Casting for Auto Locks

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Product Code N.A.
Quality and Standards As per BIS.
Uploaded on February 2007


Zincs castings of various sizes and shape are used in Auto Locks Assembly. Usually die casting zinc alloy is used for this purpose due to

  • High productivity
  • Good as Casting surface finish and appearance
  • Do not require much machining
  • Can be cast within close dimensional tolerance
  • Their section can be cast with case.
  • Very Low metal wastage
  • Very Low rejection.

Market Potential

Open market and Automobile units are in need of the Auto Locks. Hence there is good scope for this product. It is better to do the production of Zinc diecasting for Auto Locks near the Auto Lock Manufacturing units' Cluster. There is very good scope in and around Aligarh city which has cluster group of Auto locks manufacturing units.

Basis and Presumptions

Number of shifts Single shift of 8 hrs.
Working days per Annum 300
Working efficiency 75%
Time period for achieving full capacity utilisation 3 years
Labour wages As per the minimum Wages Act of State Govt.
Margin money 25% on an average of project cost
Interest rate on fixed and working capital. 15% on average.
Estimated life of the project 20 Years
Land cost and construction cost It has been assumed that the project is established in rented shed.
Cost of Machinery and Equipments Prevailing cost of the Market
Seeing present practice, it has been assumed that the die and Raw material will be supplied by the Lock Assemblers.  

Implementation Schedule

Nature of Activities

Period in month (Estimated)

Scheme Preparation and Approval 1
SSI Provisional registration 15
Sanction of loan required if any 3
Clearance from State Pollution Control Board 2
Placement of order for delivery of machinery 3
Installation of machinery 1
Power connection 3
Trial Run 5
Commencement of regular production After 5 months

Technical Aspects

Process of Manufacture

Melting of zinc Ingots (4500C) - Clearing - Diecasting - ejection of casting - runner breaking - Primary inspection - Fitting - Final inspection - Buffing - despatch.

Quality Control and Standards

As per customer's specification. Die cast components should be free from blow holes, pin holes, shrinkage, coldshut etc. They should be free from dimensional inaccuracies. Zinc alloy should be as per specification of the customer. Generally Zinc alloy (IS MAC-3) having electrolytic Zinc with 4-6% Al is used for this purpose. Raw material is expected to be supplied by the lock assemblers.

Production Capacity (per annum)


Value (In Rs.)

1.50 Lakhs Rs. 12 Lakhs
Motive Power 40 H.P.

Pollution Control

There is not much problem of pollution. However, powerful exhaust is required for exhaust of smokes from the shed.

No Objection Certificate has to be obtained from State Pollution Control Board.

Energy Conservation

  • Maximum utilisation of machine has to be done to consume metal from the melting Furnace.
  • The Furnace should be provided with thermocouple and automatic temperature control devices.
  • Opening of the Furnace shouldbe kept closed while not in use.
  • Energy audit of the unit has to be done on a regular basis.
  • Preheating of charge should be done by keeping few ingots on holding furnace.
  • The Furnace should be properly insulated to reduce radiation.

Financial Aspects

Fixed Capital

(i) Land and Building

(In Rs.)

Rented area 300 sq. mtrs. @ Rs. 3000 per month 9,00,000

(ii) Machinery and Equipment




Amount (In Rs.)

Horizontal Hot chamber pressure die casting M/c capacity 400 gm/ shot with control panel and accessories Ind. 1 No. 2,00,000
Electrical Resistance furnace for melting zinc alloy Ind. 1 No. 1,00,000
Arc welding machine Ind. 1 No. 15,000
Fitting equipment and Buffing equipments Ind. - 15,000
Bench drilling machine (1 HP) Ind. - 10,000
Weighing Machine (Platform type) 200 kg cap.     10,000
Air compressor (3 HP)     25,000
Pedestal Grinder (2 HP)     10,000
Flexible shaft grinder (2 HP)     10,000
Bench grinder double ended (1/2 HP) Ind. 1 No. 8,000
Pheusmatic grinder Ind. 1 No. 4,000
Material Handling equipments Ind.   5,000
Testing Equipments Ind   20,000
Pollution Control Equipment (Exhaust) Ind   10,000
Energy conservation facilities     Already included in the
accessories of Furnace
Cost of power connection including transformer     1,00,000
Electrification and Installation charges     50,000
Tools and other fixtures     20,000
Office equipment/working tables     20,000
Total 6,32,000
(iii) Pre-operative Expenses Rs. 50,000
Total Fixed Capital = 2 + 3 (As shed is rented)
  = Rs. 6,82,000

