steel. Alloy
Steel wire rods are used for the manufacture of rollers & balls. The cages and
retainers are made out of plain carbon steel of 1008 & 1015 grade.Other materials
like stainless steels are also used as per the customers requirements .
Approximate required composition for BEARING RACEs are:-
Constitute % Composition
Phosphorous 0.05
CAGE'S
BALL'S
These are following three methods which are being used by units manufacturing
bearing races (Soft Turned).
BAR ROUTE :-
Bar Turning
(Trepanning is the operation in which the outer race & inner race is parted off from
Radius Formation
Track Formation
In the Seamless Tube Method the Drilling and trepanning operation are not
required , the remaining operations are as follows :-
Parting
This process technology is preferably being used for the outer Dia of 25mm or
higher size. Apart 40% of the total volume of Soft Races turning is being produced
by using above mentioned method in the cluster.
23
Forging Method:-
Bearing Races are manufactured by Hot Forging Method. The operation of Drilling,
parting, and trepanning are not required while using Forging Method. The Metallic
closed Dies are used in Hot Forging Method. This method is more suitable and
economical for outer Dia of 30 mm and above size. In the cluster Approx. 10% of
Bearing Races are produced by using Forging Method. The Forged Bearing Races
are machined/finished as Indicated in the earlier method.
The Bearing Outer & Inner Races manufactured by using any one of the
method mentioned above are then supplied to large scale and small scale Bearing
manufacturing Unit. The further sequence of operation for manufacturing of
Bearing are as under
Assembly of Outer & Inner Races with Balls / Roller & Cage duly suited and
Packing
Heat Treatment
At each of the three steps, different processes are available, depending on the product.
Grinding
Surface grinding
Steel Ball :-
Steel Ball with Close tolerance and desired surface finish are produced by using
SAE-52100 Steel Rod. The process flow diagram for
Wire is fed from de-coilers into cold Header Machines when ere it cut into Blanks,
then pressed into balls between hemispherical dies.
26
Flow chart
Oil Lapping (with the help of H.S. Diesel oil and Chromium Oxide)
Inspection
Grading
Greasing
Packing
27
Steel Cage's:-
Steel Cages are manufactured by using Bearing Grade Steel Sheet. These sheets
are stamped with the help of Hydraulic Presses and various dies to provide the
desired form and size of Steel Cage.
Blanking
Bending
Drawing
Piercing
Cleaning
Inspection
Metal Shields - Bearing Metal Shields is protective closures which retains lubricants and assist
in preventing contaminants from reaching internal surfaces.
Dust
Shields - The aperture usually found in the top cover housing is sealed to form a barrier to
assist prevention of airborne contamination into the contact area
Shielded Bearings - A shielded bearing has a metallic shield on the backside and
Shielded bearings are not sealed bearings. With the shielded type of bearing, grease may
enter the bearing readily, but dirt is restricted by the close fitting shields. If there is no
shield on the backside of this bearing, the excess grease can escape into the inner
bearing cap of the equipment bearing housing.
Chapter-2
The following section present on Analysis of Business operation for the Bearing
and Bearing Component Cluster Jaipur. The following factors have been taken into
consideration in the Analysis.
Raw Material
Quality Standard
Infrastructural Facilities.
The raw material SAE 52100 Spherodised bearing steel only available from few Indian
Supplier.
Internationally, the accent is on achieving higher and higher quality levels of bearings.
Higher precision, minimum handling damages and maximum cleanliness are the thrust
areas for development. Individual units have their own grading of quality. SKF, for
example, designates t, as Q77, Q66, Q55, where Q66 is reported as the prevalent level
and Q55 as the level aimed at International manufacturers are moving towards special
bearings, and sub assemblies involving bearings, where production of small batch
quantities becomes more attractive.
High rates and consistency of productivity have been achieved by the manufacturers
abroad by line manufacture. The market demands there, permit mass production
techniques and thereby bring in economies in production.
30
- Upgrading of technology has generally come not from within or from market forces
but usually from the collaborator's insistence, if the latter has stakes, either financial or
through its name.
The following testing facilities are not available in most of the cluster units.
