Rural Engineering Project Feasibility Report on

DEVELOPMENT OF A SMALL-SCALE INDUSTRY

FOR COMBINATION LOCK MANUFACTURING UNIT
Submitted in partial fulfillment of the requirements for the award of the degree of

BACHELOR OF TECHNOLOGY DAYALBAGH

EDUCATIONAL INSTITUTE FACULTY OF
ENGINEERING DAYALBAGH, AGRA
SESSION 2018-2019

Under the supervision of

Dr. Rahul Caprihan

Submitted By

Ankit Ghai 136332 Lalit Lohiya 154145

Abhyuday 146401 Manmohan Singh 154146
Aditya Kumar 154125 Nitesh Motwani 154153
Aman Singh Anami 154128 Pankaj Kumar 154154
Aradhya Kulshreshtha 154130 Pratyush Priyadarshi 154156
Biresh Kumar 154135 Puneet Kumar Singh 154158
Harsh Katara 154139 Siddharth Sharma 154174
Vinay Kharwar 154182

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 CERTIFICATE
This is to certify that the entitled rural engineering project " COMBINATION
LOCK MANUFACTURING UNIT” has been prepared and submitted by:

Ankit Ghai Lalit Lohiya

Abhyuday Manmohan Singh
Aditya Kumar Nitesh Motwani
Aman Singh Anami Pankaj Kumar
Aradhya Kulshreshtha Pratyush Priyadarshi
Biresh Kumar Puneet Kumar Singh
Harsh Katara Siddharth Sharma
Vinay Kharwar

towards partial fulfillment of the requirements for the award of the degree of B.
Tech of the Faculty of Engineering, Dayalbagh Educational Institute,
Dayalbagh, Agra.

The work is original and I forward it with remark that the contents are genuine.
I recommended that the merit of the dissertation be assessed according to the
rule of D.E.I. (Deemed University) for award of Bachelor of Technology

Prof. Rahul Caprihan

Department of Mechanical Engineering
Faculty of Engineering
Dayalbagh Educational Institute
Agra 282110

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 ACKNOWLEDGMENT

We express our gratitude to Prof. Rahul Caprihan, Department of

Mechanical Engineering, Faculty of engineering, D.E.I., Agra, the precious
pieces of advices of his guidance, continuous encouragement and cooperation
in every respect. His esteemed inspiration and generous direction bring the
work towards completion.

Also Prof. K. Hansraj, Department of Mechanical Engineering, Faculty of

Engineering, And Dayalbagh Educational Institute was kind enough for his
valuable guidance and operation whenever required

Last but not the least we are also highly thankful our class mates and friends
for their Last cooperation.

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Table of Contents

1. The objective of rural engineering project…………………………………………………1

2. Small-scale industries…………………………………………………………………………………2
3. Brainstorming……………………………………………………………………………………………5
4. IDEAS GENERATED…………………………………………………………………………………….6
5. Survey………………………………………………………………………………………………………16
6. Market potential……………………………………………………………………...........................29

7. Process of manufacture…………………………..........................................................................33

8. Layout of plant………………………………..……………………....................................................39

9. Capital requirements……………………………………..………..................................................42

10. Break even analysis…………….....................................................................................................44

11. Proposals for raising capital requirement ………………...............................................46

12. Project Implementation…………………………………...........................................................49

13. Conclusion……………………………………………………………………..….…….…………….50
14. References………………………………………………………………………..…………………...51
 THE OBJECTIVE OF RURAL ENGINEERING
PROJECT

India is a country of villages and its development is synonymous with the

development of the people living in rural areas. India is a vast and second
most populous country in the world. (According to the 1991 census, 74.28
percent population of our country reside in the countryside). But a big
part of this population has been leading an uncertain economic life due to
non-synchronization of employment opportunities in the agriculture
sector because of the fast-growing population.
The stress on rural development is also due to many constraints facing the
rural areas, which generally suffer from inadequate infrastructure facilities
and technological advancements. The rural areas are not well placed in
terms of even minimum needs like safe drinking water, primary health, and
road transport. This apart, the rural population suffers from indigence,
ignorance, and illiteracy. Their traditional outlook towards development has
been preventing them from taking full advantage of the incentives offered by
the Government. Also, the ownership of land and other assets has been
heavily concentrated in hands of a few. It is precisely for this reason that the
benefits of rural development programmers failed to reach the rural
population targeted for these benefits to the extent expected.

Development is potential-related, and it can be attained to the extent of

the existing development potential, which is measured by the 5 un-
exploited resources, talents, margin of sophistication and the ‘willpower'
which implements development policy. Development is the conditioning
of progress, and when efforts are laid towards the use of Growth
potentials in rural economy and Society, it is rural development.

The basic idea of the Rural Engineering Project is to come up with a

project idea with the aim to set up a small-scale industry that fulfills
the following objectives:
• The customer of the manufactured product should be the common man. •The

product should be an item that is used in everyday life.

• The product should be not too expensive.

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• The manufacturing process should provide livelihood to as many
people as possible
• Including skilled and unskilled labor.
• The initial setup to manufacture it should not be too high.
• Should be able to compete within the market with the currently
existing counterparts.
• Should have a market.
• It should desirably be in sync with nature and not pollute the environment.

• It should be safe and not pose any danger to the consumer.

• Raw material required should be preferably available locally or nearby.

• It should not require too complex technical knowledge.

• The end product should be simple to use by the consumer.
• Maintenance should desirably be available once handed over to the consumer.
• Maintenance should not be too costly or infeasible.
• It is desirable that it is better and more efficient than the currently
existing counterparts.
• Access to a local industry where a similar product is already being
manufactured is required to study the process.
• It is desirable that the local people can be trained with ease with the
methodology required in the manufacturing process.
• The product should be of good quality.
• Profit margin should be sufficient to sustain its continued production.
• It is desirable to have a scope for extension/ improvement/ to meet
future demands/needs.
Small-scale industries

Small-scale industries (SSIs) also known as MSMEs are defined & categorized
by the Micro, Small & Medium Enterprises Development Act, 2006. The act
categorizes different scale of industries on the basis of investment in plant &

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 machinery in case of manufacturing industries and on the basis of
investment in equipment in case of service sector industries.

