VIRTUAL INDUSTRY SET UP INCLUDING HIERARCHY , MPS, MRP, MARKETTING,OR, QUALITY ENGINEERING, INDUSTRIAL ENGINEERING

1. AVISHKAR'16

2. Presenting you…

3. • World-Class products & services at competitive
prices.
• Application Optimized Solutions
• Solutions to improve their rotational efficiency &
effectiveness, in turn making them more successful
and profitable.
MISSION
• The RHA Vision – To be reckoned as one of the leading
players in the Industrial Bearings segment in India.
• We aim to be amongst the top 6 leading brands (in
terms of market share) in Industrial bearing segment
by 2030.
• Our vision serves as the beacon and guides every
aspect of our business by describing what is needed
for achieving sustainable and quality escalation.
VISION

4. • CHANDRAPUR MAHARASTRA - Chandrapur industrial area . India’s largest thermal power
plant, many coal mines, cement and paper factories, huge lime stone deposits, bauxite, iron,
and chromite mines are the sources of wealth for the district.
• Total minerals available in Maharashtra.
Location of our plant in Chandrapur
Industrial Estate in Maharashtra - 442406

6. Manufacturing Site

7. Introduction to Bearing
The word “Bearing" incorporates the meaning of "to bear," in the sense of "to
support," and "to carry a burden." This refers to the fact that bearings support and
carry the burden of revolving axles.
APPLICATIONS:-
Automotive steering column, printing machine, pumps, rolling mills, planetary gears,
railway experiment etc.

8. Our Products
5-Cylindrical Roller Bearings
1-Tapered Roller Bearings 2-Needle Roller Bearings 3-Spherical Roller Bearings
4- Axle Boxes Bearings 6-Self Aligning Ball Bearings

10. Manufacturing Process of Components
Green Manufacturing
Bar or tube stock is fed into
screw machine which cut
the raw materials into rings
of roughly correct
dimension
Heat Treatment
To enhance durability and
increase life of cut metal
piece
Grinding
1-Face Grinding-Grinding stone used
to grind the surface to required
dimension
2-Center Less Grinding-outside
diameters ground to square them
with surfaces.
3-Bore and Race Grinding-inner and
outer groves are cut into raceways
Honing
The groove between the
outer and inner rings in
which the balls run is
honed to nanometer
precision
Cleaning
Cleaning , lubrication and
packaging are conducted in
dust free areas.

11. Manufacturing Process of Components
Pressing- Headers
snip off a short length
of wire and press them
between cup like
depressions
Flashing- The balls roll
between two file cut
disk removing flash
and nibs.
Multiples Groove
Grinding- Making
rolling element
uniform .
Tumbling- To remove
excessive material and
rough spots by abrasive
grit and water.
Heat Treatment-
Hardened and
tempered to give
toughness.
Precision Grinding-
Balls roll against
grinding wheel

12. Manufacturing Process of Components
• Made from low carbon steel, (brass , alloyed steel in
gas turbines).
• Stamped from strip steel.
• Cold formed in shaped dies.
• Two halves are joined by Riveting, Welding.
CAGES
• Used to retain lubricant inside the bearing and to keep
abrasive and corrosive contamination outside the
bearing.
• Stamped from low carbon steel, molded rubber tailored
to specific applications.
SEAL

14. Targeted Industries
Adhani Power Plant Lohara Coal Mines

16. Bill of Material
S.No. Description Material Cost (in Rs.)
1. Balls Ni-Cr Steel Wire 3500/kg
2. Races AISI 52100 175.00/ kg
3 Rollers
High Carbon Chrome
Steel Rods
110.00/kg
4 Cages Brass Sheet 420/kg