Metallographic
The Machinery and equipment used by majority of SSI units for manufacturing of Bearing
Races are of sub standard and obsolete. Even the SSI Bearing manufacturing units are
using the second Hand Imported Grinding & Honing Machine which are having Lesser
Tolerance Accuracy so the bearing manufactured by these units are not preferred by
International Industrial Buyer.
The Product require high degree of precision the manufacturer are unable to
maintain Accuracy with in 2 microns. In accordance with the standard of International
Market. The existing plant & machinery can give accuracy with 4 microns.
The profile cutting operation of Bearing Races is not properly done due to Non
Availability of optical profile grinder.
(1). Use of Kerosene for Splash Cleaning for Assembled Bearing and Swab Cleaning
of Individual Parts.
(6) Mar Quenching Oil is being used for Quenching, but Mar Quenching Salt is not the
practice.
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(10) Micro Structure Like Type of Martensite, Retained Austenite, Benetic Structure , is
not being inspected.
(13) Speed, Feed and Depth of cut for Turning and grinding are not optimum .
(18) Forging Dies are made of H 11 & H13 Hot Die Steel and Hot H21 & H 23 material.
The Quality of Bearing Races is concerned SSI Units have to follow the relevant
specification, drawing and other instruction provided by the purchaser. The system of
100% inspection is being followed without any process wastage. However some of the
Bearing manufacturer permit 1% process wastage. In the event of rejection the unit has
to make payment for loss of the raw material the Bearing Manufacturer.
The main defects of Ball Bearing Races are Track Centre out (for which Unit is 100
Micron) eccentricity in outer Dia and Track Dia or Base and Track Dia. The Radius form
on Outer Dia and base of race is not proper which Account for major rejection.
The gauge calibration facility are not available as the gauge are required to be calibrated
periodically in order to ensure the quality of product. The most of SSI/Artisan Unit of
Cluster do not have the well organized marketing channel and Demand forecasting
system and are facing marketing problem due to lack of availability of sufficient fund and
other resources required for Advertisement & Publicity, Credit required by the buyers,
Branding, Market Assessment etc.
Most of Artisan Units are having defective Product pricing system. The units are cutting
prices due to cut throat competition.
32
The Bearing Manufacturing SSI Units are only supplying to replacement market.
There is very vast scope to supply OEM & Other sector if they produce standard quality of
Bearing.
SSI Bearing Manufacturing Units are also facing challenge from Indian Large
Scale Bearing Manufacturer like SKF, NEI, TATA Bearing etc. as large scale unit have
made Huge Investment for Product Technologies, Collaboration from world leader of
Bearing Industry. Large Scale units have employed the professionally qualified work force
and producing at higher volume as compared to SSI Units, and hence taken a lead in all
the functional Area of Manufacturing, R & D, Marketing etc. More over these units are
using latest and Innovative technique to have their higher productivity, quality and
profitability. The SSI Units are far away and yet to adopt these technique tool for their
betterment 25 % of total demand for bearing industry is met by imports. While a part of
the imports come through official channels, there is also a huge volume of illegal imports.
legal Imports generally represent the specialized bearings not manufactured in India.
There are a large variants of imported bearings, each holding a small market share in
India. Though, the quality of bearings manufactured by large players in India is
comparable to world standards, domestic manufacture is not viable due to the small size
of the market segment.
Most of the unit, the enterprise structure is proprietary or partnership type. The
proprietor/ partner himself look after the Management Aspect and Keep over all control of
the functioning of the unit and in most of the cases they do not posses the required
technical/Managerial back ground.
33
Technological Awareness of Entrepreneur are not upto the level. It need to be improved
so they can successfully compete the era of liberalization and globalization.
Finance is the most critical problem of the Industry in term of shortage of finance,
delayed payments, difficulties in getting bank finance and additional requirement of credit.
Units require to maintain large inventory and it's the experience of manufacturer that the
working capital need are not fully realized by the bank & financial institution and it directly
affect their market.
The SSI Units faces common problem regarding availability of skilled man power, A
worker After working for a period of few year in this Industry leave the Job to start his own
turning unit or to get higher wages from another unit.
There is no regular training facilities available where the manufacturer and worker
undergo need based training.
The SSI Units also faces problem about less availability of trained man power such as
turner, tool maker etc.
