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DEPARTMENT OF HEAVY INDUSYTRYCG Scheme Proposal of

Common Engineering Facility Centre (CEFC) for

Textile Machinery and Allied Engineering IndustryBy

Science Engineering & Technological Upliftment (SETU) Foundation

MEETING OF DHI - CG SCHEME COMMITTEEUDYOG BHAWAN, NEW DELHI

AUGUST, 2016

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Key Objectives of CEFC

– Global competiveness

– To develop prototype product /component manufacturing

– To provide training and strengthen industry institute

interaction

– To provide design support for critical component of textile

machineries

– To provide testing and calibration facilities

– To provide automation consultancy for improving process

efficiency

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Industrial Estates in various region of South Gujarat –Surat, Bardoli, Navsari, Valsad,

Vapi,, Ankleshvar, Dahej, Bharuch, Vadodara and Vyara. (No CEFC in this region)

Around 400 Industrial units approached for the survey in the catchment area and

316 response received. Blank Survey Form

Members of SEVA – TMMA has visited and studied various facilities available in India

like Co- India and Sitark at Coimbatore, CMTI at Bangalore, IGTR at Ahmedabad and

ATI at Mumbai.

Technological gap due to lack of awareness on technical textiles, technology

obsolesce, poor policy framework, poor infrastructure, lack of skilled workforce

Enhance employability

Standardization of component and processes

Harmonize different segments and components

Global competitiveness

Need assessment & challenges

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Blank survey form

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Non availability of Indian standards (manufacturing,

application and safety) are leading to very heavy

loss. While all developed countries are leading with

it.

With this modern CEFC we will be able to provide

input to develop the standards.

Standardization of Component and Processes

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Due to lack of Harmony all manufacturers are

designing their components, process and machines

& wasting time and money

Lack of common platform leads to Non-sharing of

experience within peer group hampers the growth

of industries in totality

Any hidden talent needs common platform

Harmonize Different Segment and Component

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Insufficient exposure to export markets

Loosing market due to large import of machineries

Low quality and market compliances for

international market

Poor quality and workmanship of product

Most entrepreneur are in low/medium product

range targeting local market only

Global Competitiveness

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Major Machine Manufacturer and their turn over in and around Surat

Units

1306.5 Crore1387.2 Crore

532.8 Crore

48 Crore

Units

Units

Units

INDUSTRY AND MARKET ANALYSIS

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DELHI-MUMBAI INDUSTRIAL CORRIDOR DMIC

LOCATION OVERVIEW 35 kms from Surat, 274 kms from Mumbai

Nearest railway station Bardoli 6kms from site.

Main line connecting Udhana – Surat, Nandurbar -

Bhusawal

Nearest domestic airport Surat 45 kms from site.

Nearest international airport

Chhatrapati Shivaji International Airport

Mumbai 289 kms from site.

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BARDOLI

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PROPOSED BUILDING LAYOUT

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Total Area of 2.56 Acre. The Ground Floor Construction area is 2478 Sq. Meter and First floor Construction area is 2093 Sq. Meter.

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SCIENCE ENGINEERING & TECHNOLOGICAL UPLIFTMENT (SETU) Foundation

Foundation– Common Engineering Facility Centre: Two leading

associations, Surat Engineering Vikas Association (SEVA) and Textile

Machinery Manufacturers Association, India (TMMA) have come

together along with Sardar Vallabhbhai Patel Education Society

(SVPES) to set up a Common Engineering Facility Centre (CEFC) for

the Textile Machinery and Light Engineering sector in Surat. The

CEFC will be promoted as Centre of Manufacturing and Testing

Excellence by emphasising on prototype development,

manufacturing, testing, validation and skill development. The

Facility will help in speeding the engineering of Textile Machinery

and Light Engineering by setting up all the processes under one roof

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The CEFC is planned with an aim to increase efficiencies of the micro, small and medium scale units in and around Surat by offering common facilities which are not available with the individual units. The primary objective of the Centre would be to provide quality services to the customers by satisfying their industrial requirement as well as impart technical and managerial training in Textile Machinery and product development

The Facility would provide support and offer services for designing and manufacturing of small and medium size Textile Machinery components. The Facility would inculcate quality and safety measures in design, manufacturing and usage of various types of Textile Machinery

The Centre would aim at fuelling growth into the sector by addressing the gaps in terms of skills and knowledge. The Centre would house a Training Centre to train the individuals in achieving and practising highest professional standards