17. Machine and their costs
S.No. Activity Machines
Approx.
Cost(Rs. In lakh)
No. of
Machines
1. Manufacturing Bearings
Races by Bar Route
&Seamless Tube Method
CNC Machine for Races
Turning/Machining
20
3
2. Forging Bearing Races
Followed by Heating
Induction Heating Furnace for
Forging 300kW,3 kHz-For All
Lines
20 1
3.
Heat treatment By
Hardening & Tempering
Natural Salt Bath Pit type
Furnace
2 1
4.
Grinding Followed By
Honing Of Outer &Inner
Races
Face Grinder
Centre less Grinder
Bore Grinder
10
8
3
1
1
1
5. Honing Honing Machine 4 1
6.
Washing Of Races Washing Machine(Self
Fabricated)
1.4
1
7. Lapping Machine Lapping Machine
15
1
8.
Cages & Shields
Production by Stamping
Hydraulic Presses & different
Dies
20 3

18. Machine and their costs
9. Pinning In Cages Pinning press 0.2 1
10
Riveting Cages in
Bearings
Riveting Press ,Hydraulic
20 ton
.3 1
11. Cold Heading Cold Heading Machine 12 3
12 Flashing
Ball Flash Removing
Machine
6 1
S.No. Activity Machines
Approx. Cost(Rs.
In lakh)
No. of
Machines
13 Heat Treatment
Hardened Followed by
Tempering on rotatory
Type of Furnace
25 1
14 Tumbling Tumbler 3 1
15 Oil Lapping
With the help of
H.S.Diesel oil and
Chromium Oxide Caustic
Soda Washing Inspection
Grading Greasing
6 1
16
Assembly of Outer
&Inner Races with
Balls/Roller & cage
Marking
Machine/Comparator
4 1

19. Machine and their costs
S.No. Activity Machines
Approx.
Cost(Rs. In
lakh)
No. of
Machines
17
Measuring &
Inspection
Tools and Gauge,
Comparators, Dial Gauges,
Demagnetizers,
Micrometer, Slip gauge,
Surface Plate, Telescope
Gauge, Cylindrical Gauges
etc.
10 1
18 Testing Laboratory Equipment 3 1
19.
Load,RPM,Noise,Tem
perature Checking
Load ,RPM,Noise,
Temperature Inspection
Setup
2 1
20 Packing Sleeve Packing 1 1
21
Workshop Machine
Tools
Surface Grinder/Duplex
Grinder Bench Drilling
machine Pedestal Grinder
Tool post Grinder Electric
Arc Welding M/c 0.5 Work
Shop M/c Tools
18 1
TOTAL COST =2.979 Crores

20. S.No. Activity Estimated Time Period
(Months)
01. Scheme preparation & approval 0 – 2
02. Registration under MSME Act 2006 and sanction of loan 2 - 5
03. Construction of Structure 3-19
03. Placement of Orders for Machines 18-20
04. PFA License 20-22
05. Power Connection 21-23
06. Installation of Machines 23-24
07. Recruitment of Staff & Trial run 24-25
08. Commercial Production 25TH onwards.

21. Hierarchy

22. Sr. Hierarchy level Nos. Values (per month)
1. E1 1 85000
2. E2 3 70000
3. E3 3 62000
4. E4 25 55000
5. E5 35 35000
6. E6 65 25000
7. E7 30 12000
TOTAL 165 50,66,000

23. Range of our Product
S.NO. BEARINGS
INNER DIA.
RANGE
1. Cylindrical Roller Bearing 20-75 mm
2. Spherical Roller Bearing 10-80 mm
3. Needle Roller Bearing 15-70 mm
4. Tapered Roller Bearing 17-100 mm
5. Self Aligning Ball Bearing 15-30 mm

24. Product code and their MRP
Bearing No. MRP in Rs Bearing No. MRP in Rs
CRB20 290 SABB15 340
CRB30 350 SABB20 400
CRB40 430 SABB25 450
CRB50 460 SABB30 480
CRB60 510 TRB1747 430
CRB70 600 TRB3065 700
SRB10 990 TRB5085 850
SRB20 1100 TRB70100 990
SRB30 1500 NRB20 330
SRB40 2000 NRB30 410
SRB50 2600 NRB40 460
SRB60 3550 NRB50 520
SRB70 4000 NRB60 540
CRB- CYLINDRICAL ROLLER BEARING SABB-SELF ALIGNING BALL BEARING
TRB- TAPERED ROLLER BEARING SRB-SPHERICAL ROLLER BEARING
NRB- NEEDDLE ROLLER BEARING
Last Two digit- Inner Diameter
Rolling Elements Diameter Ranging from 7 to 25 mm

