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TABLE OF CONTENTS
CHAPTER PAGE
1. Executive summary………………………………………………………..……3
2. Project background and history…………………………………………………6
3. Marketing analysis and marketing concept…………………………………….9
4. Material inputs…………………………………………………………………19
5. Location site and environment………………………………………………...23
6. Project engineering……………………………………………………………25
7. Organisation and overhead costs……………………………………………...46
not until 1995 that spiral lamps manufactured in China were commercially available. In 1980,
Philips introduced its model SL, which was a screw-in lamp with integral ballast. The lamp
used a folded T4 tube, stable tri-color phosphors, and a mercury amalgam. This was the first
successful screw-in which replaced an incandescent lamp. In 1985 Osram started selling their
model EL lamp which was the first CFL to include electronic ballast. Since then the
technology of fluorescent lamps has been developing until today that it can replace the
incandescent lamp.
In Zimbabwe the greater population of the nation has not known the benefits of using
compact fluorescent lamps. The Zimbabwe Electricity Supply Authority (ZESA) and other
players in the lighting industry have been negotiating with the government in order to ban the
use of incandescent lamps in Zimbabwe. In response the government refused to pass the ban
but there is a possibility of increasing import duty on the incandescent lamps. Increasing
import duty on incandescent lamps will not solve the problem because on the Zimbabwean
market some incandescent lamps are fetching as little as $0.15.This means even if we
increase its duty by 300% it is still the best buy for saving money.
2.1.2Background
Continuous power cuts have become a norm in our country which has left everyone pointing fingers to the national power utility;Zimbabwe Electricity Supply Athourity (ZESA). This has shown ignorance on our part as citizens and consumers that we can also take part in the reduction of power imports by usage of power saving electrical goods. The compact fluorescent lamp (CFL) which may also be called the “energy saver” bulbs is one of the devices we can adopt to reduce our power bills from household level up to national stage .These bulbs consume less energy than the traditional incandescent light bulbs which have been in use in almost every Zimbabwean household.
The issue of global warming has raised alarm the world over the but third world countries like Zimbabwe have been looking at first world nations like the United States to take the initiative to stop global warming .We must follow other countries which have taken their own steps further by phasing out the incandescent lamps and introducing the compact fluorescent lamps which are more friendly to our environment.
African countries have been known with a tradition of extracting minerals, exporting them whilst raw and then importing the finished products. This has also been happening in our own country, Zimbabwe, since we have been importing incandescent light bulbs from China and other countries yet we have the glass industry with abundant raw materials in metal and gas for the production of incandescent lamps. This has also been the case with compact fluorescent lamps which are imported into Zimbabwe. A huge amount of money has been lost
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by Zimbabweans who have been buying these imported commodities as some of the bulbs blow out just after installation.
In a bid to reduce load on our power supply, reduce our contribution to global warming, reduce the number of imports, create employment and increase the Gross Domestic Product of Zimbabwe this project is going to look at the feasibility of the local commercial production of compact fluorescent lamps. The need to provide employment to reduce migration of Zimbabweans into neighboring South Africa where industry is sound is also the inspiration behind this project.
2.3 Project sponsors
The project needs adequate sponsorship for it to be successful. The project will be sponsored
by the organizations shown in figure 2.1.
Type of sponsorship Sponsor/Organisation
Supervision and co-ordination of the project University of Zimbabwe
Funding for acquisition of plant machinery
and setting up of buildings
Infrastructural Development Bank of
Zimbabwe and The Commercial Bank of
Zimbabwe
Money to cover expenses such as transport
and internet costs
Self
Data on existing bulb manufacturers and
market of compact fluorescent lamps in
Zimbabwe
ZESA Holdings
Data on existing bulb manufacturers and
market of compact fluorescent lamps in
Africa
Southern African Power Pool
Figure 2.2 Project Sponsors
2.3 Costs of studies and investigations already made
Activity Costs
5
Transport $30Communication $3Research on internet $25Stationary $5Food $40Report preparation and documentation $20Total $118
Fig 2.3 Costs of studies performed
CHAPTER 3MARKETING ANALYSIS AND MARKETING CONCEPT
3.1.1 Basic idea of project
The basic idea of the project is to set up a Compact fluorescent lamp (CFL) manufacturing
plant as a profitable business entity. The implementation of this project will go a step further
to complement the efforts of the power utility Zimbabwe Electricity Supply Authority
(ZESA) to introduce it as a demand side management strategy. The plant will produce 2U,
spiral and 3U CFLs .The units will be marketed to individual retailers in the country and to
power utilities in the region through Southern African Power Pool (SAPP).
