Ceiling Fan
Ceiling Fan
Ceiling Fan
OF
CEILING FAN MANUFACTURING PLANT
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Cost of Project
Particulars Amount in Lacs
Land Owned/Leased
Building & Civil Work Owned/Leased
Plant & Machinery 15.50
Furniture & Fixture 0.50
Other Misc Assets 1.00
Working Capital Requirement 7.78
Total 24.78
Means of Finance
Particulars Amount in Lacs
Own Contribution 2.48
Term Loan 15.30
Working capital Loan 7.00
Total 24.78
1. INTRODUCTION
In this case, flipping blades upside-down when possible would make fans more
effective on updraft, because when the blades are left right side up, they might not blow
nearly as much air on updraft, especially on industrial ceiling fans. Ceiling fans are an
especially economic choice in warm, humid environments. Ceiling fans can be operate in
different ways. Some come with a pull-chain or pull-cord control. Some fans operate on a
variable-speed control where a dial, which works like a dimmer switch, is mounted on the
fan. Some fans have their controls mounted on the wall, while others come with wireless
remote controls that transmit radio frequencies or infrared control signals to the receiver
installed in the fan.
2. PRODUCT DESCRIPTION
Ceiling fans are a useful, economical and practical solution for reducing cooling needs in
the spring or in summer. It can be used in residential and commercial areas.
1. Metal: Steel strips coil, Steel sheets, Steel bars, Iron metal, Steel pipes etc.
To form stator and rotor core part - cold rolled non grain oriented electrical steel strips
can be used, for shaft forming steel bar can be used. Blades will be formed using steel
sheet. And to form motor casing/cover iron metal can be used. Downrod will be
formed with Steel pipes.
2. Plastic: PP, PVC, Plastic granules can be used to form some plastic parts for ceiling
fan.
3. Electric components: Capacitor, Wires, Winding wire, Terminals etc.
4. Insulation material
5. Other components: Ball bearings, Nut bolts, washers, cotter pins, springs, Paint etc.
After importing required raw material; quality checking, sorting will be done.
Chemical Analysis, Physical Testing, Pressure Test & Leak Checking, Electronic
Dimensional Checking of metal raw material will be done. The quantity of raw materials
being handled and it will store it in store department or in raw material inventory. Quality
control of raw material is the maintaining of all the procedures that are needed to be taken to
produce a quality full product. In sorting procedure the different types of materials or parts
will be sorted out like plastic, metals, electrical components etc. It will be separated and
material will be stored and later on it will dispatch to assembly line.
Design
To effectively develop a product design specification for the fan, need to know
customer need, trending designs, demand of the product and the basic function of the fan. The
basic function of a fan is to cause effective air flow in a room and this should be
accomplished for a long usage of several years at varying rotations per minute. The quality of
fans is rated by their performance which is in moving the air effectively and quietly. This is
monitored by such factors as the length, pitch, and number of ceiling fan blades, and their
revolutions per minute (rpms). The angular edges of the fan blades are also known as the
pitches which are especially significant for the effective movement of the air. The shape
empowers the blade to apply strain to the air before it and in this manner the air is constrained
downwards. Design of blades is such that blades are sloped in direction of rotation,
anticlockwise. Blade lengths for most of the fans are standard 48 inch, 24 inch etc. The most
widely used materials for making ceiling fan blades are Wood, Plastic and Metal. Some
manufacturers are providing customizable fan designs as per consumer’s house interior
design to making interior both look and feel cool. Some ceiling fan designs are shown below:
ii. Stator and Rotor manufacturing- To form stator core, sheet lamination is used to
form a laminated core instead of a solid piece to reduce eddy current losses. A cold
rolled non grain oriented electrical steel strips is fed into a reciprocating stamping press
with progressive stamping dies to form strips for laminated stator core. The die moves
with the press, and when the press moves down the die closes to stamp the metal part.
Stator core is the steel part consisting of thin steel sheets (laminations) stacked
together; usually with a thickness of about 0.5 millimetre. The laminations are bonded
in order to create a stable core. Interlocking, Clamping, Welding, Bonding are some
techniques to join the steel lamination stacks. Rotor can be formed using similar
process.
Welding technique- The laminations/lamellas are stacked loosely and subsequently
joined with a weld seam using welding machine.
iv. Downrod forming - Downrod used to suspend the fan down from the ceiling. Steel
pipes will be cut off in required length and are also inspected for defects. Further
pipes will be drilled using drilling machine.
v. Motor cover manufacturing- Die casting
Motor covers of ceiling fan will be formed with die casting process. Iron will be
melted in induction furnace with required amounts of iron metal. Contaminants are
removed from the melted iron, and the iron, once melted, is then cast. Casting is the
process of pouring the iron into a mould thus giving it a shape; shape of fan cover
or motor casing. The melted-liquid iron will be filled in mould and will be allowed to
set into moulds/slabs for solidification. Later cooling will be done. And formed parts
will be ejected out. Further formed metal parts polishing and panting will be done.
For painting these formed parts either liquid paint or powder coating will be used.
Manufacturers can also form rotor part using die casting process.
Stator winding
Ceiling fan stator winding can be broken down into three steps: paper insertion
process, winding process, stator impregnation varnish dripping process. Paper insertion and
stator winding are be done 2 times for inner and outer slots respectively. This process
machines are automated, only manual loading and unloading the ceiling fan motor stator,
which significantly improves production efficiency and saves production costs. Firstly,
inserting the insulation paper into the inner ring of the stator will be done, and then the coil
winding of the inner ring of the stator will be completed. Further inserting the insulation
paper into the outer ring of the stator will be done and the coil winding will be done for the
same. After the ceiling fan motor stator winding, the fan stator fan starts the impregnation
varnish dripping, help the enamelled wire of the stator can be fixed, so that the coil is not
loose and the wire is not twisted, the friction between the wire and the wire is reduced, and
the insulation performance of the stator can be increased. Besides, varnishing process of
stator; stator buffing can also be done.