1. Micro Scale Enterprise: Manufacturing enterprises in which investment in

plant & machinery does not exceed Rs 25.00 lakhs and service sector industries
in which investment in equipment does not exceed Rs 10.00 lakhs are termed as
microscale enterprises.

2. Small Scale Enterprise: Manufacturing enterprises in which investment in

plant & machinery is more than Rs 25.00 lakhs but does not exceed Rs 5.00
crores and service sector industries in which investment in equipment is more
than Rs 10.00 lakhs but does not exceed Rs 2.00 crores are termed as small-scale
enterprises.

3. Medium Scale Enterprise: Manufacturing enterprises in which investment

in plant & machinery is more than Rs 5.00 crores but does not exceed Rs 10.00
crores and service sector industries in which investment in equipment is more
than Rs 2.00 crores but does not exceed Rs 5.00 crores are termed as medium
scale enterprises.

Importance of Small-Scale Industries:

SSIs are the backbone of the world economy and this is the main
reason why even governments are providing various sops and
financial benefits for encouraging more and more MSMEs to
flourish. The existence of small-scale industries is must as:

• Partner in nation building

• Customized Products
• Employment to local people
• Creation of jobs
• Discipline into the industry

There are a number of small-scale industries ideas which if

implemented throughout the nation, can provide work & jobs to
farmers & villagers. Some of them are as follows:

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1. Primary Processing units: Let us say, there is a snacks manufacturing unit in
a quite developed district and the unit procures all of its raw materials from the nearby
dealers, as the promoters cannot afford to procure unprocessed raw crop directly from
the, process the crop first and then use it. They want already processed, i.e. graded &
sorted crops according to their needs.
In such cases, small farmers who cannot afford to set up a grading & sorting
plant sell their crops at lower prices. Setting up of grading & sorting units by
small-scale players will encourage farmers to grow crops as they are adding
value to their products and hence enabling them to sell their product into the
market at competitive rates.Therefore, by setting up small-scale primary
processing units in the villages and backward districts, we can assure the
greater value of agricultural produce, better lifestyle of farmers, increased
awareness among farmers & villagers, etc.

2. Job work for larger companies: Once a company reaches a stage where it
has pan-country customers, then such companies start strategizing their production
methods to reduce costs and increase overall returns on capital in the long-term. If
an MNC keeps on building factories all over the country, then most of its liquid fund
will be blocked in long-term assets and slow down its growth. Hence, such MNCs can
provide work order to smaller players of different states, and especially at places
where the demand of the products is not substantial, to reduce costs and keep the
fund flowing. If a small player manufactures products for larger companies, one thing
is assured that the factory of such small player will never remain closed.

3. Organic products industry: With the increased use of fertilizers and

pesticides all over the world, the quality of products, as well as the quality of
the soil, is eroding day by day. Many countries have started to abolish fruits &
vegetables, clothes, etc. which aren't organic. There are many opportunities
for our small-scale industries to usher into this sector by setting up poly
houses or engaging in hydroponic farming, hence increased organic
cultivation in the long run.

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 BRAINSTORMING
Effective brainstorming can be accomplished by following simple
brainstorming do’s and don’ts with your team. A brainstorming session is a
tool for generating as many ideas or solutions as possible to a problem or
issue. It is not a tool for determining the best solution to a problem or issue.

The best way to have meaningful ground rules is to have the team create
their own. Try performing a mini-brainstorming session around creating
brainstorming ground rules. It should provide a nice opportunity to
practice the skills necessary for an effective brainstorming session.

With that, here are four key ground rules that are useful when
conducting a brainstorming session:

1. There are no dumb ideas. Period. It is a brainstorming session, not a

serious matter that requires only serious solutions. Remember, this is one of the
more fun tools of quality, so keep the entire team involved!

2. Don’t criticize other people’s ideas. This is not a debate, discussion or

forum for one person to display superiority over another.

3. Build on other people’s ideas. Often an idea suggested by one person

can trigger a bigger and/or better idea by another person. Or a variation of an idea
on the board could be the next “Velcro” idea. It is this building of ideas that leads
to out of the box thinking and fantastic ideas.
4. Reverse the thought of “quality over quantity.” Here we want quantity; the
more creative ideas the better. As a facilitator, you can even make it a challenge to
come up with as many ideas as possible and compare this team’s performance to the
last brainstorming session you conducted.

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 IDEAS GENERATED

1. Seeds and Fertilizer Manufacturing

2. Combination Locks Manufacturing
3. Multi-utility Furniture
4. Washing Machine cum Exercise Machine (Without Electricity)
5. Water Pumping System using Wind Power
6. Potato Chips Manufacturing Unit
7. Soap and Detergent Manufacturing
8. Design and Construction of Solar Drying System for Food Prevention
9. Polymer Water Diesel
10. Disposable plates and bowl by dry leaves
11. Manufacturing of Rear-View Mirror
12. Candle Manufacturing

Abstracts of above-listed ideas are mentioned later. Students

discussed the various abstracts and participated in brainstorming
sessions to further decide the suitable idea.
Afterward, we discussed the ideas with our guide Prof. Rahul
Caprihan and finally Combination Locks Manufacturing was
selected as our final idea for Rural Engineering Project.

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Project Ideas
Biresh Yadav

Design and construction of a solar drying system for food preservation.

The solar drying system utilizes solar energy to heat up the air and to dry any
food substance loaded, which is beneficial in reducing wastage of agricultural
product and helps in the preservation of the agricultural product. Based on the
limitations of the natural sun drying e.g. exposure to direct sunlight, liability to
pests and rodents lack proper monitoring, and the escalated cost of the
mechanical dryer, a solar is therefore developed to cater for this limitation.

This project presents the design, construction, and performance of a mixed-mode

solar dryer for food preservation. In the dryer, the heated air from a separate solar
collector is passed through a grain bed, and at the same time, the drying cabinet
absorbs solar energy directly through the transparent walls and roof. The results
obtained during the test period revealed that the temperatures inside the dryer and
solar collector were much higher than the ambient temperature during most hours
of the day-light. The temperature rise inside the drying cabinet was up to 74% for
about three hours immediately after 12.00 (noon). The dryer exhibited sufficient
ability to dry food items reasonably rapidly to a safe moisture level and
simultaneously it ensures a superior quality of the dried product.