3.1.2 Objectives of the project
- To manufacture Compact fluorescent lamps at a profit in Zimbabwe.
- To guarantee customer satisfaction in our products.
- To gain the largest markets share in the lighting industry.
- Marketing the CFLs effectively to maximize sales by effective marketing strategies.
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3.1.3 Strategies
Strategies are developed, resources committed and programs of activity assembled for the
purpose of achieving and maintaining competitive advantage in some defined area. Strategic
marketing treats market scope as a matter of strategic choice .These choices follow major
environmental uncertainties for example technological changes clearly affect market.
Segmentation, targeting and positioning are major marketing tools used to gain dominance in
the market as they differentiate the company’s product from that of its competitors.
3.1.3.1 Market segmentation
It is the strategy of dividing diverse markets into smaller, more homogenous sub-markets,
and serving those submarkets with your product. The CFL market can be segmented to those
who need colored lamps to those who need clear white lamps, those who want spiral shaped
lamps , those who want u shaped lamps and also the wattage of the lamps .The market can
also be segmented according to the type of light fittings in people’s homes and offices that is
screw lamp holders or bayonet holders. Bolt on segmentation will be applied in the project
where the firm will access the external data e.g. demographic data to determine the differing
customers’ needs.
3.1.3.2 Targeting
The firm is targeting the following markets:
- Urban Residential lighting
- Offices and street lights
- Regional power utilities
- Rural electrified and solar powered homes
3.1.3.3 Positioning
Positioning a product involves designing a marketing program including the product mix that
is consistent with how the company wants its products or services to be perceived. The
strategy the firm adopts is then driven by desired positioning .Positioning aims to influence or
adjust customer perceptions of a product or brand and let the brand occupy a preferred or
unique position in customers minds. The brand needs to be distinguished from other brands.
Product attributes, price and image enhancements are the major components of positioning.
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The variables of prices versus performance and focused versus market coverage can be used
to select an optimal market position .A nice packaging of the product also position the
product in a way that the customers will have a good perception of the product. The firm will
have to use a position that permits the offering of a standard product across the entire market.
A market knowledge audit has to be performed to determine if the firm is using knowledge to
develop an optimal market position. The audit will cover issues like customer knowledge,
process knowledge, technology knowledge and strategic knowledge.
3.2 Demand and market
3.2.1 Structure of market
In Zimbabwe on the manufacture’s point of view the lighting products market is oligopolistic.
Currently there is no light bulb manufacturing Company in Zimbabwe. The light bulbs used
in Zimbabwe are imported from Malaysia; Indonesia, Europe and China. In Africa the only
existing bulb manufacturing company is in Lesotho which is owned by Philips and Eskom.
The general quality of the CF lamps supplied by the supermarkets and registered dealers in
electrical industry such as Destiny Electronics and Electro-Sales are of good quality.
Nevertheless there has been an influx of low quality CFLs and even incandescent lamps of
low quality due to lack of policy formulation to protect the consumers from low quality
products.
Brands sold Retailers
Philips Destiny electronics
Luhouis; Philips and Osram Power speed
Osram, Philips and Luhouis Spar supermarkets
Luhouis;Philips and Osram Electro-sales
Luhouis; Philips and Osram Food world
Table 3.1 Existing suppliers of compact fluorescent lamps
3.2.2 Past imports and their future trends; volumes and prices
These values as shown by the Southern African power Pool (SAAP) about the CFLs imported
into Zimbabwe in 2008 and 2009.