Assembly
The rotor will mounted on the fan cover and it will be fixed inside cover grips. Shaft
will be pressed within the stator. This stator mechanism will be mounted on the bearing and
spring; which is attached to fan cover. Air gap between the stator and the cover will be
inspected. Then the stator will be fixed in a housing of fan cover. Ball bearing will be
inserted both side of stator shaft. Both top and bottom metal fan cover will be screwed with
screws, nut and bolts. Further capacitor will be fixed in capacitor clamp with the down rod
and electrical wiring will be done with motor. Canopy will be fixed on electrical wiring. The
blades will be placed on a metal plate or fan cover at the bottom and will be screwed by two
tightly fixed screws one behind the other. The weight of the blade is supported on the cover
plate. Then as per design specification required number of blades fixed symmetrically to the
hub. Final product will dispatch for testing.
Testing
1. Quality Control- the finished product are tested for hardness, strength, durability,
reliability, and other factors to ensure they meet the required specifications. At the
testing station, electric and internal physical parameter testing is performed. To ensure
the reliability of the product, all the electrical and physical parameters will be
verified.
2. Voltage testing- Low voltage and high voltage testing
3. Lock rotor test
4. Motor winding inspection will be done.
5. To verify the machine’s ability to perform in accordance with its required rating and
careful inspection, followed by surge comparison, winding resistance, and high-
potential testing.
6. Airflow testing- This testing can be done at air delivery room using anemometer vane
probe
3. PROJECT COMPONENTS
The land require for this manufacturing unit will be approx. around 2500-3500 square feet.
We have not considered the cost of Land purchase & Building Civil work in the project. It is
assumed that land & building will be on rent & approx. rental of the same will be Rs.50,000-
60,000 per month.
This is semi-automatic type of plant and production capacity is set to 200-220 pieces
of finish product per day.
Machines-
Riveting machine
To rivet blade and blade shank this machine can be used.
Stamping machine
Stamping machine is used in motor part forming.
Forging Press
To forge shaft this machine can be used.
Polishing/Buffing machine
Metal parts polishing can be done using buffing machine.
Heating Chamber
After powder coating heating is usually required to finish curing the coating.
3. High and low voltage test equipment- To test the operation of fan motor with different
voltage.
4. Anemometer- To inspect airflow of fan this tool is used.
Trademark- It’s a sign, design which identifies product of a particular source from
those of others.
GST
NOC from Fire Department.
NOC From Pollution Department (if applicable)
Udyam Registration is required.
Labour Registeration.
PROJECTED BALANCE SHEET (in Lacs)
PARTICULARS 1st year 2nd year 3rd year 4th year 5th year
Liabilities
Capital
Opening Balance 5.17 8.53 12.59 16.28
Add:- Own Capital 2.48
Add:- Retained Profit 5.19 7.86 10.55 13.70 16.32
Less:- Drawings 2.50 4.50 6.50 10.00 12.00
Current Assets
Sundry Debtors 3.76 4.72 5.57 6.46 7.39
Stock in Hand 7.92 9.78 11.51 13.35 15.28
Cash and Bank 2.15 2.53 2.87 3.51 3.48
Loans and advances/other current assets 1.00 1.50 2.00 1.50 2.00
TOTAL : 29.31 30.86 32.44 33.75 35.78
PROJECTED PROFITABILITY STATEMENT (in Lacs)
PARTICULARS 1st year 2nd year 3rd year 4th year 5th year
Capacity Utilisation % 30% 35% 40% 45% 50%
SALES
CEILING FAN 94.05 118.12 139.18 161.41 184.86
PARTICULARS 1st year 2nd year 3rd year 4th year 5th year
SOURCES OF FUND
Own Margin 2.48
Net Profit 5.39 8.74 12.40 16.89 20.64
Depriciation & Exp. W/off 2.53 2.15 1.83 1.56 1.32
Increase in Cash Credit 7.00 - - - -
Increase In Term Loan 15.30 - - - -
Increase in Creditors 2.79 1.34 0.73 0.77 0.81
Increase in Provisions & Other liabilities 0.75 0.25 0.20 0.24 0.29
PARTICULARS 1st year 2nd year 3rd year 4th year 5th year
REPAYMENT
Instalment of Term Loan 1.70 3.40 3.40 3.40 3.40
Interest on Term Loan 1.50 1.32 0.95 0.58 0.20
The views expressed in this Project Report are advisory in nature. SAMADHAN
assume no financial liability to anyone using the content for any purpose. All the
materials and content contained in Project report is for educational purpose and
reflect the views of the industry which are drawn from various research material
sources from internet, experts, suppliers and various other sources. The actual
cost of the project or industry will have to be taken on case to case basis
considering specific requirement of the project, capacity and type of plant and
other specific factors/cost directly related to the implementation of project. It is
intended for general guidance only and must not be considered a substitute for a
competent legal advice provided by a licensed industry professional. SAMADHAN
hereby disclaims any and all liability to any party for any direct, indirect, implied,
punitive, special, incidental or other consequential damages arising directly or
indirectly from any use of the Project Report Content, which is provided as is, and
without warranties.