- The Tiny/Artisan Units are scattered in Different Area. They are functioning under
rented shop and due to availability of lack of space, the placement of machinery &
handling of material with in the unit is not proper.
- There is dearth of quality BDS in the Area of technology, Marketing, Export, Health
& Safety etc.
Networking among R & D Centre, Technical Training Centre, Testing Centre are not
present in cluster.
34
Chapter 3
The reflections of technological achievement are seen in the quality of the product.
The bearings manufactured by the Indian industry have to improve considerably to meet
international standards. If the roots of the problem are to be identified, one comes to the
following conclusions:
Technology Gaps:
Induction Heating
Furnace for The outstanding features
Forging 300 kw, 3 KHz - of the forging shop
For all include:
Lines.
Oil Fired furnace Automatic bar
300 tone power press loading
200 tone power press Induction heating
100 tone power press Laser sensor
50 tone power press assisted ESA
Hydraulic ring rolling technology for
machine capacity to roll precise bar feed
up to 300 mm. diameter control and auto
Screw press having Bar End Ejection
capacity : 350 tone On line control &
Special die sinking monitoring of
machine forging
Bar shearing machine temperature
Hardness testing Highly sensitive
machine equipments press load
Laboratory for testing of monitoring system
final products of forging High speed forging
with chemical process
composition and micro eliminating risk of
examination cracks due to
temperature drop.
Auto monitoring
system for yield &
tool life.
Heat Treatment :
Hardening & Tempering
1 - Heating 850 C Natural salt bath Pit Temperature Controlled
(Austenitizing) to alter the type furnace with pre- Energy Efficient Heating
structure of the material. heating Furnace Funace
Liquid carburising
processes
Gas carburising
processes
Continue
hardening
processes
36
Greasing
Packing
Assembly of Outer & Hydraulic power press AUTO INNER & OUTER
Inner Races with Balls / DIAMETER
Roller & Cage INSPECTION,
duly suited and locked by AUTO IR & OR ULTRASONIC
power press WASHING MACHINE, AUTO
CONSERVATION OIL
SPRAYING MACHINE
Automatic Lines(AUTO
COMBINING & CAGE
ASSEMBLY MACHINE),
AUTO GREASING &
SHIELDING MACHINE,
AUTO
DEMAGNETIZING
MACHINE, , AUTO BALL
BEARING ASSEMBLY
MACHINE ,
Pinning Press
Marking Machine Laser Marking M/C
38
Ultrasonic Testing
Oxygen contain
Checking
R.A. Value
measurement for
Rough
measurement.
Calibration Testing
equipment
Testing Nominal Laboratory
Equipment
Load ,RPM, Noise, Load ,RPM, Noise, AUTO DOUBLE SIDE
VIBRATION & NOISE
Temperature etc Temperature etc
INSPECTION MACHINE, AUTO
Checking For final Checking For final DOUBLE SIDE SENSITIVITY
inspection inspection Set-up INSPECTION MACHINE, AUTO
RADIAL INTERNAL
CLEARANCE & SENSITIVITY
INSPECTION MACHINE ,
Packing Sleeve packaging
machine/Shrink Packing
Chapter 4
Bearing Steel :
The most common material used in the manufacture of bearing rings, balls
and rollers is Alloy steel conforming to specifications SAE 52100. This material has
become standard material for the industry all over the world. While the basic
material remains the same, the steel manufacturers all over the world have been
improving this material in order to improve the life span and quality of the bearing.
The Indian steel manufacturers although manufacturing steel to specifications SAE
52100, are not able to meet the requirement of the bearing manufacturers in so far
as purity and oxygen content is concerned. Therefore, bearing Steel
Manufacturers should be equipped with Vacuum Degassing & Vacuum Oxygen
De-Carburising Equipment (LEYBOLD HERAEUS, Germany.) In order to
maintain Oxygen content < 15ppm . The tubes are tested to ensure that the steel
is free from injurious imperfections such as piping, cracks, porosity, segregation or
injurious inclusions as referred to in ASTM-381.The inclusion rating is evaluated in
accordance with Plate III of ASTM E-45,The tubes are spheroidized and annealed
to ensure that the microstructure consists of spheroidized commentate in a ferrite
matrix with carbide size conforming to Plates 2 to 4 as per IS 4398-1972 and CG
2.1 - 2.3 as per SEP 1520-78.Spherodise annealing and normalising improves the
machinability of the annealed hypereutectoid steel and improves its microstructure.
