ASSEMBLING/MOUNTING OF ELECTRONICS COMPONENTS ON PCB

Transcription

1 ASSEMBLING/MOUNTING OF ELECTRONICS COMPONENTS ON PCB PRODUCT CODE : NA QUALITY AND STANDARDS : As per Customer requirement PRODUCTION CAPACITY :,20,000 Nos. (per annum) Value : Rs. 46,80,000/- MONTH AND YEAR : June, 204 OF PREPARATION PREPARED BY : Sh. Major Singh Deputy Director (Electronics). INTRODUCTION Printed circuit board (PCB) is base of any electronics/electrical equipment. A PCB provides the connectivity to the electronic component such as resistor, capacitor, coils, pots, diodes, FET, transistor, ICs, transformer etc. to form a complete electronic circuit. In the present scenario, the existence of electronics equipments cannot be imagined without a PCB. The PCBs are not only providing the connectivity among the electronic components but also reduces the size and increases the efficiency of the electronic equipment. Broadly the PCBs may be divided in two categories i.e. single layer PCBs and multi-layer PCBs. One can easily find the contribution of electronic industries in each and every field of our daily life i.e. entertainment, communication, education, R&D, Public Services, Defence, Transport, Agriculture, health care services etc. With the growing demand of electronic equipments/appliances in every sphere of human beings the electronic industry is growing up with a very fast rate. Similarly, the demand of micro servicing industries such as assembling/mounting of electronic component on PCBs to meet the requirement of the small/medium/large scale electronic industries is also increasing. This project profile is prepared for the leaded electronic components to be assembled on PCBs. The PCBs & components are provided by the customer. -00-

2 2. MARKET POTENTIAL Assembling/Mounting of Electronics Components on PCB PCBs are used in each & every electronic and most of the electrical equipments. The working of any electronic equipments such as home appliances, entertainment equipment, testing, medical equipments or even defense electronic equipment etc. cannot be imagined without a PCB. The small, medium and large scale units have Nos. of vendors to carry out the specific job. The mounting of electronic components on PCB is also a one of the ancillary job. The charges for this type of job depend on the size and level of complexity of the PCB. The test equipments, raw material required to run this type of service unit are indigenously available. With proper marketing, high quality and competitive price this type of units have sufficient scope in the present scenario. 3. BASIS AND PRESUMPTIONS i. The basis for calculation of Production Capacity has been taken on Single Shift Basis on 75% efficiency. ii. The maximum capacity utilisation on Single Shift basis for 300 days a year. iii. During first Year and Second Year of operation the capacity utilisation is 60% and 80% respectively. The unit is expected to achieve full capacity utilisation from 3rd year onward. iv. The Salaries & Wages, Cost of Raw Materials, Utilities, Cost of Land and Rent etc. are based on prevailing rates in in and around Delhi NCR. These cost factors are likely to vary with time and location. v. Interest of term loan and working capital loan has been taken at the rate of 2% on an average. This rate may vary depending upon the policy of the financial Institutions/agencies from time to time. vi. vii. viii. ix. The cost of Machinery and Equipment refer to a particular make/model and the prices are approximate prevailing in The breakeven point percentage indicated is of full capacity utilisation. The project preparation cost etc., whenever required could be considered under Pre-operative expenses. The essential production machinery and test equipment required for the project have been indicated. The unit may also utilise common test facilities available at Electronics Test & Development Centre (ETDCs), Electronics Regional Test Laboratories (ERTLs) and Regional Test Centres (RTCs) -0-

3 Electronics Division 4. IMPLEMENTATION SCHEDULE The major activities in the implementation of the project have been listed and the average time for implementation of the project is estimated at 2 months. Preparation of Project Report : Month 2. Registration & Other Formalities : Month 3. Sanction of Loan by Financial Institutions : 3 Months 4. Plant/Machinery a. Placement of Orders : Month b. Procurement : 2 Months c. Power Connection/Electrification : 2 Months d. Installation/Erection of Machinery/Test Equipment : 2 Months 5. Procurement of Raw Materials : 2 Months 6. Recruitment of Technical Personnel etc. : 2 Months 7. Trial Production : th Month 8. Commercial Precaution : 2 th Month NOTE: Many of the above activities shall be initiated concurrently. Procurement of raw materials commences from 8 th month onwards. When imported plant & machinery are required, the implementation period of the project may vary from 2 months to 5 months 5. TECHNICAL ASPECTS 5.. Assembling/Mounting Process The incoming electronic components and PCBs are tested for the required specification. In the assembly line electronic components such as resistor, capacitor, coils, diodes, transistors, ICs, SCRs etc are fitted on the PCB at their appropriate location at different stages. These PCBs then passed over the heat wave soldering bath for soldering of component to the PCB. In the next stage, unwanted leads of the components are removed and proper soldering of the components is checked with the help of magnifying glass fitted with tube light. Then the assembled PCB is tested for its specification with the help of appropriate test jigs before despatch to the customer. Inspection of raw materials/components/sub-assemblies 5.2. Quality Specification (Standards) No specific standard available, quality should be ensured as per specific customer demand. -02-