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Promoters Key Stakeholders

Government of India (GoI)

Textile Machinery

Manufacturers’

Associations, India

(TMMA)

Surat Engineering Vikas

Association (SEVA)

Sardar Vallabhbhai Patel

Education society,

(SVPES)

Government of Gujarat

Industrial Associations

Government Institutions

Textile Engineering Industry

General Engineering Industry

Skilled and un-skilled Human

resource

Ancillary industries catering

to heavy industries in and

around Surat

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Textile Machinery Manufacturers’ Association

Textile Machinery Manufacturers’ Association, India (TMMA),

(www.tmmaindia.net) is a premier association representing the

interest of the Textile Machinery manufacturers in India. TMMA is

well recognized by the government of India, and various national

and international bodies. TMMA acts as a catalyst in the promotion

and overall development of the Textile Engineering Industry by

influencing policy decisions and strategic developments. The

association provides a number of services to its members to

strengthen the competitiveness of the Textile Engineering Industry

and promote ‘Made in India’ brand in important textile markets

across the world.

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Surat Engineering Vikas Association

Surat Engineering Vikas Association (SEVA),

(www.sevasurat.com), is a registered trust & society under, the

trust & society act, vide Registration no. F/146/Surat Date:

29.02.2008 and Guj/1565/Surat, Date: 29.02.2008,

respectively. It’s a premium association and working for the

upliftment of Micro, Small & Medium Enterprise and acts as a

catalyst for industries & institutes and its linkage. It is

promoted by Surat Engineering Professionals’ Association

(SEPA)with an objective to undertake Cluster Quality &

Productivity Improvement programme supporting Small &

Medium Scale Enterprises as well as local industries

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Sardar Vallabhbhai Patel Education Society

Sardar Vallabhbhai Patel Education Society (SVPES),

(www.fetr.ac.in )is a registered trust and society under, the

trust & society act, vide Registration no. F/706/Surat Date:

07.09.1996 and Guj/806/Surat, Date: 10.09.1996, respectively.

It is located at Isroli, Bardoli, district Surat. The aim of society

is to carryout overall development of students’ community

especially of rural area and the nation as whole.

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PROPOSED FACILITIES OF CEFCThe following components will be set up in the SETU

Foundation CEFC to offer common facilities to the

members

Proto type Development Centre (PDC)

Training Centre (TC)

Design Centre (DC)

Testing and Calibration Laboratory (TCL)

Heat Treatment Unit (HTU)

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: Product Development Centre:

Customize and Specialized critical component manufacturing, Process improvement sub assemblies, Quality and productivity improvement tools or components, Plastic moulds, press moulds, press tools, jigs and fixtures and precision components, machine development, R&D, drafting of drawing, reverse engine, mould design, press tool design, jigs & fixture design, critical component manufacturing, heat-treatment Job work – hardening and tampering.

List of Equipment for Product Development Centre/ Proto type Development Centre

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S No. Equipment Units Per unit

(Rs Lakh) 1 CNC Wire cut EDM, X/Y axis travel

of 500*300 & 600*400 2 100.00

2 CNC Spark EDM Table size 800*400mm with standard accessories.

1 150.00

3 CNC Spark EDM Work Table size 300* 350mm spark Erosion

1 130.00

4 600*450*300 CNC HMC with various types of cutters & attachments

1 200.00

5 450*250*300 Jig Grinding Machine with standard accessories.

1 72.00

6 CNC VMC Machine, 2 130.00 7 CNC Milling Machine with various

types of cutters & attachments. 1 80.00

8 200*350 CNC Turning Centre with all accessories & attachments.

1 60.00

9 600*450*450mm Conventional Milling Machine with various types of cutters & attachments.

2 20.00

10 300*2000 Conventional Lathe Machine with all standard accessories & attachments.

3 20.00

11 200*600 Cylindrical Grinding Machine with all standard accessories.

2 25.00

12 300* 800mm Surface Grinding Machine with chuck, coolant system & all standard accessories.

2 25.00

13 3 D Pantograph Machine with all standard accessories.

1 30.00

14 300 mm Shaping Machine with all standard accessories.

1 2.00

15 Tool & cutter grinder with standard accessories & face mill grinding, radius/ helical grinding attachments.

1 25.00

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Tool & cutter grinder with standard accessories & face mill grinding, radius/ helical grinding attachments.