25. Forecasting Analysis
Observation(y(t)) Error(e(t)=y(t)-u(t-1))
Correction(α*e
(t))
Forecast(u(t)=u(t-
1)+α*e(t))
580 -20 -2 598
530 -68 -6.8 591.2
520 -71.2 -7.12 584.08
545 -39.08 -3.908 580.172
540 -40.172 -4.0172 576.155
550 -26.155 -2.6155 573.54
575 1.4605 0.14605 573.686
570 -3.686 -0.3686 573.32
Assuming Initial forecast = 600 (product 1) Self Aligning Ball Bearing
Observation Error Correction Forecast
1200 -50 -5 1245
1220 -25 -2.5 1242.5
1240 -2.5 -0.25 1242.25
1230 -12.25 -1.225 1241.025
1150 -91.025 -9.1025 1231.9225
1100 -131.9225 -13.1922 1218.735
1315 96.2647 9.62647 1228.36
1250 21.638 2.1638 1230.5238
Assuming Initial forecast=1250 (product 2) Needle Roller Bearing

26. Forecasting Analysis
Observation Error Correction Forecast
380 -20 -2 378
370 -8 -0.8 377.2
390 12.8 1.28 378.48
375 -3.48 -0.348 378.132
355 -23.132 -2.3132 375.82
360 -15.82 -1.582 374.238
360 -14.238 -1.4238 372.8142
365 -7.8142 -0.78142 372.03
Assuming Initial Forecast = 380 (product 3)Taper Roller Bearing
Observation Error Correction Forecast
1340 -30 -3 1367
1330 -37 -3.7 1363.3
1300 -63.3 -6.33 1356.97
1390 33.03 3.303 1360.27
1295 -65.273 -6.5273 1353.74
1370 16.2573 1.62573 1355.39
1365 9.6 0.96 1356.35
1360 3.65 0.365 1356.72
Assuming Initial forecast=1370 (product 4) Cylindrical Roller Bearing

27. Forecasting Analysis
Observation Error Correction Forcast
235 5 0.5 230.5
225 -5.5 -0.55 229.95
230 0.05 0.005 229.955
225 -4.955 -0.4955 229.46
220 -9.46 -0.946 228.514
230 1.486 0.1486 228.66
215 -13.66 -1.366 227.29
225 -2.294 -0.2294 227.06
Assuming Initial Forecast= 230 (product 5) Spherical Roller Bearing
Observation Error Correction Forecast
165 -5 -0.5 169.5
160 -9.5 -0.95 168.55
155 -13.55 -1.355 167.195
175 7.805 0.7805 166.41
160 -6.41 -0.641 165.769
145 -20.77 -2.077 163.69
160 -3.69 -0.369 162.021
Assuming Initial Forecast= 170 (product 6) Axle Boxes Bearing

28. CATEGORY A (PRICE>₹700 ) SRB10,SRB20,SRB30,SRB40,SRB50,SRB60,SRB70 ,axle boxes
CATEGORY B (700>PRICE>500) CRB60,CRB70,NRB50,NRB60,TRB5085,TRB3065,TRB70100
CATEGORY C (PRICE<₹500) CRB20,CRB30,CRB40,CRB50,SABB15,SABB20,SABB25,SABB30,TR
B1747,NRB20,NRB30,NRB40
SELLING PRICE=
(0.10*A+0.30*B+0.70*C=815.83+202.28+295.33=1313.44
Hence, Selling Price=₹ 1313.44
Forecasted value of N= 3921.65 per day
Hence forecasted no. of products per year=13,33,361.34
ABC ANALYSIS: CATEGERIZATION OF PRODUCTS

