Tumbler Locks
Introduction
As is revealed from the name itself, Tumbler Locks are used for locking of doors, shutters of houses/shops. Tumbler locks are a kind of pad locks. The body of the tumbler lock is pressure die casted from Aluminium or Zinc alloy. The tumbler locks are available in different shapes and sizes, among them the most common are 20, 25, 30, 35 and 46 mm. These locks are opened with the help of a key made from either brass, mild steel or die casted non ferrous metal, To operate the lock, the key is inserted in the key hole provided at the bottom of the
| Product Code | 343301008 |
| Quality and Standards | IS 4230:1967 |
| Production Capacity | Qty. : 2.40 Lakh Nos. (per annum) Value : Rs. 148.8 Lakhs |
| Uploaded on | April 2007 |
lock, opposite side to shackle. These locks are used to lock windows, Almirah, trunks etc.
The alloy used to manufacture such locks is known as "Mazak" Alloy. Mazak alloy is an alloy having Zinc as the base material. The composition of other elements in Mazak alloy used for this purpose is as follows
| Aluminium | 4% |
| Copper | 2.7% |
| Magnesium | 0.1 to 0.3% |
The alloy having the above composition is hard and strong and can be easily diecasted. Pressure die-casting has been widely used to produce sound and strong castings of accurate dimensions as they need no final machining to size. The surface is smooth and good.
Market Potential
Since Lock is an essential household item, its demand is ever increasing.Tumbler lock being a stout lock is considered to be a good quality lock.
Basis and Presumptions
It is considered that the unit is run 300 days in a year with 16 hours per day. The rates for raw material, labour, machinery etc. have been taken as prevailing at the time of preparation of project scheme. Margin money requirement, terms of loan, interest rates may vary from time to time and institution to institution providing finance, which may be verified. In this project profile, the rate of interest has been considered as 12% per annum.
Implementation Schedule
It is estimated that it may take 4-5 months from conception to commercial production including preparation of project report, finalization of loan from financial institutions, procurement of machinery, erection and commissioning, recruitment of staff and labour, registration and clearance from authorities
Technical Aspects
Process of Manufacture
Tumbler lock consists of the following main components
- Body
- Cylinder
- Levers and its mechanisms
- Shackle and
- Tumbler key
Body
Housing of lock mechanism, which contains all the parts except key and shackle is known as body of the tumbler lock. However, one end of the shackle is also fitted in the body. The body of the lock is pressure die casted from Aluminium or Zinc alloy called Mazak Alloy. After pressure die casting, the burrs and sharp edges are removed and polished. Body can also be painted or plated depending upon the requirement.
Cylinder
Cylinder is also pressure die casted part from Aluminium or Zinc Alloy. It is the housing for lever tumbler mechanism. It is fitted inside the body of lock during assembly.
Lever and Lever Mechanism
Levers are mostly press cut from brass or mild steel sheets. These levers along with springs are fitted inside the cylinder which rotates inside the body to keep open or close the lock with the help of key.
Shackle
It is that part of the lock which passes through the staple loop on the door and is engaged to lock bolt when pushed inside the lock and key is turned lock. Shackle are made from mild steel rods, cut to size, notched and bent to the shape. These are generally nickel plated.
Key
The key is an important member of lock and key arrangement. It is made of brass or mild steel. It is flat, has long bit or blade with V groves made on one or both edges according to the lever mechanism.
All these components are manufactured in various sizes and shapes of the lock. Manufactured components are then assembled and movement of lever cylinder, shackle fixed in position with the help of a pin. The tumbler locks are painted or nickel plated before packing for dispatch.
Production Capacity (per annum)
Item |
Qty. in Nos |
Price Per Piece |
Total (In Rs.) |
| Tumbler Lock Size 20 and 25 mm | 96000 | 55 | 5280000 |
| Tumbler Lock Size 30 and 35 mm | 120000 | 65 | 7800000 |
| Tumbler Lock Size 40 mm | 24000 | 75 | 1800000 |
| Total | 240000 | 14880000 |
| Motive Power | 10 KW. |
Pollution Control
No special arrangements are suggested for pollution control. However, proper disposal of electroplating waste must be ensured.