4 Assembling/Mounting of Electronics Components on PCB 5.3. Production Capacity Quantity Value :,20,000 Nos. per annum : Rs.46,80, Motive Power 0 KVA (Approx.) 5.5. Pollution Control The Government accords utmost importance to control environmental pollution. The small-scale entrepreneurs should have an environmental friendly attitude and adopt pollution control measures by process modification and technology substitution. India having acceded to the Montreal Protocol in September 992, the production and use of Ozone Depleting Substances (ODS) like Chlorofluoro Carbon (CFCs), Carbon Tetrachloride, Halogens and Methyl Chloroform etc., need to be phased out immediately with alternative Chemicals/Solvents. A notification for detailed rules to regulate ODS phase out under the environment protection Act 986, have been put in place with effect from 9 th July The following steps may help to control pollution in Electronics Industry wherever applicable- i) In Electronics Industry, fumes and gases are released during Hand Soldering/Wave Soldering/Dip Soldering, which are harmful to people as well as environment and the end products. Alternate technologies may be used to phase out the existing polluting technologies. Numerous new fluxes have been developed containing 2-0% solids as opposed to the traditional 5-35% solids. ii) Electronics Industry uses CFCs, Carbon Tetrachloride and Methyl Chloroform for cleaning of printed circuit boards after assembly to remove flux residues left after soldering and various kinds of foams for packaging. Many alternative solvents could replace CFC-3 and Methyl Chloroform in Electronics cleaning. Other Chlorinated solvents such as Trichloroethylene, per- Chloroethylene and methylene Chloride have been used as effective cleaners in Electronics Industry for many years. Other organic solvents such as Ketones and Alcohol's are effective in removing both solder fluxes and many polar contaminants Energy Conservation With the growing energy demand and shortage coupled with rising energy cost, a greater thrust in energy efficiency in industrial sector has been given by the Govt of India since 980s. The energy conservation Act 200has been enacted on 8th August 200, which provides for efficient use of energy, its conservation and capacity building on bureau energy efficiency created under the Act. -03-

5 Electronics Division The following steps may help in conservation of electrical energy:- i. Adoption of energy conserving technologies, production aids and testing facilities. ii. Efficient management of process/manufacturing machinery and systems, QC and testing equipment for yielding maximum energy conservation. iii. Optimum use of electrical energy for heating during soldering process can be obtained by using efficient temperature controlled soldering and de-soldering stations. iv. Periodical maintenance of motors, compressors etc use of power factor correction capacitors. v. Proper selection and layout of lighting system. vi. Timely switching On-Off of the lights. vii. Use of compact fluorescent lamps wherever possible etc. 6. FINANCIAL ASPECT 6.. Fixed Capital Land and Building Built up area on rent 00 Sq. Yard 6... Machinery and Equipments S.No. Description Ind/Imp Qty Value (Rs.) Heat wave soldering machine Oscilloscope (50 MHz) LCR-Q Meter Function Generator Power Supplies (0-30V, 3 Amp) 4½ Digit Digital Multimeter Analogue Multimeter Magnifying glass fitted with tube light Temperature control soldering station Soldering Iron 25 W Soldering Iron 65 W Variac Rheostat Misc. Ind ,50,000 25,000 6,000 6,000,000 5,000 5,000 8,000 2, ,500 2,500 4,000 Total 3,70,

6 Assembling/Mounting of Electronics Components on PCB Other Fixed Assets S. No. Description Ind/ Imp Qty. Value (Rs.) Electrification 0% of Cost of Machinery and Equipment. Office Equipment, Furniture & Working tables etc. Tools, Jigs, fixtures etc. Pre-Operatives Expenses - Ind - - LS ,000,0,000 30,000 20,000 Total,97,000 Total Fixed Capital Rs. 5,67, Working Capital (per month) Personnel S.No. Designation Nos Servicing Engineer Cum Manager Accountant/cum computer operator Skilled Workers Semi-Skilled Workers Peon/ Watchman Total Add Pre 5% of Total Salary 3 2 Salary/ Month (Rs.) 30,000 2,000 5,000 2,000 0,000 Total Salary (Rs.) 30,000 2,000 45,000 24,000 0,000,2,000 8,50,39,50 Total,39, Raw Material Requirements per Month (for 0,000 units) S.No. Description. Consumables (Solder, Flux, Chemicals, Adhesive, Wires etc.) Ind/ Imp Value per unit (Rs) Total Value (Rs) Ind 7 70,000 Total 70,000 NOTE:- The Quality and value of Raw Material requirement vary with Design and features of the PCB. -05-