Working Capital (per month)

(i) Personnel

Administrative Supervisory


Manager 1 No. Rs. 4,000 4,000
Engineer cum-Supervisor 1 No. Rs. 4,000 4,000
Accountant (Part-time) 1 No. Rs. 1,000 1,000
Clerk cum Typist (Part-time) 1 No. Rs. 1,000 1,000

Technical Skilled and Unskilled


Skilled worker 1 No. Rs. 3,000 3,000
Semi-skilled worker 1 No. Rs. 2,500 2,500
Unskilled worker 2 Nos. Rs. 2,000 4,000
Peon–cum–watchman 1 Nos. Rs. 2,000 2,000
Total     21,500
Perquisites @ 15%     3,225
Total     24,725

(ii) Raw Material



(In Rs.)

Zinc Alloy ingots Ind (Alloy ingots will be supplied by the customer) 5% Burning loss will also be allowed.)  
Various consumables Ind 20,000
Total 20,000

(iii) Utilities (per month)


Amt.(In Rs.)

Power 5,000
Water and Misc. 1,000
Total 6,000

(iv) Other Contingent Expenses (per month)


(In Rs.)

Rent 3,000
Telephone 1,000
Consumable stores 500
Transport charges 1,000
Advertisement and publicity 500
Postage and stationery 500
Insurance taxes, and other misc exp. 3,000
Repairs and maintenance 1,000
Total 10,500

(v) Total Recurring Expenditure (per month)



(i) + (ii) + (iii) + (iv) = Rs. 61,225
(vi) Total Working Capital (for 3 Months) = Rs. 1,83,675

Total Capital Investment

(i) Fixed Capital Rs. 6,82,000
(ii) Working capital (3 months) Rs. 1,83,675
Total Rs. 8,65,675

Machinery Utilisation

  • Working efficiency—75%
  • Single shift
  • 25 working days in a month.

Financial Analysis

Cost of Production (per year)

(In Rs.)

Total Recurring cost 7,34,700
Depreciation on machinery @ 10% 49,200
Depreciation on furnace @ 20% 20,000
Depreciation on tools and fixture @ 25% 5,000
Depreciation on office equipment @ 20% 3,000
Interest on total investment @ 15% 1,29,851
Total 9,41,751

Turnover (per year)



Rate (In Rs.)

Value (Rs.)

Zinc die casting for Auto Locks per shot of 400 grm shot about 3-4 various castings like Roter, Body casting etc. 1,50,000 shot @ Rs. 8 per shots conversion charges 12,00,000

Net Profit (per year) (Before Income Tax)

  Total Sales – Total Cost of Production
  = Rs. 2,58,249

Net Profit Ratio

  Net Profit
  Turnover ×100
  = 21.5%

Rate of Return

  Net Profit per year
  Total Investment ×100
  = 29.83%

Break-even Point

Fixed Cost (per annum)

(In Rs.)

Depreciation on machines and equipment tools, fixtures and office equipments 77,200
Rent (Annual) 36,000
Interest on Total Investment 1,29,851
Insurance 24,000
40% of salary and wages 1,18,680
40% of other contingent expenses excluding rent and insurance 26,400
Total 26,400

B.E.P Annual fixed cost ×100
  Annual fixed cost + Profit
  = 61.47%

Additional Information

In this Project Die and Raw material will be supplied by the customer as per present practice in the field of die casting.

Addresses of Machinery and Equipment Suppliers

  • M/s. H.M.T. Limited
    Die casting and Plastic Machinery
    Division, HMT P.O., Bangalore-31
  • M/s. P.K. Engineering Works
    B-1, Industrial Estate, Aligarh. U.P.

Addresses of Raw Material Suppliers

  • M/s. Hindustan Zinc Limited
  • M/s. Minerals and Metals Trading Corpn. of India Limited.
    1-8-32/15, Bapubagh, Panderghast
    Road, Secunderabad-3
  • M/s. S.S. Agarwal and Co.
    Sabzi Mandi, Kanwari Ganj,
    Aligarh, U.P.

Addresses of Chemical Suppliers

  • M/s. Greaves Foseco Limited
    Chinchwad, Pune-411019
  • M/s. I.V.P. Limited
    Regd. Office, Shashikant Nedij
    Marg, Ghorupodio, Mumbai-33.

For further information please contact

Information Manager
TIMEIS Project