To accomplish spherodise annealing and ormalising,temperature controlled energy
efficient electrically heated furnace with a capacity of 6,000kg and oil fired
furnaces with capacities of 3,500kg to 4,000kg are being proposed for SME sector
. The spherodise annealing and normalising process provides improved ductility,
removal of residual stresses, improved machinability and grain refinement.
Race Turning :
Benefits :
These machines are built on the Modular concept for Productive, trouble free
Running with minimal operator Intervention. They are ideally suited & developed
for small to medium sized disk type components that are made in large volumes
like bearing rings, water pump rings, sleeves, brake pistons etc. These machine
offers many high productive features that enhances productivity significantly
1.High rate of production
2. Cost effective
3. Less wastage
40
The CNC, SPM and convectional turning machines for centreless, cylindrical and
round operations. SPM type convectional turning machines for proof turning and
some other special operations. PLC and hydraulic type convectional machining
centres for various operations are being used in SME sector as advance
technology .
HEAT TREATMENT : Following Plant & equipment for Heat Treatment are
being proposed in SME Sector
Forging : Manufacturers of closed die Forgins for Bearing Race equipped with
Following Equipments in SME Sector.
Hot & Cold Automatic Forming plant operates at an average speed of 110 ppm
providing the utmost production efficiency when compared to the conventional
forging process. The Hotmatic AMP 30 S/AMP-50S three-station hotformer is
ideally suited to the production of parts for the automotive, fittings and bearing
industries are being suggested for large scale units .
Benefits :
Simple operation and conversion
High production output (up to 140 parts/minute)
Accurate transfer
Broad range of parts (e.g. cams for passenger vehicles)
Fully developed and proven machine design
Ring Rolling Process :. The raw material is heated in an induction bar heater and
in precisely temperature-controlled furnaces, which provide scale free heating. The
plant is equipped with gas cutting and hacksaw machines and modern shearing
machines for raw material cutting. The plant uses pneumatic, mechanical and
hydraulic power presses for forging. Sun Forge C-1/285, G.I.D.C.,Phase II, Aji Ind.
Estate,Rajkot - 360 003, Gujarat have equipped with such technology .
Cold Rolling Plant : Ring Rolling Machin- D51A, D51B, D52 and D53K series ,
D51A & D51B series of vertical type Ring Rolling (Zhucheng Shengyang
Machinery Co., Ltd ) and Hatebur Coldmatic coldformers (AKP 3-5 | AKP 4-5 |
AKP 4-6 S | AKP 5-5 ) produce precision and complex parts formed directly from
42
wire. The parts produced this way are characterized by precision tolerances,
quality surface finish and overall strength, are being also used in Bearing sector.
Benefits :
Machine have advantages of small volume and compact structure and saving
material and power and so on, which also widely used for hot rolling of ring like
blank in bearing forging and auto gear and flange manufacture industry. D52 &
D53K series of CNC horizontal type Ring Rolling Machine have the following
advantages: advanced structure, numerical programme control, high automation
degree and productivity and saving material and power and so on. Especially
D53K CNC Ring Rolling Machine, it can roll rings simultaneously in radial and axial
direction and is the ideal equipment of processing large scale seamless rings,
which has been widely used in spaceflight, aviation, ship, petrochemical industry
and power industry and so on.
Manufacturing of Bearing Cage & Shields : The following plant & Machineries
are being suggested for SME Sector
AIDA Transmax TMX Transfer Press or Straight Side 2-point Transfer
Presses
Rivet insertion
Rivet, which is a part of bearing-cage, is manufactured from a steel wire. . The process of
rivet insertion is implemented by specialized machines. The cage set is made of two
identical cages joined by a rivet.
Benefits :
Low noise and low vibration which contribute to extended die life
Note: Manu Yantralaya has adopted transfer presses & consistently marching
ahead to furnish the needs of customers belonging to ball bearing industry..