Energy Conservation
No special energy conservation measures are to be taken. However, energy efficient machines have been suggested.
Financial Aspects
Fixed Capital
| (i) Land and Building | |
| (i) and 300 sq. mtr. @ Rs. 5000 per sq. mtr including registration | 1500000 |
| (ii) Cost of land development, fencing, approach road, inside roads, land scaping, drainage etc. @ Rs. 1000 per sq. mtr. | 300000 |
| (iii) Total built-up area 250 sq. mtrs. as follows | |
|
375000 |
|
900000 |
|
300000 |
| Water System (including Bore Well + over head tank etc) | 500000 |
| Total civil cost= cost of land + building | 3875000 |
(ii) Machinery and Equipment
Description |
Ind./ Imp. |
Qty. |
Rate |
Total (In Rs.) |
| Hand operated Hot chamber Pneumatic pressure die casting Machine upto 400 gm.capacity with double Toggle Adjustable all steel made ejector and high speed diesel burner and electricals etc. | Ind. | 5 | 120000 | 600000 |
| Power Press 10MT capacity with 1HP motor and electricals | Ind. | 2 | 95000 | 190000 |
| Air compressors 150 to 200 lbs Sq. inch capacity with 1 HP motor suitable for Pressure die casting machine above at S.No. (1). | Ind. | 5 | 20000 | 100000 |
| Bench Drilling machine 10 mm drill dia capacity with 1/2 HP motor and electricals. | Ind. | 2 | 16000 | 32000 |
| Bench Grinder 200 mm dia wheel and 3/4 HP motor | Ind. | 1 | 9000 | 9000 |
| Lathe 1500 mm bed with 2 HP motor and electricals floor model | Ind. | 1 | 125000 | 125000 |
| Electroplating plant/painting equipments | Ind. | L.S. | 150000 | |
| Generator Set(electricity Backup) | 300000 | |||
| Total | 1506000 | |||
| Erection and Commissioning @ 10% of the cost of the machinery | 150600 | |||
| Cost of Dies, Tools and Measuring instruments | 150000 | |||
| Cost of Office equipment and furniture | 100000 | |||
| Total (i) | 1906600 | |||
| (iii) Pre-operative Expenses | 50000 | |||
| Total Fixed Capital ( i+ii+iii ) | 5831600 | |||
B. Working Capital (per month)
(i) Personnel
Designation |
No. |
Salary (Rs.) |
Amount (In Rs.) |
| Foreman | 2 | 10000 | 20000 |
| Skilled workers | 10 | 6000 | 60000 |
| Semi-skilled workers | 16 | 5000 | 80000 |
| Clerk-cum-Typist | 1 | 8000 | 8000 |
| Watchman/Peon | 2 | 3000 | 6000 |
| Total | 174000 | ||
| Employees benefits @ 22% | 38280 | ||
| Total | 212280 | ||
(ii) Raw Materials
Particulars |
Ind./Imp. |
Qty. |
Unit |
Rate/Unit (Rs.) |
Amount (In Rs.) |
| Mazak Alloy | Ind. | 3.00 | MT | 150000 | 450000 |
| Springs | Ind. | 200 | Kg | 50 | 10000 |
| MS Sheet 24 SWG | Ind. | 1000 | Kg | 45 | 45000 |
| Misc. items such as electroplating salt, paint, oil, diesel etc. | Ind. | LS | 200000 | ||
| Total | 705000 | ||||
(iii) Utilities
Amount (Rs.) |
|
| Power 4000 kWH units @ Rs. 5.5 /unit | 22000 |
| Total | 22000 |
(iv) Other Contingent Expenses
(In Rs.) |
|
| Postage and Stationery | 3000 |
| Transportation | 15000 |
| Telephone | 3000 |
| Maintenance and Repair | 3000 |
| Packing | 10000 |
| Insurance | 2000 |
| Misc. Expenses | 10000 |