Year Volumes Average price per unit
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2008 3 500 000 $4
2009 2 000 000 $4
Table 3.2 Past imports and prices
3.2.3.1 ROLE OF INDUSTRY IN THE NATIONAL ECONOMY
China is said to be the main producer of lighting products accounting for 80% of the world’s
exports of compact fluorescent lamps. The lighting industry also contributed to the fast
growth of the Chinese economy which is rated the fastest growing economy in the world. The
major roles of the CFLs industry in the economy are:
- Creation of employment for both skilled and semi skilled Zimbabwean population
- Increase the Gross Domestic Product of the country through export band local sales
- Since CFLs use 70% less of energy used by incandescent lamps the implementation
of this project will reduce the nation’s revenue directed towards the importation of
power .This will also reduce the power bills in homes and offices.
- The load on the national grid will be reduced therefore more areas can be connected
on the grid and improve the general livelihood of the nation.
- Power outages which have been affecting industry and the nation at large can be
history by the implementation of such a project. Industry and mines which are the
main movers of the economy will perform much better than at the present in an
environment which is free of power cuts.
3.2.3.1NATIONAL POLICIES
- The government of Zimbabwe together with the national power supplier ZESA has
been promoting the electrification of rural areas .This project complements such
policies by the reduction of load on the national grid to enable new connections.
- The project supports the environmental management authority in the development of
environmental friendly technologies.
- Generally the improved performance of all industries influences the political situation
in a country.
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- Other governments have still in the process of making policies which discourage the
use of incandescent lamps in the near future so this project will help the country and
other countries in the region to implement such a good idea.
- The project helps the power utility in the Demand side Management Power stations
program which encourages the use of compact fluorescent lamps.
3.2.4 Approximate present size of demand
These values are based on the number of CFL units sent to SAPP by power utilities of
Southern African countries. At the present moment about 250 000 compact fluorescent lamps
have been sold over the counter to individuals. Despite the low volumes of sales recorded so
far in Zimbabwe the local power supplier requested to be supplied about 3 000 000 CFLs for
the period 2010. There strategy of exchanging the incandescent lamps used in households
with compact fluorescent lamps when a customer pays bills is to be adopted in this project nd
the costs is added to the power bills. This strategy helps to increase the sales of the
commodity and the saving of electricity.
Wattage
colour
Colour
appearance
Fitting
type
Burning hours Type of
lamps
Length Quantity
for the next
three years
14/15 Warm
white
BC 8000
&
10000
&
15000
3 U CFL
LAMPS
115mm 9 787 481
ES 2 446 870
18/20 WARM
WHITE
BC 9 787 481
ES 2 446 870
22/24 WARM
WHITE
BC 115mm
&125mm
9 787 481
ES 2 446 870
22/24 COOL
WHITE
BC 3 262 493
ES 815 623
Total 40 781 168
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Table 3.3 Approximate present size of demand
BC- Bayonet Cap.
ES- Edison Screw.
3U lamps- Number of U shaped glass tubes.
3.2.5 Selected targets
- Urban residential homes
- Commercial buildings
- Other nations in the Region.
- Rural electrified and solar powered homes
- City council for street lighting for roads.
- Power Utilities
Strategies to be used for targets
The local power authority ZESA has taken an initiative together with suppliers of lighting
products in Zimbabwe to raise awareness of their energy saving capabilities. There is need
for the marketer to look for the needs and the expectations of the customer and use the
information to make quality compact fluorescent lamps. Awareness campaigns can be raised
by advertising, promotions and road shows. The other strategy is to make sure that there is
internal competency to provide the basis for optimizing market place performance. This looks
at strategic leadership, strategic planning, financial planning, innovation, productivity,
employee practices, quality and information systems. Since the CFL market is still in its early
growth stages it therefore means the firm can get a large market share by reducing prices.