7 Electronics Division Utilities Power 8,000 Water 2,000 Total 0, Other Contingent Expenses. Rent Rs. 30, Postage & Stationery Rs., Telephone/Telex/Fax charges Rs., Repair & Maintenance Rs. 5, Transport and conveyance Charges RS. 6, Advertisement/Publicity Rs. 2, Insurance and taxes Rs. 2, Miscellaneous Expenses Rs. 5,000 Total Rs. 53,000 Total Recurring Expenditure (per month) Rs. 2,72,50/- Say Rs. 2,72,000/ Total Capital Investment Total Fixed Capital Rs. 5,67,000 Total Working Capital (for 3 months) Rs. 8,6,000 Total Rs. 3,83, FINANCIAL ANALYSIS 7.. Cost of Production (per annum in Rs.) Total Recurring Expenditure 32,64,000 Depreciation on Plant & 0 % 37,000 Depreciation on tools, jigs, fixtures 25 % 7,500 Depreciation on office equipment, 20% 22,000 Interest on total capital 2 %,65,960 Total 34,96,460 Say 34,96, Turnover (per annum) Item Qty. (Nos) Average Rate (Rs.) Value (Rs.) Job work of PCB. (Component mounting),20, ,80,

8 7.3. Net Profit (per annum) = Turnover cost of production = Rs.,84,000 Assembling/Mounting of Electronics Components on PCB 7.4. Net Profit Ratio = Net profit per year Turnover per year X 00 = 25.2% 7.5. Rate of Return = Net profit per year Total Capital Investment X 00 = 85.6% 7.6. Break-even Point Fixed Cost Per annum in Rs. Rent 3,60,000 Depreciation on machinery & 0% 37,000 Depreciation on tools, jigs and 25% 7,500 Depreciation on office equipment, 20% 22,000 Interest on total capital 2%,65,960 Insurance 24,000 40% of Salary & Wages 6,67,920 40% of Other Contingencies(Excluding rent & insurance),00,800 TOTAL 3,85,80 SAY 3,85,000 B.E.P = Fixed Cost Fixed Cost + Net Profit X 00 = 53.9 % -07-

9 Electronics Division Additional Information: The Project Profile may be modified/tailored to suit the individual entrepreneurship qualities/capacity, production Programme and also to suit the location wise characteristics, wherever applicable. The Electronics Technology is undergoing rapid strides of change and there is need for regular monitoring of the national and international technology scenario. The unit may, therefore, keep abreast with the 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 systems and ISO 400 defines standards for Environmental Management System for acceptability at international level. The unit may adopt ISO 9000 standards for global competition. The unit may contact the respective State Pollution Control Board and the Central Pollution Control Board for guidance on Pollution Control measures. Conservation of Energy is of national importance and the unit may strictly adhere to the energy conservation measures. Prior to Registration with Director of Industries/Industries Commissioner/Respective District Industries Centre, MSEs is required for manufacturing the product. The percentage of margin money may vary as per bank's discretion. -08-

10 Assembling/Mounting of Electronics Components on PCB ADDRESSES OF MACHINERY, EQUIPMENTS & RAW MATERIAL SUPPLIERS. M/s. Vaiseshaka Instruments Testing & measuring equipments 2, Post Box Stall, 38 Industrial Area, Ambala Cantt, Haryana 2. M/s. Aplab 6 Vasundhare, 6 th Floor 2.7 Sarat Bose Road, Kolkata M/s. International Electronics 202 Champakalal Industrial Estate, 05 Sion East, Mumbai M/s. Sumitron Exports Pvt. Ltd., 27, Community Centre Naraina Phase I, P.O. Box 0227 New Delhi M/s. Advance Tech Services, Soldering Equipments & Circuit Aids 56, 2 nd Floor, Rani Jhansi Road New Delhi M/s. Inde Enterprises, 745, Sector- 8B, Chandigarh 7. M/s. Bergen Associate Pvt. Ltd., 082, Sector 27-B, Chandigarh M/s. India Associates 6, Rest House, Crescent Off. Church St., Bangalore - 9. M/s. Navanidhi Electronics Pvt. Ltd -60/, Shehapuri, Nacharam, Hyderabad M/s. Control Signals C-62, hari Nagar, Ashram New Delhi 004 tech@controlsignals.ner The Consumables such as solder, Flux, Chemicals, Adhesives etc. may be procured from the local market. -09-