Aditya Kumar

Soap and detergent manufacturing.

In modern society due to awareness towards the hygiene, Toilet soap has
now become the necessity of life. Urbanization and development to tourism
industry have led to both increases in demand and improvement in the
product quality. As a result of today, the markets are flooded with a variety of
soaps varying in both physical and functional attributes. Various types of
soaps available can broadly be categorized into three categories namely
perfumed soap, carbolic soaps, and medicated soaps. There is a tremendous
scope for production in both of small and large scale due to the exponential
growth of soap demands. The new entrepreneur can invest in this project.

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The mixed oils are taken in a pan and heated to approximately 70 degrees
centigrade. Caustic soda solution is added for saponification reaction. Soap is
formed, builders like sodium silicate soapstone, talc, etc are added when the
saponification is over. Though mixing of the material is made color all perfumes
are added. Finally, the soap is transferred to rames at all levels to settle down.
The wet soap is taken out of the frames, cut into bars, stamped and packed.

Lalit Kumar Lohiya

Multi-utility furniture.

Multi-utility furniture are the way of the future and they are only going to become
more and more common as living space continue to shrink. With space now at a
premium, getting multipurpose furniture for your home is the best way to save
on space and reduce clutter without losing out on storage functionality.

Multi-utility furniture is a furniture that conveys multi-functionality

in a single unit. These furniture units are space-savvy and provide
various uses thanks to their clever design, hence, serving more
than one purpose while occupying the space of one.

The basic concept to make multi-utility furniture is that Both houses and schools
must have some furniture for learning that is multi-functional and affordable, as
families are generally below the poverty line and most of the houses are very small
to keep furniture like study table. It will directly benefit rural houses, students,
education and on a long-term – overall development of the village.

Abhyuday Kumar

Polymer waste diesel

Plastic waste in India has become an increasingly pressing problem over the years.
With increasing dependence on plastic, the tendency to dispose of plastic casually
has also become a part of the mainstream. Over the years, several wastes

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to wealth mechanisms have been adopted to recycle and reuse plastic in
innovative ways. One such trend has been the conversion of plastic waste to
fuel and making it usable for both domestic and industrial purposes. Given
India's huge daily generation of over 15,000 tonnes of plastic, the prospects
of conversion to fuel are abundant, provided there is sufficient infrastructure
available. The current Union government's focus on waste management via
Swachh Bharat Abhiyan also addresses the issue of plastic waste and ways
with which the problem could be dealt with.

The fuel obtained from conversion of plastic is completely

environmentally friendly due to the absence of any toxic substances.
Apart from producing petroleum and diesel, this technology will also
ensure that urban and semi-urban areas become plastic-free, as instead
of disposing of plastics as waste, they can be converted to fuel.

Nitesh Motwani

Washing Machine cum Exercise Machine (Without Electricity)

The machine consists of an aluminum cabin with a wire cylinder inside, which
holds the laundry. The cylinder is connected to a bike chain and pedal system.

Laundry is placed inside the machine, along with hot water and detergent,
and left to soak for ten minutes. Then, the user pedals to spin the laundry
and clean it. A small faucet on the cabin drains the soapy water, and then
the whole machine is refilled with clean water for a final rinse cycle. All in
all, it’s an elegant and simple solution for families living in rural areas
who might otherwise be without a washing machine

Ankit Ghai

Disposable plates and bowls by dry leafs

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These are commonly used for serving food at marriages, religions and social
functions. The laborious craft can now be converted into a machine operation to
make these containers in elegant shapes and sizes. Such cups and plates are
made out of plant leaves of beautia, arecanut sheath, banana etc.

These have good dimensional stability and are inexpensive, hygienic and
biodegradable.leaf plates are the perfect alternative to Plastics/Polymer-
based products and also Paper-based products about which the entire world
is concerned about. We focus on food packaging and one-way dishes.

Our claim: outdoor tableware has to be fully renewable and fully

biodegradable. There are more than 5,000 leaf cup making machines in
operation in U.P., Bihar, M.P., Jharkhand, Himachal Pradesh, Gujarat,
Maharashtra, A.P., Karnataka. There is a large scope for setting up
cottage scale units in the North Eastern Region.

The cups and plates are also in large demand by hawkers, fast food
restaurants, star-hotels, mass feeding and for prasadam in religious institutions.

Siddharth Sharma

Candle Manufacturing

Candles are lighted not only for religious purposes but also as an item
made for decoration these days. Not only the traditional white candles
but these days candles of different shapes, sizes, colors, fragrances
are available in the market. Innovative ideas such LED fitted candles,
reusable candles, and many others can be seen in markets.

The biggest benefit of the idea is the raw material required. We only need wax
and wicks initially. Using molds and stearic acids, candles can be made with
machines quite easily and efficiently. Another advantage of the idea is the task
force required need not be much skilled for making basic candles. Skills can be
improved with the need for improved quality, purposes and designs of candles.

Also, such a business can be started keeping the rural taskforce in mind that
does not have the access to advanced education. Cost of starting such a venture
is also quite economical, resulting in a win-win situation for all stakeholders.

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Aman Singh Anami

Water pumping system using wind power

Energy from the air can be utilized in multi-various ways. It can be tapped
directly from the air in the form of electrical energy. The contribution of these
sources in the total consumption of energy in the world is about 15%. The scope
for application of air energy now stands inherently enhanced through intensive
research and development carried out all over the world. Air can be directly
utilized for the purpose of cooking and drying. By the same time, it can be also
used for the boiling of water, air heating, and refrigeration. In our project wind
energy is used to rotate the wind blades. This blade coupled to the shaft. At the
end of the shaft the flywheel is placed. The eccentric arrangement is provided in
the flywheel. When the blade rotates automatically flywheel also rotates. Due to
the eccentric arrangement, the rotation motion of the flywheel is converted into
linear motion. This reciprocating motion is given to the handle of the pumping
system. The up-down motion of the handle is given to the piston, where the
water is sucked using pressure variation from the lower ground. Finally, the
water is supplied to the outlet. Wind blade provides the continuous motion
which helps to supply the water continuously. Since time immemorial, the main
source of energy has been coal, oil, natural gas, nuclear energy, wood, and coal.
However, all these sources are limited and are the main cause of pollution and
this has led to development and more focus on sustainable energy supply with
minimum pollution effects. Hence research and analysis have shown that wind
energy, solar energy, and biomass are the most prominent solutions to the
above problems because they are eco -friendly and readily available in nature.