Marketing strategies consists of selecting a target market and developing a marketing mix to
satisfy the market’s needs. A target market is a defined group of consumers with whom the
firm wants to create marketing exchanges .A marketing mix is the overall marketing offer to
appeal to the target market. It consists of four basic areas: product, pricing, communications
and distribution. The firm will effectively blend product, price and distribution and
communications decisions into a different marketing mix designed to serve its target market.
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3.3 Marketing concept
The marketing concept suggests that firms seek to meet the customers’ needs at a profit.
Satisfying customer needs requires integrated and coordinated efforts throughout the
organization. The organization should focus on long term success. In the project the
customers’ need can be satisfied by producing lamps that have a longer lifetime than
incandescent lamps at a reasonable price. The quality of the light which the lamp produces is
of importance to the buyer. The wattage of the lamps also differs and the customers buy
according to their own interests. The price of the lamps should be affordable and at the same
time not compromising their quality to ensure customer satisfaction. Generally the product
should be a best buy than other lamps of the same type.
PRODUCT
PLACE
PRICE
PROMOTION
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TARGET MARKET
The place variable seeks to create time, place and possession utility by having the product available where and when targets customers will buy it. In the case of CFLs it will be supermarkets, hardware, and utility offices where electricity bills are paid
PRODUCT: The product variable
is the attributes that has the
potential to satisfy customers e.g
quality and durability
Price variable establishes the amount of money that the buyer is expected to pay for the finished lamp. The prices range from $2.50 to $13.00 depending on the
Promotion variable is the communication between the firm and the targeted consumers. The firm will use:
Radio and TV adverts
In store promotions
Figure3.1 The Marketing Mix
3.3.2 Anticipated competition from existing producers and suppliers
Stiff competition is anticipated from these well known brands listed below:
- Philips
- Osram
- Eveready
There is also competition on the compact fluorescent lamps with other lamp types such as the
incandescent lamp, light emitting diodes (LEDs), fluorescent tubes and halogen lamps. The
advantage of producing compact fluorescent lamps against incandescent or halogen lamps is
that CFLs save energy by up to 75% therefore they protect the environment from
greenhouse gases emitted by thermal power stations and at the same time they save money by
their long lives. The energy saving aspects of LEDs as compared to those of compact
fluorescent lamps are much better but compact fluorescent lamps are preferred in our
environment. They are favored because lamp fixtures in homes are mainly screw or bayonet
therefore CFLs can easily be fixed on these without changing the lamp holders.
3.3.3 Localisation of markets
(a) Local
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Price variable establishes the amount of money that the buyer is expected to pay for the finished lamp. The prices range from $2.50 to $13.00 depending on the
Promotion variable is the communication between the firm and the targeted consumers. The firm will use:
Radio and TV adverts
In store promotions
MARKET PLACE REASONS FOR CONSIDERING IT AS
MARKET
HARARE All these places are towns and that is where
potential users and selling points of compact
fluorescent lamps are located.
MUTARE
GWERU
MASVINGO
BINDURA
KADOMA
BULAWAYO
MARONDERA
Table 3.4 local markets
(b) Foreign
These are sold to power utilities in the southern African region who submitted their CFL
requirements to Southern African Power Pool.
Country Power Utility
Angola ENE
Malawi ESCOM
ZAMBIA ZESCO
SWAZILAND SEC
Namibia NAMPOWER
South Africa ESKOM
Mozambique EDM
Table 3.5 Foreign markets
3.3.4 Sales programme
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The firm apply the Just -In –Time manufacturing system which means that the production is
influenced by demand. Since the demand of compact fluorescent lamps in the region is above
that of the compact fluorescent lamps in the region the firm will sell all the lamps in the year
they are manufactured. The lamps will be sold to regional power utilities and individuals and
other companies.
3.3.5 Estimate annual sales revenues from products and by products
The firm is expected to produce lamps that will all be sold during the within the year in which
they are manufactured since the demand of these lamps is very large considering the numbers
of lamps required by the regional power supply authorities .These lamps will be sold at about
$ 2.50 per unit which is the price of the lamps which are being imported from Lesotho.