1 25.00

50 mm Pillar Drill Machine with all standard accessories and attachments

2 5.00

75 mm Radial Drill Machine with all standard accessories & attachments.

1 15.00

Heat Treatment Furnace of 600*250*260* 120mm Chamber size. Lower Chamber 730*400*300*120 & Upper Chamber 730*400*300* 140 with Direct/case/Tempering up to 50 mm Thickness with all accessories.

1 70.00

Metal Microscope having Magnification up to 50/100/200/500/1000 with all accessories

1 10.00

100MT Power Press with various press tools & dies, jigs & fixtures complete with hydraulic arrangements & accessories.

1 40.00

150 MT Injection Moulding Machine with all accessories.

1 65.00

6 mm Shearing Machine with all accessories.

1 5.00

300 Amp. Arc Welding Set with inverter& Oxy-Acete. Gas Welding set with cutter & nozzles complete with all accessories.

1 5.00

250 KVA capacity DG SET with Kirloskar’ Alternator & Engine, Radiator cooling, Diesel Tank, Exhaust chimney. Batteries, Panel board & all accessories.

2 50.00

Air Conditioning Equipment consisting Compressor, electric motor, Condenser, pumps, cooling tower, valves & piping.

1 200.00

 

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Air Conditioning Equipment consisting Compressor, electric motor, Condenser, pumps, cooling tower, valves & piping.

1 200.00

10 H.P. Air Compressor, Receiving Tank, Filter, valves & Piping.

1 40.00

Material Handling Equipment, various types of trolleys, Pallet Trucks, Cases, Bins etc.

1 30.00

Electrical Installations H.T /L.T cabling, Panels, Transformer, D.P structure, Busbars, ACB, COS, Electrical Fittings & fixtures & lighting

1 100.00

Misc Equipment like Hand Power Tools, Spanners, small m/c tools, carbide tools, files, drill sets etc.

1 50.00

Total  

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: Training Centre:

Short & Medium Term TRAINING -related to HR / skilled Man power/ Technical/ Product / Process / specialised sector/ innovation / entrepreneurship / Quality / Marketing / Sales/ Lean Manufacturing/ Energy Efficiency / Standardization etc.

List of Equipment for Training Centre

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S No. Equipment Unit

s Per unit

(Rs Lakh) 1 10' long & 12" swing Engine /Trainer Lathe

& Automatic Horizontal Lathe Machines, with 3 jaws/4jaws chucks, earners, mandrels, collets, gears train assembly & all other accessories & various attachments.

2 20.00

2 6 long & 8" swing Engine /Trainer Lathe & Automatic Horizontal Lathe Machines, with 3 jaws/4jaws chucks, carriers, mandrels, coIlets, gcars train assembly & all other accessories & various attachments.

2 10.00

3 39"* 11 ^Universal Horizontal Milling Machine with indexing head, various milling cutters & all standard accessories as well as various types of attachments like vertical milling, slotting, circular milling, rack milling etc.

2 35.00

4 CNC Programming Station with P1I Server/Software& complete with all accessories

3 5.00

5 Standard Conventional Machines 6 4.00 6 Standard Workshop Machines and

Equipment like Radial Drill, Work Benches & vices Shaping machine. Power Hacksaw etc.

2 20.00

7 Various Measuring Instruments, like Vernier, Micrometer, Slip Gauges, Profile Projector

2 20.00

8 Air Conditioning Equipment 5 0.60 9 10 H P. Air Compressor, Air Receiving Tank,

Air Filter, valves & connected Piping. 1 20.00

10 Material Handling Equipment, various types of trolleys. Pallet Trucks, Cases, Bins.

1 10.00

11 Misc Equipment like Hand Power Tools, Spanners, small m/c tools, carbide tools, files, drill sets etc.

1 10.00

 

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: Design Centre:

Design Centre: 3D modelling, design and drafting, legacy data conversion, metal casting stimulations, mould flow analysis, reverse engineering etc.

S No. Equipment Units Per unit

(RsLakh) Total

(RsLakh) 1 CAD programming Machine with all

std. accessories & attachments 2 3.00 6.00

2 Pro/ENGINEER Wildfire-Ill Master CAM V9 CAM program, VERICUT

2 30.00 60.00

3 Deniord CNC Training Software 2 5.00 10.00 4 Desktops with Monitors, Printer /

Scanner / Copiers and accessories 10 2.00 20.00

5 3D Printer and Peripherals 1 150.00 150.00 6 Air Conditioning Equipment 6 0.70 4.20

Total 250.20  

List of Equipment for Design Centre

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: Testing and Calibration Laboratory:

Calibration, Testing and Certification of measuring Instruments. Testing the physical, chemical properties of materials and its certificate.

