Project Profile - ELECTRONIC COUNTER

INTRODUCTION:

         Electronic event counters are used to count the number of times an event occurs and can generate output signal for a particular application. These Programmed Pre-Set Counters usually accept inputs from any “make” contact so can be used with pulses from switches, relays, controller outputs or push buttons and generate output signals as required depending on the input signal which can be used to control various functions in a process. The proximity sensor detects the input signal and generates the output signal as programmed in the counter. There are different types of counters for different applications. Electronic counters are generally used in the industries to control the process/operation with specified cycle operation or interval. They find application in the control of functions of industrial machinery or process at varying time intervals for textile industry plastic industries, pharmaceutical industries, petro-chemical industries, power plants etc. Electronic counter consist mainly a proximity sensor, counter, integrated circuits, display panel, transmitter and other electronic components.

MARKET:

         The total production of Electronic equipments in the control, instrumentation and industrial sectors during 2004-05 was Rs 8,300 core as compared to Rs 6,100 core during the year 2003-04. The control, instrumentation and industrial Electronics sector of the Electronics industry play a vital role in the modernization through instrumentation and automation in India’s manufacturing, public utility services and infrastructure sector. As the automation process in the major manufacturing industries like petrochemical, cement, textile, steel, fertilizers, chemicals and manufacturing sectors are likely to increase in the coming years there will be increase in the demand for more process control instruments and equipments. This will have direct impact on the demand for products like Electronic counters and as such the demand for Electronic counters are bound to grow e tin the coming years. Hence there is enough potential for more number of units in this line.

Basis & Presumptions:

         The basis for calculation of production capacity has been taken on a single shift basis on 75% efficiency,
         The maximum capacity utilization on single shift basis, for 300 days in a year. During the first year and second year of operations, the capacity utilization is 60% and 80% respectively. The unit is expected to achieve full capacity utilization from the third year onwards,
         The salaries and wages, cost of raw materials, utilities, rent, etc. are based on the prevailing rates in and around Thrissur. These cost factors are likely to vary with time and location,
         Interest on term loan and working capital has been taken @ 16% on an average. This rate may vary depending upon the policy of financial institutions/agencies from time to time,
         The cost of machinery and equipments refer to a particular make/model and the prices are approximate,
         The break-even point percentage indicated is of full capacity utilization,
The project preparation cost, etc. whenever required could be considered under the pre-operative expense,
         The essential machinery and equipments required for the project have been indicated. The unit may also utilize common facilities available at Electronics Test & Development Centers (ETDC) and Electronic Regional Test Laboratories (ERTLs) set up by state Governments and STQC Directorate of Department of Information Technology, Ministry of Communication and Information Technology to manufacture products conforming to Bureau of Indian Standards.

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 12 months:

         Note: Many of the above activities shall be initiated concurrently,

         When imported equipments are required, the implementation period of the project may vary from 12 months to 15          months,

         Procurement of raw materials commences from the 8th month onwards.

TECHNICAL ASPECTS:

Process:

         The incoming raw material and components are tested for required quantity and specifications. The manufacturing process involves Electronics assembly and Electro mechanical hardware assembly. In electronics assembly all the components are shaped, formed and soldered on pre-designed printed circuit boards. The assembled printed circuit boards are tested for desired performance. The electromechanical components such as connectors, sockets switches, LED display are assembled as per the design of the panel of the equipment. Subsequently the electronic assembly and electromechanical assembly are further assembled to form a compact unit and encased in a metallic or plastic cabin. The final product is then calibrated and tested as per relevant design specifications and customer requirements.

Production Capacity per annum:

Pollution Control:

         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 1992, the production and use of Ozone Depleting Substances (ODS) like Chlorofluoro Carbon (CFC), Carbon Tetrachloride, Halons 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, 1986 have been put in place with effect from 19th July 2000.
         The following steps are suggested which may help to control pollution in electronics industry wherever applicable:
         In electronic 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 – 10% solids as opposed to the traditional 15 – 33% solids. Electronic industry uses CFC, 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-113 and Methyl Chloroform in electronics cleaning. Other Chlorinated solvents such as Trichloroethylene, Perchloroethylene and Methylene Chloride have been used as effective cleaners in electronics industry for many years. Other organic solvents such as Ketones and Alcohols are effective in removing both solder fluxes and many polar contaminants.

ENERGY CONSERVATION:

         With the growing energy needs 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 1980s. The Energy Conservation Act, 2001 has been enacted on 18th August, 2001 which provides for efficient use of energy, its conservation and capacity building of Bureau of Energy Efficiency created under the Act.
The following steps may help for conservation of electrical energy:

         Adoption of energy conserving technologies, production aids and testing
         facilities.
         Efficient management of process/manufacturing machineries and systems, QC and testing equipments for yielding maximum Energy Conservation,
         Optimum use of electrical energy for heating during soldering process can be obtained by using efficient temperature controlled soldering and disordering stations,
         Periodical maintenance of motors, compressors, etc.
         Use of power factor correction capacitors. Proper selection and layout of lighting system; timely switching on-off of the lights; use of compact fluorescent lamps wherever possible, etc.

FINANCIL ASPECTS:

A) Fixed Capital

i) Land and Building

ii) Machinery & Equipments

B) Working Capital

Recurring expenditure per month

i) Staff & Labour

ii) Raw Materials p.m

iii) Utilities

iv) Other contingent expenses per month

Additional Information:

         The project may be modified/tailored to suit the individual entrepreneurship qualities/capacity, production programmer 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 discretion,

NAMES AND ADDRESSES OF MACHINERY &
EQUIPMENT SUPPLIERS