Installed capacity is determined based on equipment manufacturers’ technical specification which is 1200 units per hour. It also depends on the number of shifts. The company will have 3 shifts.
6.1 (b) Determination of practical / achievable capacity
Practical capacity or achievable capacity should be determined after adjustment of the following with the installed capacity.
- Available production hours taking into consideration holidays, normal shut down days and normal idle time.
- Normal time loss in batch change over, break downs of machines, repairs etc- Loss in efficiency due to ageing of the machines/ equipment
Taking these into consideration there are about 12 holidays in Zimbabwe which the plant would not be operational on Sundays. The capacity of the plant will be calculated as follows after determination of the following parameters:
Manufacturers’ Specifications - capacity per hour = 1200 units
No of shifts (each shift 8 hours) = 3 shift
Holidays in a year:
Sundays = 52 days
Other holidays = 13 days
Annual maintenance from is done within these 13 holidays.
Preventive Weekly Maintenance for the machines on Sunday.
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Normal idle capacity for batch change over,
Lunch, personal need etc = 1 hr per shift
Calculations for the plant capacity
Installed Capacity for the machine = 365 x 8 x3x 1200 = 10.5 million units
Practical Capacity = ( 365 – 52– 13) x ( 8 - 1) x 3 x1 200 = 7.6 million units
For normal years 3, 4 and 5 the normal capacity is calculated as (3.5+5+7)/3=5.2 million
Production schedule for the plant
Year Units to be
produced
Actual capacity utilisation
1 1 500 000 14.2%
2 3 000 000 28.6%
3 5 500 000 52.4%
4 6 000 000 58.8
5 7 000 000 66.7%
6.2 Relationship between sales plant capacity and material inputs
According to Eugene et al in Financial Management Theory and Practices the relationship
between sales is proportional to its production. It’s reasonable to assume that cash ,accounts
receivable and inventories will be proportional to the sales .It is advisable for the plant to
install more capacity due to economies of scale in building capacity. Even if plant is
operating at maximum capacity most companies produce additional units by reducing
downtime for maintenance, by running at a higher optimal speed, or adding a second or third
shift. In the short run the company may not have a close relationship between sales and net
plant and equipment.
During the initial years of the plant managers build the actual planned expenditures on plant
and equipment. It is difficult to continue increasing sales unless capacity is added therefore it
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is reasonable to assume that long term ratio of net plant and equipment to sales will be
constant.
6.1 Scope of project
Year Expected production Technologies used Target market
1 2 000 000 CAM Zimbabwe
2 4 000 000 CAM Zimbabwe
3 6000 000 CIM Southern Africa
4 8 000 000 CIM Southern Africa
5 10 000 000 CIM Southern Africa
6.2 Tables 6.1 showing scope of the project
6.4 Technology and equipment
6.4.1 Technologies and processes that can be adopted
Fig 6.2 Product cycle.
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DESIGN PROCESS
CAM
MANUFACTURING PROCESS
NC – Numeric Control
CNC-Computer Numeric Control
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Design conceptualization
Feasibility study with CFL design information
CFL Design specificationssss
Design need
SYNTHESIS
Design evaluation
Design analysis optimization
Design Analysis modelDesign
documentation
ANALYSIS
CAD +CAE
Production planning
Production of CFLs
Quality control
Packaging ShippingProcess planning
Design and procurement of new tools
Order input materials
Marketing
NC,CNC,DNC programming
DNC- Digital Numeric Control
The process of making compact fluorescent lamps is complex other than that of making
incandescent lamps which does not involve processes like coating or fusion. This however
makes the capacity for the plant produce fewer lamps than an incandescent lamp plant of the
same size. The machines are automated to make production easy and faster. For the industry
to survive there is need to produce products with better quality at a lower cost and with
shorter lead time. To achieve these there is need to use computers huge memory capacity, fast
processing speed and user friendly interactive graphics which are capable to automate and tie
together some cumbersome and separate engineering or production tasks. This reduces the
time and costs of product development and production. Computer aided design
(CAD) ,Computer-aided engineering(CAE) ,Computer-aided manufacturing(CAM)are the
technologies that can be adopted for these purposes during the production cycle.