Pratyush Priyadarshi

Manufacturing of Rear-View Mirrors

A rear-view mirror is a mirror in automobiles and other vehicles, designed

to allow the driver to see rearward through the vehicle's rear window (rear

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windshield).In cars, the rear-view mirror is usually affixed to the top of the
windshield on a double-swivel mount allowing it to be adjusted to suit the
height and viewing angle of any driver and to swing harmlessly out of the
way if impacted by a vehicle occupant in a collision. The rear-view mirror
is augmented by one or more side-view mirrors, which serve as the only
rear-vision mirrors on motorcycles and bicycles.

A prismatic rear-view mirror—sometimes called a "day/night mirror"—can be tilted

to reduce the brightness and glare of lights, mostly for high-beam headlights of
vehicles behind which would otherwise be reflected directly into the driver's eyes at
night. This type of mirror is made of a piece of glass that is wedge-shaped in cross-
section—its front and rear surfaces are not parallel. Currently, rear-view mirrors are
manufactured using high tech capabilities which include bending, machining,
drilling, milling, sandblasting, edge grinding or seaming, coating, screen printing,
etching, laser treatment and laminating. Alas, the cost of production is higher
resulting in higher product prices for the consumer.

Thus, I think we should create a feasibility report on the manufacturing of

rear-view mirrors in REP as there is the chance to exploit the production
of rear-view mirrors at a cheaper rate also which requires a lower skill
set. Thus, rural people can be employed and our SSI will be able to
produce employment for the same. Resulting in improving life and
standard of living of rural area along with infrastructure development

Harsh Katara

Seeds & Fertilizers Manufacturing

It is a plan to set up a small scale manufacturing unit which will produce

seeds for various vegetables and fruits and for also protecting the field
fertilizers too. The size of the manufacturing unit will be such that it is
able to fulfill the requirement of the nearby farms. It will help the farmers
to easily access the required raw materials for farming and reduce their
effort of buying the raw materials from a distant place.

Manmohan Singh

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Combination lock

The combination lock is one opened not by a key but by the alignment of
its interior parts in a definite position. The most common types have an
internal mechanism consisting of a series of three or four interconnected
rings or discs that are attached to and turned by a central shaft. Manually
rotating the outside knob or dial turns the discs, each of which is
"programmed" to stop at a notched opening or gate.

Combination locks come in two varieties: hand and key change. One
kind of hand combination lock that does not use internal wheels is the
pushbutton lock, commonly installed in office doors and affording
some measure of security. Pushing three or four buttons in order or
together releases a shaft or deadbolt, allowing the door to open. The
internal mechanism operates similarly to conventional padlocks.

A typical combination lock of the padlock variety has twenty component parts,
generally made of stainless steel or cold-rolled steel that is plated or coated to resist
corrosion. Combination locks are constructed to last a lifetime, and their parts are
not intended to require repair or replacement. In addition to steel, two other raw
materials are essential to the combination lock. Nylon is used for the spacers that
separate the discs, enabling them to turn independently, while zamak, a zinc alloy, is
molded under pressure to form the bar, shaft, and outside dial.

Puneet Kumar Singh

Magnetic Levitation

Imagine that two bar magnets are suspended one above the other with like poles
(two north poles or two south poles) directly above and below each other. Any
effort to bring these two magnets into contact with each other will have to
overcome the force of repulsion that exists between two like magnetic poles.

Magnetic levitation is the phenomenon in which two magnetic objects are

repelled from each other in a vertical direction. The phenomenon, also known as
MAGLEV, has long been recognized as having some important commercial
applications. The most significant of these is the construction of MAGLEV trains
which are propelled a few inches above a track at very high rates of speed.

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Vinay Kharwar

Bread Making Plant

Bread products are more and more popular around the world. Almost all
factories are looking for a totally automatically production line to
increase production. The four basic ingredients for bread are flour, water,
yeast, and salt. By adding different other ingredients or changing
different methods, the same machine can make various bread.

In general, for bread stores, more diverse products are more competitive.
Therefore, with one machine or only one producing line to make many kinds of
products is the most important for manufacturers. Manufacturers can save
investment money for machines. They just need to change recipes or ingredients
and can make competitive products. The proposal is for middle bread factories. By
using the least machines and equipment to make various bread, manufacturers can
invest the least and get the most. From the proposal, manufacturers can do their
best to change any methods to make various products.

Aradhya Kulshreshtha

Potato Chips Manufacturing Unit

The popularity of snack food is growing fast day-by-day and potato

wafers have emerged as a clear favorite. India is one of the largest
producers of potato. Besides being used as a daily food item in various
vegetable preparations, potato today increasingly finds use in the form of
chips or wafers as snacks food. The potato chips and wafers are popular
processed food items that give considerable value addition to potatoes.

The main consumers of potato chips and wafers are families,

especially in urban and semiurban areas. Besides, hotels,
restaurants, canteens need potato chips in significant quantities.
In India around 12 million tonnes of potato is grown which is about 4% of the
total world production However, the per capita consumption of potatoes is low.
It is estimated that 25% of the potatoes, which is spoiled due to several reasons
such as transportation, type of packing, availability of cold storage capacities
during harvesting season, a glut in the market etc. could be saved by making

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various preserved potato products. Potato chips are one of such
products which have an immense potential as this is considered as
one of the traditional food of India. Potato chips are needed to be
made in a scientific manner and under hygienic conditions.

There is a huge demand to be met for potato chips in interior and remote
places in India. It is a good idea to start small and develop the business
locally or in a remote area before stepping into the big market, as setting
up a large-scale plant will require a lot of capital investment.