Assembly Section : Automatic Line from R& S Machine China are being proposed for
large scale
Quality control : Some advance Machine & equipments are being used as mentioned
under:
Form and surface finish measuring instrument is being used for checking the micro
geometry, it evaluate parameters like Form geometry and surface finish of components
Roller Sorting Machine
Bearing Noise Level & Vibration Tester
ADVANCE TESTING EQUIPMENTS : The following testing equipment s are being used
by M/S KANSARA ENGINEERS PVT. LTD.Jodhpur .
Chapter 5
PROJECT PROFILE
: Prepared By : -
2.0 MARKET & DEMAND ASPECT : The demand for bearing industry is
derived from demand in two key user segments - automobile and
industrial sector growth. The automobile industry is the largest growth
47
driver for OEM market as it accounts for almost 45% of total bearing
market.
Engineering sector, which accounts for 28% of total share, holds the
second growth driver. Considering the high reliance of bearing industry
on automobile sector, the fate of bearing industry is largely dependent
on production of vehicles.
The demand of bearing is also linked to heavy-duty industrial
application in rolling stock, rolling mills, heavy earth moving
equipments and other heavy machinery, accounting for 21% of total
bearing market. However demand in the latter category is met through
imports and therefore does not have significant impact on domestic
growth .
Up Swing in Automobile Sector ,The Indian Automobile sector has
grown 16.5% in FY03 contributed by export growth of 65.3% and
domestic growth of 14.8%. The automobile industry comprising of
commercial vehicles, passenger cars, multi-utility vehicles, two/three
wheelers and tractors has performed extremely well in FY03. The
sharp growth of this sector has been partly driven by the impact of
lower interest rate on demand, intermediated by a competitive financial
sector, which has steadily cut prices of automobile loans as interest
rates went down.
Infrastructure has received a fillip in last 2 years through N-S-E-W
corridor and Golden Quadrilateral projects. The transformation of road
transport industry through these initiatives will lead to higher demand
for commercial vehicle industry. Passenger cars continue to grow in
double digit driven by rising aspiration levels and easy availability of
cheap finance. Within two wheelers, we expect motorcycle industry
growth to continue on its growth path.
After two bad years, the tractor industry is also likely to witness a
revival with completion of inventory correction phase and good
monsoons likely to drive demand. The positive outlook for auto sector
augur well for bearings demand and we expect all segment of
automobile industry to report strong growth in the coming year.
Export Potential
Exports of bearings companies has increased at a CAGR of 13% in
last seven years from 1995-96 to 2001-02 at Rs2.5bn.Big players in
Indian ball and roller bearing have been already exporting a part of
their production to developed countries like US, Europe etc. Domestic
players are already sensing the outsourcing opportunity and have
initiated the process of manufacturing a range of bearings for meeting
the requirements of global customers.
The Indian bearing industry, especially the companies having
technical/ financial collaboration with global players like SKF Bearings,
48
FAG Bearings, Timken India, ABC Bearings and NRB Bearings are
expected to garner higher price in export market.
The OEM and replacement market control the market dynamics of
Bearing. The OEM and replacement market both account for 40% of
total demand of Bearing Industry individually. The Bearing
Manufacturer are only supplying to replacement market. There is vast
market of OEM Sector The SSI Bearing Manufacturing units of cluster
are mainly supplying to the replacement market of Bearing. On the
other hand a number of SSI Races Manufacturing Units are supplying
the Soft turned Bearing Races to the following large scale units. In the
Bearing & Bearing component manufacturers cluster Jaipur Approx.
10% of Bearing Races are produced by using Forging Method.
The tests are conducted as per I.S. & A.S.T.M. standards. In the Laboratory, tests
such as Chemical Composition, Including rating, carbide Bending, Grain Size and
other tests are conducted. Once the material s approves after spherodized
Annealing, it is send for turning process where Inspection of pre-turned races is
done, continuous dimension inspection during turning process,100% Crack
Detection testing,100% Visual Inspection for dent, forging spots, rust & Burr of
turned races is done. After getting approval material is transferred for dispatch.
6.0 PRESUMPTIONS: -
(1) To improve the energy efficiency of the plant, it has to run
continuously.
The scheme is based on two shift of 75% efficiency 25 days/month
and 300
days per annum
(ii) Labour wages has been taken as per market rate. It is likely to vary
depending upon the location of the project .