| Marketing Expense | 20000 |
| Total | 66000 |
| (v) Total Recurring Expenditure (per month) (i) + (ii) + (iii) + (iv) | 1005280 |
| (vi) Working Capital for 1½ months 1005280 x 1½ | 1507920 |
| Say | 1507920 |
C. Total Capital Investment
| (i) Fixed Capital | 5831600 |
| (ii) Working Capital for 1½ months | 1507920 |
| Total | 7339520 |
Financial Analysis
Cost of Production (per year) |
Amount (Rs.) |
| Total recurring cost | 12063360 |
| Depreciation on Machinery @ 10% | 150600 |
| Depreciation on Building@5% | 193750 |
| Depreciation on Dies and Tools @25% | 37500 |
| Depreciation on Furnitures @ 20% | 20000 |
| Interest on Capital Investment @ 12% | 880742 |
| Total | 13345952 |
Turnover (per year)
Item |
Qty. Nos. | Rate (Rs.) | Total (Rs.) |
| Tumbler Lock Size 20 and 25 mm | 96000 | 55 | 5280000 |
| Tumbler Lock Size 30 and 35 mm | 120000 | 65 | 7800000 |
| Tumbler Lock Size 40 mm | 24000 | 75 | 1800000 |
| Total | 14880000 |
Profit (per year)
|
= Rs. 14880000-13345952 |
|
| = 1534048 |
Percentage Profit on Sales (Net Profit Ratio)
| Net Profit (per year) × 100 | |
| Turnover | |
| = 1534048× 100 | |
| 14880000 | |
| = 10.31 |
Rate of Return
| Net Profit × 100 | |
| Capital Investment | |
| = 1534048× 100 | |
| 7339520 | |
| = 20.9 |
Break-even Point
Fixed Cost |
(In Rs.) |
| Depreciation on Machinery @ 10% | 150600 |
| Depreciation on Building@5% | 193750 |
| Depreciation on Dies and Tools @25% | 37500 |
| Depreciation on Furnitures @ 20% | 20000 |
| Interest on Capital Investment @ 12% | 880742 |
| Insurance | 24000 |
| 40% of Salary and Wages | 1018944 |
| 40% of Other Contingent Expenses (excluding Insurance) | 307200 |
| Total | 2632736 |
| Profit | 1534048 |
| B.E.P | Fixed Capital × 100 --------------------- Fixed Capital + Profit |
| = 2632736 × 100 | |
| = 2632736 + 1534048 | |
| = 63.18 |
Addresses of Machinery and Equipment Suppliers
- M/s. Basant Industries Corpn.
Industrial Area 'B',
Ludhiana
- M/s. Hind Engg. Works,
Opp. D.S. College,
Aligarh - M/s. Singhal Engg. Works
Subhash Road,
Aligarh - M/s. Daulat Industries Corporation
Civil Lines,
Ludhiana - M/s. Bhag Sons,
Indl. Area 'B',
Ludhiana - M/s. Kalsi Machinery Mfg. Pvt. Ltd.
G. T. Road,
Ludhiana - M/s. P. K. Engg. Works
Opp. D.S. College,
Aligarh - M/s. Prakash Engg. Works
Agra Road,
Aligarh - M/s. James Engg. Works
31, Thembur Chetty Street,
Chennai - M/s. Atlas Engg. Works
G.T. Road,
Batala - M/s. Perfect Machine Tools Co.
123-Mount Road,
Chennai - M/s. Hindustan Metal and Engg.Co.
B–10, End. Carpenter Street,
Mumbai - M/s. Komal Industries Corporation
51-Biggan Street,
Mumbai - M/s. Non-Ferrous Metal Corpn.
174, Sardar Vallabh Bhai Patel
Road, Mumbai - M/s. Bombay Metal Syndicate,
106-Kila Street,
Mumbai-4 - M/s. Essential Machine Tools Pvt. Ltd.
5-Nyaymurthi, G.N. Vaidya Marg,
Bank Street, P.O. Box No. 2,
Behind State Bank, Fort,
Mumbai - 400001.
For further information please contact
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