15
Questionnaire for Consumers
(Combination Locks)

1. Name of the Respondent :

2. Are you aware of the different types of locks available in the market
Yes No
3. If yes, then the varieties you know
Simple Locks with key

Combination Locks
Hydraulic Locks

Special Security Locks (Fingerprint & Face Locks)

4. Are you aware of the different types of locks brands available in the market
Yes No
5. If yes, then the brands you aware of
Link Locks
Godrej locks
RR Locks
Medeco

6. How do you aware of the brands

Word of Mouth
Advertisement
Company Sales Person
Agent

7. Present brand of locks you are using

Link Locks
Godrej locks
RR Locks
Medeco
 Any other
8. What factors influenced you to by this brand.
Quality
Easy Availability
Price
Other reason

9. Did you ever lost or forget your keys

Yes No
10. If Yes, How many times you lost your keys
1
2
3
More than 3 times

11. You find conventional locks cumbersome

Yes No
12. May you spend more money on locks having high security
Yes No

13. According to you what is the probability that your house can be robbed?
10 %
20 %
30 %
More than 30% times

14. Are you satisfied with your present locks on the basis of security and all?
Yes No
15. Do you think our product of combination locks will be successful in the market?
Yes No
16. Any advice from your side for this product.

Thanks for Answering!

Questionnaire for Retailers
(Combination Locks)

1. Name of the Respondent :

2. Age:
Below 25 Years

25-35 Years
35-45 Years
45 and above

3. What is the mindset of the customer when buying any lock?

Quality
Easy Availability
Price
Other

4. Locks of which range is selling like a hot cake.

Below Rs. 200
Below Rs. 300
Below Rs. 400
Above 400

5. What is the cost of the most expensive lock in your shop?

6. Which brand locks have the highest sales

7. Is your sell is effected by the brand value

Yes No
8. According to you, Customer may spend more money on locks having high security
Yes No

9. Are you satisfied with present locks on the basis of security and all?
Yes No
10. Do you think our product of combination locks will be successful in the market?
Yes No
11. Any advice from your side for this product.

Thanks for Answering!

 MARKET POTENTIAL

Use in daily life: The combination padlocks are perfect for both
indoor and outdoor tasks such as gym lockers, school & employee
lockers, cabinets, pantries, toolboxes, gate & door hasps, garages,
sheds, fences and general storage.

Market Size and Forecast:

The market is expected to expand at a CAGR of 38.9% during the forecast

period of 2016-2023. The market growth will be driven by the rise in the
burglaries, larceny-thefts, and motor vehicle thefts. According to the
National Crime Reports Bureau, the thefts constituted 30% of the total crime
in India. Further, the rising concerns among the consumers regarding the
safety and security of the office premises and the other private premises
will expand the market growth. Moreover, the private and government
corporate agencies are upgrading their security installation systems which
will lead to the increase in the growth of the market.

Market Segmentation:

Our in-depth analysis of the India Smart Door market includes the
following segments:

By Technology

Mobile App based

Non- Mobile App based

By Biometric

Face Recognition Door Locks

Palm Recognition Keypad Door

Locks Iris Recognition Door Locks
Voice Recognition Door Locks
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Finger Print Recognition Door Locks

By Unlock Mechanism

Keypad Door Locks

Touch to open
Mobile App based door locks

Hybrid/Integrated door locks

By End User

Commercial

Residential

Growth Drivers and Challenges:

The growth of the market is primarily driven by the rise in the security concerns
among the Indian population. The rise in identity frauds has led to the installation of
the smart door locks systems in the residential and commercial premises. Further,
the rise in the criminal activities including burglary and theft has led the people to
shift from mechanical door locks systems to the smart door lock systems, thus
propelling the growth of the smart door locks market. Moreover, the rapid pace in
real estate growth has led to the expansion of the market. The growth in the
hospitality industry and increasing competition in order to provide better services
will encourage the hotel room owners to install the smart door technology, which in
turn will lead to the expansion of the India smart door locks market. The
introduction of the land acquisition bill by the Government of India will speed up
the process for industrial corridors and development of smart cities. These rising
investments in infrastructural facilities would lead to the installation of the smart
door lock system. Moreover, the technological advancements have paved the way
for the development of smart door locks across the India. The smart door locks
include the digital technology with easy user interface. The user can operate the
smart door locks by using their smart phones. The users can generate the e-key
through their mobile and can keep a

30
 track of who is going in or out. Moreover, the introduction of the hybrid
smart locks with multiple locks systems will lead to the expansion of the
market. The growth of the market is further fueled by the introduction of the
product on the e-commerce platforms such as Amazon, Flipkart and others
by the various manufacturing companies. The availability of the high speed
internet services and increasing technological population has increased the
demand for the mobile-app based smart door lock systems.

Key Players

Samsung Smart
Home Yale
Godrej
Sentrilock
Kwikset
Lockitron
Schlage
Haven Locks

August

Price Ranges
Combination locks come in various price ranging from Rs. 50-200.
Godrej locks come at even more higher prices of 400-600 Rs.

Customer prefer security over price which is mostly ensured by

Godrej and is most selled lock in India.

Market Competition
Lock manufacturing falls under the small-scale industries (SSI) sector in India
and is dominated by the unorganized sector, which accounts for two-third of its

31
 annual turnover of Rs 1,200-1,300crore. The Rs 400-crore organized sector
boasts of brands such as Link, Harrison and Europa, apart from Godrej. The
boom in the housing sector and increasing awareness about security
systems in the country have kindled the interest of multinationals too.
Companies such as Ingersoll Rand, Kaba, Sargent and Greenleaf (S&G) and
the world's leading lock manufacturer, Assa Abloy, are all keenly eyeing
India and apparently, some of them have started trading their wares. In the
recent years, Godrej introduced a wide variety of locks offering various
levels of security to various kinds of customers.