In lamp bulbs manufacturing industries computer-aided design (CAD) is the technology
concerned with the use of computer systems to assists in creation, modification, analysis and
optimization of the lamp design. These CAD tools can be used to manipulate shapes of the
lamps to be produced in the plant, design mechanical parts for the equipment used in the
manufacturing process, design of the electronic ballasts and layout of machinery in the plant.
The greatest benefits of CAD are that it can save considerable time and reduce errors caused
by having to redefine the geometry of the product design from scratch every time it is needed.
CAM is the technology concerned with the use of computer systems to plan, manage and
control manufacturing operations through either direct or indirect computer interface with the
plant’s production resources. The product cycle for the manufacturing of compact fluorescent
lamps is composed of two main processes. The design process starts from customers’
demands that are identified by the marketing personnel and ends with a complete description
of the product, usually in form of a drawing. The manufacturing process starts from the
design specifications and ends with the shipping of the actual product. There are two types of
activities which are involved in the design process which are synthesis and analysis. The
manufacturing process begins with process planning, using drawings from the design process
and it ends with the actual products. The outcome of process planning is a production plan, a
materials order, and machine programming. In lamp manufacturing one of the most
significant areas of CAM is numerical control (NC). This technique of using programmed
instructions to control the machine tools that can cut bent the glass tubes into finished
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products. Another significant function of in bulbs manufacturing is the programming of
robots, which may work in work cell arrangement, selecting, and positioning tools and
workpieces for numerical control machines. They also perform operations of assembling
parts on machines like on the capping machine and the fusion machine.
Computer-aided engineering (CAE) is a technology concerned with the use of computer
systems to analyze CAD geometry, allowing the designer to simulate and study how the lamp
or other components such as ballast will behave so that the design can be refined and
optimized.CAE allows the engineer to catch any errors before going to the time and the
expenses of building and testing physical prototypes.
The technology called computer-integrated manufacturing is to be used in the project to
combine the three technologies mentioned earlier using a database as a way to run the entire
plant more efficiently. It has an impact on shipping, scheduling, accounting and other
management functions in addition to the engineering design and production functions.CIM
has the following benefits
- CFLS can be produced with improved quality.
- New products are developed more rapidly and at a lower costs, that is , reduction in
lead times and savings in material.
- Better customer service.
- Reduced design costs.
- Simple production plan.
- It forces review and improvement of existing design and manufacturing practices and
production planning.
6.4.2 Technology description
The material inputs as described in chapter 4 of the project are used to manufacture these
lamps using the processes as shown in the diagram below .the
28
Fig 6.2 CFL Manufacturing Overview diagram
6.4.2 Technology description
Glass tube cutting.
Glass tubes are fed into the glass cutting machine where they are cut to a specific length .The
machine has a trough for storage of glass tubes. When a glass tube is fed in the tube will be
automatically sent to the cutting mechanism to cut into specific length. The tubes will be sent
to end glazing mechanism. A detective device will remove an uncut tube. It is then sent to the
bending machine. The cutting machine automatically supplies tubes to the bending machine.
Tube bending
The tube from cutting machine then is bent and molded into a U shaped tube. Tubes are fed
from the cutting machine and fed into the heating device of the bending machine. At initial
stages of heating the tube is moved transversely in order to make the heating uniform. At
later stages of heating the tube is bent only on one side, so the tube will not move
transversely in order to let the tube to be heated just on the bending side. The bending is
29
proceeded with synchronous heating, making the bottom part of the tube to be much thicker.
The forming mold is applied controlled temperature in order to make the surface smoother.
Washing and coating
The U formed glass tube is cleaned, coated and dried in the washing/ coating machine before
baking it. The clean glass tube is dried by hot air and then coated with aluminum oxide at the
end of the tube by supersonic wave and dried off again. The tubes are conveyed to a position
of coating .Before coating the tubes are reversed and fluorescent paste is filled into the tube.