29. TOTAL FIXED COST= ₹Cr. 69.0558
Machine Cost 2.979 Cr.
Fixed Wages 6.0792 Cr.
Power Station Equipment 0.2 Cr.
Land(incl. 5% Stamp Duty) 10.1976 Cr.
Cost of Foundation 1.17 Cr.
Cost of Structure 20.925 Cr.
Cost of Flooring 21.91Cr.
Cost of Plastering 0.8455 Cr.
Cost of Wiring 2.52 Cr.
Cost of Furniture 2.12Cr.
TOTAL LAND+
INFRASTRUCTURE
Cr. 59.79

30. • Weighted Average of Weight of Product = 0.6*150+0.4*700=370g
Contribution of Various Components in Weight
• Average Variable Cost Per Product for raw materials = ₹ 499.8

31. • Variable Wages(E5+E6+E7)= Cr.3.852 per annum
• Variable Wages per annum per Product= ₹ 35018.2
• Variable Wages per Day per Product = ₹ 102.99
• Ratio of E5:E6:E7= 1:2:3
• Hence the wages of Unskilled Worker =₹17.165
Semiskilled Worker= ₹34.33
Skilled Worker= ₹51.5
Electricity Cost per Product= ₹38.46(3*12.82)
Transportation Cost per Product= 8% of Selling Price (₹ 105.07)
TOTAL VARIABLE COST=₹ 718.99

32. Formula: Selling Price*N=Fixed Cost + Variable Cost*N
SP= ₹1313.44 (Weighted Average)
FC= ₹69,05,58,000
VC= ₹718.99
Hence, Estimated N= 11,61,675.5 Units
But the Forecasted Value of N= 13,33,361.3 Units
Hence No. of years to achieve the break even point
1-(1333361.3-1161675.5)/(4000*340)= 0.8737 years
Therefore, we’ll require 0.8737 Years to achieve BEP

33. • Assumptions - 1. Constant Demand
2. Instant Supply
3. Shortage not allowed
• Ordering cost Co=₹ 8000
• Carrying cost Cc = (8 %) 0.08 of ₹ 1313.44 = ₹105.072
• Demand = 3921.67*340=1333369.4
• Using formula , EOQ = 𝟐 ∗ 𝑫 ∗ 𝑪𝒐/𝑪𝒄
=14249.24
• No. of orders , n=D/Q
=93.57 per year

34. • Therefore, time between two orders, T= 0.0106 Years(i.e. 3.847 Days)
• Assuming Lead time, L= 4 Days
• Since , T<L
• L’=4-3.847=0.153 Days
• Therefore Reordering Point= L’*D=600 Units
• Therefore, we’ll place an order of 14250 Units in 3.847 days when inventory falls
to 600 Units

35. Quality and Safety Check
RHA Bearings follows ISO/TC 4 ISO STANDARD
Subcommittee Subcommittee Title
ISO/TC 4/SC 4 Tolerances, tolerance definitions and symbols (including GPS)
ISO/TC 4/SC 5 Needle, cylindrical and spherical roller bearings
ISO/TC 4/SC 6 Insert bearings
ISO/TC 4/SC 7 Spherical plain bearings
ISO/TC 4/SC 8 Load ratings and life
ISO/TC 4/SC 9 Tapered roller bearings
ISO/TC 4/SC 11 Linear motion rolling bearings
ISO/TC 4/SC 12 Ball bearings
RHA Bearings is a 6 SIGMA Certified company which enhances the productivity of our company.
RHA Bearings follows ILO (International Labour Organization) Standards.

36. Quality Testing Machines Pictures
Waviness, roundness MWA100C
Noise and vibration testing MVH 90C/200C
Dimension testing MAD 35D
Optical inspection MZS 35D
Non destructive testing MPB 320A

37. SWOT Analysis

38. Marketing Methods
• Survey
• Advertisement (In News Paper, In Magazines)
• Social Media (YouTube, Facebook)
• Website (http://amarblp.wixsite.com/rhabearings)
• Organize Bearing Conferences
• Global Business school
• Collaboration with NGOs.

39. Bibliography
• msme.gov.in
• aibaba.com
• skf.com
• 99arces.com
• Indian Bearing Report
• tolexo.com
• nbcbearings.com
• wix.com
• mahavat.gov.in
• iso.org
• industrybuying.com