ANALYSIS OF DATA AND RESULT

Consumers are aware of the different locks available in the market like simple
(lock and key type), Combination locks and Special Security Locks (Fingerprint
& Face Locks). Also the brands in market for locks are known to the consumers. They
get the knowledge of locks mainly by advertisement and further it travels by word of mouth
sales person. Agents are less efficient as consumers don’t have time to attend them. Mostly
preferred brand by the consumers are Link locks and Godrej locks. Quality seems to be
primary aspect which consumers look up to when buying a lock and some factor of price is
also included as secondary aspect. Consumer do lost their keys of their locks because of
which they buy locks again if they don’t have spare keys. Presently consumers are satisfied
with the locks but may spend more money on more secure locks. A product will get
successful if it is secure and put it into range of public demand.

Quality: As in this department there should be no compromise done so as to

get a good reputation of the product and let us compete with brands.

Promotion and Distributor: Promotion should be done by advertisement and

also doing consumer promotions (like schemes, discounts and contests).

Marketing Strategy to enter and stay in market pricing: The correct

strategy will to enter the market by having a good quality product
with relatively less price than other brand like Link and Godrej.

32
 PROCESS OF MANUFACTURE

Background
The combination lock is one opened not by a key but by the alignment of its
interior parts in a definite position. The most common types have an internal
mechanism consisting of a series of three or four interconnected rings or discs
that are attached to and turned by a central shaft. Manually rotating the outside
knob or dial turns the discs, each of which is "programmed" to stop at a
notched opening or gate. However, with a four-disc lock, certain preliminary
spinning of the dial is necessary to get the lock to move the correct disc. The
knob must first be turned to the right and spun past the first number four times
before being allowed to stop beneath the marker. Next, rotating in the opposite
direction, the knob must pass the second number three times. Reversing
directions again, the user must spin the dial past the third number twice, and
so on. When the apertures of all the rings align, they enable projections on a
spring-loaded bolt to slide through, releasing the bolt and opening the lock.

Combination locks come in two varieties: hand and key change. One
kind of hand combination lock that does not use internal wheels is the
pushbutton lock, commonly installed in office doors and affording
some measure of security. Pushing three or four buttons in order or
together releases a shaft or deadbolt, allowing the door to open. The
internal mechanism operates similarly to conventional padlocks.
Many people remember the simple padlocks that graced their school lockers.
Picking these and other low-priced combination locks was frequently a game—
and one often played successfully. With practice, an aspiring lockpicker could
actually hear the audible clicks made when the protuberances on the bolt
aligned with the notches on the discs. However, manufacturers of better locks
design false gates in the discs to make cracking the lock extremely difficult.
Only experts can distinguish between the three or more false gates and the true
gate, and, since a lock with four discs can use any of 100,000,000 possible
combinations, identifying the correct one by chance is unlikely.

33
 The combination lock was invented in China, although historical records provide
little specific information about its development. Combination locks came into
popular use in the United States in the mid-1800s to secure bank vaults. The locks,
integrated into the vault doors, are a colourful footnote to the history of the old
West as western films testify. In 1873 James Sargent foiled many a real bank robber
by perfecting a time lock that, coupled with a combination lock, kept everyone out
of the vault until the clock or clocks that regulated the lock reached the time at
which it was set to open, usually once a day

Image for Representation

Raw Materials

A typical combination lock of the padlock variety has twenty component parts,
generally made of stainless steel or cold-rolled steel that is plated or coated to
resist corrosion. Combination locks are constructed to last a lifetime, and their parts
are not intended to require repair or replacement. In addition to steel, two other raw
materials are essential to the combination lock. Nylon is used for the spacers that
separate the discs, enabling them to turn independently, while zamak, a zinc alloy,
is molded under pressure to form the bar, shaft, and outside dial.

Design
A combination lock's parts can be divided into two categories: internal and external
components. Excepting the springs when extended, none of the internal parts
exceed two inches (5.08 centimetres) in length. The internal works of the locking
mechanism comprise the lever and supporting lever post and a disc shaft

34
about which disc spacers and the combination disc turn. Two, three, or four
combination discs are the key precision elements of the mechanism, but it
is the combination cam, a notched disc, that generates the combination for
the lock mechanism. The cam is also attached to the outside combination
dial that is turned by the lock's user. The internal disc spring supports the
combination discs under tension, enabling the combination to be dialled.
Other internal components in the lock case include a shackle collar that
holds the shackle (the U-shaped component that detaches from the case
when the lock has been opened) in the locked position with a latch that fits
into the shackle notch. An inner case encloses all internal parts and gives
the lock body housing strength. External parts include the lock's outer case,
the shackle, a back cover, and the combination dial.

The various components in a combination lock are made in a variety of

ways. Some components, such as those made from zamak, are injection
molded— the zamak is heated to a molten state and forced into a mold of
the desired shape. Other components, such as the combination cam and
disc, are cold rolled—passed between heavy rollers. Still other
components are drawn or machined to the proper shape. Most of the
components are then plated and finished to protect against corrosion.

35
 The Manufacturing Process
The twenty component parts of the typical combination lock are formed, drawn, cut,
pressed, and moulded on a variety of machines, both manual and automatic.

o Making the internal components

The lever, locking latch, and disc shaft are all made by injection
moulding, a process in which molten zamak is poured into a mould
and subjected to heat and pressure until it solidifies into the shape
of the mould. Although the post is shaped at room temperature, it is
also formed under high pressure. A fully constructed combination
lock. It is the combination cam, a notched disc, that
generates the combination for the lock mechanism.
Combination locks are built to last a lifetime, and their ports
are not intended to require repair or replacement.

A fully constructed combination lock. It is the combination cam,

a notched disc, that generates the combination for the lock
mechanism. Combination locks are built to last a lifetime, and
their ports are not intended to require repair or replacement.