S No. Equipment Units Per unit

(RsLakh) Total

(RsLakh) 1 CNC CMM 600*450x600 Size with

all standard accessories. 1 90.00 90.00

2 Mechanical Instruments like Dial Gauges, Callipers, Micro Meters, Slip gauges, Profile projectors, Mech Comparators, Electrical Comparator, Optical Flats, Limit Gauges, Linear measuring instruments, Gauging Systems.

2 35.00 70.00

3 Air Conditioning Equipment 4 0.70 2.80 4 10 H.P. Air Compressor, Air

Receiving Tank, Air Filter, valves & connected Piping.

1 40.00 40.00

Total 202.80  

List of Equipment for Testing Laboratory

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: Heat Treatment Unit:

It is an integrated part of product development facility, component manufacturing facility, Die, mould, press tool and jig fixture manufacturing.

 

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Focus area of proposed CEFC

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Production Prototype product /

component manufacturing

Design of critical components and machine

Process improvement techniques with better design and tooling

Use of Automation for Improving process efficiency and product quality

Production of Mould, Dies and Press Tool

Production of Jigs & Fixtures

Tooling Jobs Machine Components

Training Enhance Employability

by providing training Proto type

Development Centre Courses

CNC Manufacturing Maintenance Advance Welding 3D Printer Related to HR, skilled

manpower, Technical, product, process, specialised sector, innovation, entrepreneurship, quality, marketing, sales, Lean manufacturing, energy efficiency, standardization etc.

Consulting Design Support Productivity

Improvement Product and Process

improvement support Lean manufacturing

and energy efficiency

Testing Calibration Testing and

Certification of Instruments

testing of physical and chemical properties of materials

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Utilisation of CEFC activities as per actual survey (%)

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Total 72 Activities in

16 Titles are

proposed at CEFC

at initial and

long-term work

as per survey

Sr. No. Item / Product

Design of critical

component and machine

Prototype product

Component manufacturi

ng

Design of Dies,

Moulds and Press tools

Design & Manufactu

ringof Jigs and Fixtures

Processimprovement

techniques withbetter design

and tooling

Use of Automation

for Improvingprocess

efficiencyand product

quality

Training

Exploring New

Technology and

Applications

1Stenter Machineblower fan

a a a a a a

2Servo Motor ofEmbroidery Machine

a a a a

3Improvement ofspeed of existing Loom Machine

a a a a a a a

4Flat bed Printingmachine process improvement

a a a a a a

5Printing Machine Colour Injection System

a a a a a a a

6Recirculation of Waste Water of Processing House

a a a a a a

7Retrofitting devicein existing Machine to improve product, process

a a a a a a a

8Improvement inThermal insulation system in processing house

a a a a

9 Solar Charkha a a a a a

10Equipment for Technical textiles

a a a a

11Training for Quality and productivity improvement

a

12Training Relatedto HR work

a

13 Consultancy Work a a a a a

14Press tool, Die, Mould Manufacturing

a a a

15

Jigs and Fixture Manufacturing for improvement of Productivity

a a a

16Spare parts Development of Embroidery machine

a a a a

Total Avitivities 12 11 4 5 9 5 16 10

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Proposed Initial and long term work at CEFC as per Survey

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Estimated ManpowerTop Management

  Department  

Designation Training Centre

Design Centre

Product Development

Centre

Testing Lab Admin Total

Plant Head         1 1

Team Leaders   1 1     2

Manager 1 1 2 1 1 6

Management and Supporting Staff  

Engineers/Supervisors 1 1 2 1 1 6

Operators 4 4 8 2 2 20

Associates/Trainees 1 2 8 2 2 15

Add: Benefits            

TOTAL   7 9 21 6 7 50

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Scenario with/without establishment of CEFC

Looking to 50 Years of projection, If CEFC is there the growth of entire industries are predicted to rise steadily up to 430 % while at the same time growth of CEFC is rising up to 200 % for around 20 to 25 Years. If CEFC is not there the growth of entire segment is going negative after 8 to 10 years.

SUSTAINABILITY / LONG TERM PLANS

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THANK YOU