(iii) Rate of interest has been taken 12% on an average on fixed and
working capital. It is likely to vary due to financial outlay and the
location of the unit.
(iv) The operative period of the project is estimated to be about 8 years
considering technology obsolescence.
(v) Value of machinery & equipment is estimated on the basis
Quotations received & prevailing cost of the local mkt.
(vi) As the cost of raw Material is major part of working Capital and is
very high and as per the mrket trend the working capital is being taken
for 1.5 months only.
10 IMPLEMENTATION SCHEDULE :
S.No. Activities Period in
Months
1 Preparation of project report and selection of site 1
2 Registration 1
3 Application for Electricity Connection 1
4 Availability of finance& Procurement of machinery 6
6 Electrification & installation 2
7 Recruitment of staff 1
8 Trial run 1
Total 13
11 FINANCIAL ASPECTS:
i) Land : The requirement of land for the proposed unit would be 3000 Sq. Mtr.
purchased @ 2500 3000 2500 7500000
Shed & Building Constriction 1000 5000 5000000
TOTAL 12500000
b PLANT & MACHINERY
D. WORKING CAPITAL
i Personnel
S.NO. DESIGNATION No. Salary Total (Rs.)
1 Workshop in charge 1 30000 30000
2 Supervisor cum clerk 2 1200 2400
3 Skilled Worker 8 8000 64000
4 Semi skilled worker/ Helper 4 4500 18000
5 Peon / Watchman 3 3000 9000
Total 18 123400
Additional Perquisites @ 15% 18510
Total Expenditure in Salary & Wages 141910
52
ii Raw Material
Pune 411040
Maharastra, India
00912030527484
Mobile: +91 (0) 9892249582
2. ISTM
Lunkad Towers, Viman Nagar,
Pune - 411014, India.
Tel: +9120 41434100/01
+9120 66024901/02
Fax: +9120 26630779
www.ismt.com
Contact:
Mr. S Mallya
Executive Vice President Marketing
Email: sudhir.mallya@ismt.co.in
.
56
Annexure -a
TECHNOLOGY PROVIDERS
Technology / Plant Providers All the manufacturers in the organised sector have
entered into collaboration agreements for supply of complete process know how as well
as supply of major manufacturing machinery tool design, production control techniques
etc from them,
Company COLLABORATION
SKF India SKF Sweden
FAG, Germany
FAG Bearing India NEI
NTN
NRB Nadella, France
ABC Bearing Ltd. NSK Japan
TIMKEN India TIMKEN USA
Bimetal Bearing Ltd Clevite Corporation USA
Kansara Engineering Pvt. Ltd., NTN Japan, Nadella France
Technology Providers/ Machine & Area Concerned
equipment Providers
BRENCO Incorporated , U.S.A. Cartridge Tapered Roller
www.brencoqbs.com Bearings for Railway wagons and
Locomotives.
Hatebur Umformmaschinen AG
Postfach 916
General Guisan-Strasse 21, CH-4153 Reinach
Switzerland
Tel.: +41 61 716 21 11
Fax: +41 61 716 21 31
Finance+86-536-6516178
Product
Machine Tools Division, Beavar Road, Ajmer 305 003 Grinding M/C, & Machine Tools
Telephone: 1-631-940-9121
Fax: 1-631-940-9125
Email: info@wmwmachinery.com
info@meccanicanova.com
P. IVA: 01510581208
Head Office:
SERVICE
GEDEE WEILER (P) LTD,
871, Second Floor,
Sector 10A,
Gurgaon 122 001
E-MAIL: mohantamil@gmail.com
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Production+86-536-6511668
Finance+86-536-6516178
Schuler India Private Limited Metal Forming.
401403 Keshava , Bandra-Kurla Complex, Bandra
(East), Mumbai 400 051 India
Tel.: +91 (22) 66 80 03 00
Fax.: +91 (22) 66 80 03 99
www.schulergroup.com
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Annexure - b
The quality is of paramount importance for bearing. The organized sector units are
following global standards and use front line technology for inspection & quality control.
The unit in unorganized sector have substantial level of awareness and learning to start
defining the processes for measurement of efficiency and effectiveness.
Annexure - c
Grade C Mn Si Cr Mo