The combination disc and the cam are made of cold-rolled—passed under
huge rolls without being heated—flat strip steel; after being cold rolled,
the steel is put in a blanking die, a sophisticated cookie cutter, which cuts
(or blanks) out the properly shaped piece. The internal disc spring is
made from stainless steel round wire and produced on a spring winder
that automatically twists and turns the wire to form the traditional coil
spring. The shackle collar, like the combination disc and cam, is made
from cold-rolled flat strip steel that is blanked in a blanking die. The inner
case is produced from flat steel strip and drawn to a cup configuration.
This process requires great pressure to stretch and compress the
material as it is pressed or drawn around a die, whose shape it takes.

o Making the outer parts

The outer case is manufactured similarly to the inner case but from stainless
steel sheet instead of strip. The back cover, also stainless steel, is blanked in
a blanking die. The durable shackle is made of round bar stock

36
 and machined on a screw machine, then formed to its U-shape and
notched to accept the locking latch. It is finally annealed (heated to great
temperature before being quenched in water) to make it resistant to
hacksaws and bolt cutters. The combination dial, also zamak, is injection
moulded, then chromized. This process involves heating the part in a salt
bath rich in chromium. The steel absorbs the chromium, which hardens
on the surface as it cools rapidly. The dial is painted black and white
wiped, which leaves the numbers highlighted against the black face.

o Plating the components

Several plating and finishing processes can be used to protect the

components against corrosion. The lever, disc shaft, combination
cam, and dial are chromized. The inner case, shackle collar, and
lever post are all cadmium-plated. The shackle and locking latch are
copper nickel-plated. The outer case, of stainless steel, is
mechanically polished to enhance luster.

o Assembling the lock

Assembly of the components is precise with the back plate disc shaft,
combination cam, and spacers forming one subassembly. The outer and
inner cases are riveted together and then pierced at the point where the
shackle is inserted. The combination dial, outer and inner case unit, and
combination cam are then fastened together. Finally, these sub-
assemblies and the remaining parts are fitted together. The lock case is
closed and the edges folded over and sealed. Conventional hardware
fasteners that can be released with the proper tool are not used.

o Labeling and packaging

The remaining operation is the application of a removable tag or

label to the lock. On this tag is the combination, determined
randomly by machine draw. Lock manufacturers today jealously
guard their combination setting procedures. A typical combination
lock is sold in blister pack, a rigid molded plastic with cardboard
backing, although locks may also be individually boxed.

37
 A fully constructed combination lock. It is the combination cam, a
notched disc, that generates the combination for the lock
mechanism. Combination locks are built to last a lifetime, and
their ports are not intended to require repair or replacement.

Quality Control

Before any lock is packaged, many manufacturers completely test

the locking and unlocking sequence. Other inspections and
measurements are performed by individual operators at their
stations during both manufacturing and assembly. Combination
locks today enjoy a reputation for excellent reliability and durability.

38
LAYOUT OF PLANT

39
RAW MATERIAL: A raw material, also known as a feedstock,
unprocessed material, or primary commodity, is a basic material that
is used to produce goods, finished products, energy or intermediate
materials which are feedstock for future finished products.

STORE: Non-transitory, semi-permanent or long-term, containment, holding,

leaving, or placement of goods or materials, usually with the intention of
retrieving them at a later time. It does not include the interim accumulation
of a limited amount during processing, maintenance, or repair.

PROCESSING: perform a series of mechanical or chemical

operations on (something) in order to change or preserve it.

TOOL ROOM : A toolroom is a room where tools are stored or, in a factory, a
space where toolsare made and repaired for use throughout the rest of the
factory. In engineering and manufacturing, toolroom activity is everything
related to tool-and-die facilities in contrast to production line activity.

MANAGING AND CONTROLLING : Control, or controlling, is one of the

managerial functions like planning, organizing, staffing and directing. It
is an important function because it helps to check the errors and to take
the corrective action so that deviation from standards are minimized and
stated goals of the organization are achieved in a desired manner.

SAMPLE HOUSING: Take a sample or samples of locks for analysis.Or a

representative part or a single item from a larger whole or group especially
when presented for inspection or shown as evidence of quality.

FINAL PRODUCT: In production, a final product is a product that is

ready for sale without significant further processing

40
QUALITY TESTING: Quality assurance is a way of preventing mistakes and
defects in manufactured products and avoiding problems when delivering
products or services to customers; which ISO 9000 defines as "part
of quality management focused on providing confidence that
quality requirements will be fulfilled.

STORE OFFICE: Office supplies are consumables and equipment

regularly used in offices by businesses and other organizations, by
individuals engaged in written communications, recordkeeping or
bookkeeping, janitorial and cleaning, and for storage of supplies or data.

SHIPPING:The process of transporting an item, usually through the

mail. Shipping is a very basic, common way of getting an item from
one place to another, or from one person to another.

UNLOADING :Offloading goods from the delivery container or

vehicle.Selling goods at a very low (even below cost) price for a
quick sale or to preclude more losses.

41
 CAPITAL REQUIREMENTS
A. Fixed capital
I. Land & Buildings- 2.4 lakhs/yr II. Machinery & Tools- 4 lakhs
III. Pre-Operative expenses-
(Light Connection+ Generator & Fuel + Training)
- 3+5+1=9 lakhs
IV. Margin money for working capital
Gross working capital – current liabilities=?

B. Working Capital
I. The Operating Cycle-
Manufacturing Schedule-6
days /week Lot Size- 50 locks (20
K/yr)
Manufacturing time-30 min/lock
Credit Time-40hr/week

II. Total Operating Cycle-1 month ( Cash to cash time)

III. Working Capital= 1/12*36 lakh( Turn over)
= 2.50 lakhs
C. Capital Needed
I. Fixed Capital- 15.4 lakhs
II. Working Capital- 2.5 lakhs

Profitability:
I. Projected profit & loss statement Expenses
Materials- 6 Lakhs
Wages & Salaries-(10+4*5)*12=3.60
lakhs/Yr Other expenses-0.50 lakhs
Factory administration and sales-
2 lakhs Net Profit (Before Taxes)-

By Sales- 40 lakhs (20000locks*200 Rs/lock= 40 lakhs)

42
II. Profit Margin
Net Profit per year/Total yearly sales*100
(10 lakhs/ 20000)*100= 5000
III. Return on Total Capital
Net Profit/ Total Capital*100
(10 lakhs/ say 50
lakhs)*100= 20 IV. Return on net worth
Net Profit/ Equity Capital
10 lakhs/ say 10 lakhs=1

43
 BREAK EVEN ANALYSIS
Designed capacity in units 20,000 per year

In rupees 30,00,000 per year

Profit {per year} fixed expenses variable expenses total

10,00,000 25,00,000 5,00,000 40,00,000

Quantity Costs Revenues Profit/loss

($000)

Fixed Variable Total Total

costs costs cost revenue

0 25,00,000 0 2500000 0 -2500000

20000 25,00,000 500000 3000000 1000000 -2000000

40000 25,00,000 1000000 3500000 2000000 -1500000

60000 25,00,000 1500000 4000000 3000000 -1000000

80000 25,00,000 2000000 4500000 4000000 -500000

100000 25,00,000 2500000 5000000 5000000 0

120000 25,00,000 3000000 5500000 6000000 500000

Sales =20,000 per year

Profit (P) =10,00,000 per year

Variable cost = 5,00,000 per year

Fixed cost*(F) =25,00,000 per year

Margin of safety= 1,00,000 units in 5 years

Unit product /sold

44
BREAK EVEN POINT

As % of full capital = = 71.46%

As production, in units 100,000

As sales in Rs 50,00,000

45
 PROPOSALS FOR RAISING CAPITAL
REQUIREMENT
Financial Aspects

A) Fixed Capital

i) Land and Building:

Built up Area 200 sq.mt.

Office, stores 50 sq.mt.
Assembly and Testing 150 sq.mt.
Rent payable per annum Rs.1,20,000/-

ii) Machinery & Equipment’s:

S.No. Description Unit Cost

1 Electronic screw driver & screw 5 30,000
Feeder
2 Temp Controlled Soldering Unit 3 21,000
3 LCR Meter (programmable) 1 35,000
4 Drilling machine 1 6,000
5 Analog Multimeter 2 2,000
6 Tool Kit - 20,000
7 Personal Computer with UPS and 2 1,00,000
Printer
8 Combined Soldering De 2 24,000
soldering
Station
9 High speed mini drill set 2 20,000
10 Digital Multimeter (4 ¾ Digit) 2 32,000
11 Digital Storage Oscilloscope 1 60,000
(100 MHz)

Total 3,50,000
12 Electrification/Installatio 35,000
n charges @ 10% cost of

46
 machinery & equipments

13 Cost of office 1,00,000

furniture/test
bench etc.
14 Pre Operative expenses 50,000
Total fixed Capital 5,35,000

B) Working Capital

i) Staff & Labor/month :

S.No. Designation No. of person Total

salary/month
1 Manager-cum technical 1 15,000
Expert
2 Skilled worker 5 35,000
3 Semi skilled worker 2 8,000
4 Office 4 10,000
Assistant/Peon/Unskill
ed
5 Accountant/Office 1 5,000
Manager
6. Sales/Service Support 2 10,000
Engineer
Total 83,000
Perquisites @ 15% 12,450
Total 95,450
Say 95,000

ii) Raw Materials p.m :

S.No Description Qty Value(Rs

.)
1 Motorized Electronic Locking 300 4,20,000
unit with key pad
2 Solid Steel Bolts 600 32,000

47
 3 Interior Carpet Ls 9,000
4 Powder coated Single molded 300 6,90,000
Case
5 Battery 300 63,000
6 Packing material 300 18,000
7 Electronic components, Ls 30,000
Consumables
Total 12,62,000

iii) Utilities per month :

1 Power 4,500
2 Water 500
Total 5,000

Additional Information:

The project may be modified/tailored to suit the individual

entrepreneurship qualities/capacity, production programme and
also to suit the locational characteristics, wherever applicable,

The technology in this sector is undergoing rapid strides of

charge and there is a need for regular monitoring of the
national and international technology scenario. The unit, may
therefore, keep abreast with new technologies in order to keep
them in pace with the developments for global competition,

Quality today is not only confined to the product or service alone. It

also extends to the process and environment in which they are
generated. The ISO 9000 defines standards for quality management
system and ISO 14001 defines standards for environmental
management system for acceptability at international level. The unit
may therefore adopt these standards for global competition,

The margin money recommended is 25% of the working capital at an

average. However, the percentage of margin money vary as per bank’s

48
 discretion.

Project Implementation

The major activities in the implementation of the project

have been listed and the average time for implementation of the
project is estimated at 12 months:

Period in months
S.No
Name of the activity (Estimated)

1 Preparation of project report 1

2 Registration & other formalities 1

3 Sanction of loan by financial institution 3

4 Plant & machinery:

4.a Placement of orders 1

4.b Procurement 2

4.c Electrification & installation 2

5 Procurement of raw materials 2

6 Recruitment of technical personnel 2

7 Trial operation 11th month

8 Commercial operation 12th month

Note:
Many of the above activities shall be initiated concurrently,
When imported equipment’s are required, the implementation
period of the project may vary from 12 months to 15 months,
Procurement of raw materials commences from the 8 th month onwards.

49
 CONCLUSION
Ultra secure:-

With over 10,000 combinations, a thief will not just stumble

across the code.

Functional: -

Being able to fit any desk, safe, or locker with a new combination
lock can be significant when security is concerned. These locks
can be retrofitted into any project with ease.

Ease of Use: -

Programing the combination is as easy as pressing a button. Did

you forget the combo? Use the key that came with the lock and with
the turn of a key, simply reset it to another combination you will
remember. No need to call a locksmith to get to your possessions.

Cost Effective: -

The market price of our lock will be less(only 199 Rupees

appx.) than the other market products(only 499 Rupees appx.).
So the social acceptability will increase towards our product.

50
 REFERENCES
IMPROVEMENT IN TUMBLERS FOR PERMUTATION-LOCKS"
by Joseph Loch, U.S. patent 200070, 5 Feb. 1878. Found in
Google Books. [1]
US948280.pdf" (PDF). docs.google.com. Retrieved
2017-04-15. U.S. Patent 2,029,080
"Kaba-MAS X-09 and CDX-09 High Security Locks" (PDF).
Dec 2010. p. 8.
"Operating Instruction for the X-09 Type 1F High Security
Electronic Lock" (PDF). December 2010. Archived from the
original (PDF) on 28 July 2011.
Hoepfner, Wolfram (1970). "Ein Kombinationsschloss aus
dem Kerameikos". Archäologischer Anzeiger. 85 (2): 210–213

51