The quantity to be filled is controlled by a sensor. The tubes will be reversed again making
the coating to be distributed uniformly.
Baking
Baking eliminates all compounds except the fluorescence in the glass tube hot flowing air. At
the first stage, while the tube being heated, there are also two heads bellowing in oxygen,
making it easier to eliminate all the impurities. At the last stage, the tube will be cooled off.
Nitrogen gas is then blown in to reduce the possibility for the fluorescence to absorb
moisture.
Bead mounting
The tungsten filament and glass ring (bar) is fastened onto the lead in wires and coat the
filament with a certain quantity of oxide. At this moment, the tungsten filament is
automatically being fed in to mount on the lead in wire and the excessive edge will be cut off.
Sealing
The exhaust tube, and the mounting with the coated glass tube are combined and then fed in
automatically to the sealing machine. After the auto fed in glass tube being preheated, the
mounting will then penetrate into it. That will make the tungsten inside the tube to be heated
for shorter time. During the heating process, hot Argon is blown into the tube to prevent
oxide poisoning.The tube is then moved to the annealing oven in the sealing machine
1 st FUSION
Two glass tubes are fused so that they are communicable to each other. The two tubes will be
held into 60º to passing through a preheating oven to be heated thoroughly, in order to
prevent the tubes to be cracked at fusion. Before fusion, there is a mold to form a convexity at
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the position to be fused. Then the convexity will be burnt into a hole and fused. This type of
fusion can avoid the glass being mixed up with the fluorescence. .
2 ND FUSION
This machine is functioned to fuse the third sealed glass tube together with the two fused
glass tubes, forming a series circuit within those three tubes when lighting up. These tubes
will be heated thoroughly while passing through the preheating oven, which used to prevent
the tubes being crack at fusion. Afterwards, the position for fusion will be formed up a
convexity by a mold, then burned into a hole and fused. This type of fusion can decrease the
possibility for the glass to be mixed up with fluorescence, also the fusion hole will be bigger
and more harmony. Moreover, the reverse side of the tube will be heated at the same time of
fusion, in order to reduce the pressure deriving from fusion.
Exhausting
The semi-finished fluorescent tube is undergone through an oven. The temperature of the
oven is auto-controlled and there are four leakage detective mechanisms inside the oven.
Simultaneously, there is a water cooling system. Then the tubes will be processed through
four Argon flushing mechanisms to enhance the purity inside the tubes. Then Argon will be
filled up the tubes and the mercury also dropped in. Finally, the exhaust tube will be cut off
and the remnant tube will be removed.
Ageing
The semi-finished tube that has been undergone exhaust is to undergo ageing by lighting up
with different voltage. The procedure is to pre-heat the tungsten first, and then lighted up by
high and usual voltage. Moreover, the voltage for lighting can be adjusted at a specified
range. You only need to press the selective switch on the control-box, and then the voltage
will be switched.
Capping
The capping is done by the capping machine which has 60 sets of chucks to hold the tube.
The sets of the capping machine are used for holding the tube. The cap and tube are
31
automatically fed in the chuck; the cap will be heated to solidify the cement, and then fixing
the cap on top of the tube. The finished tube will be auto pick out of the machine.
Cement filling
The vibrator of the cement filling machine delivers the cap automatically. The cap is
conveyed to the position under a fixed cement bucket. A chuck will clamp the cap up to the
hole to fill in a certain amount of cement.
Equipment used in CFL manufacturing process
These are the machines used in the process of making compact fluorescent lamps. They all
work on a 220V single phase and 380V triple phase at 50Hz or 60Hz.The main mechanisms
of these machines are mechanical and apply heating systems therefore since polytechnics and
universities in Zimbabwe are producing graduates in the field of mechanical engineering with
the support of existing companies in the manufacturing industry these machines can be made
locally.
Figure6.3.1GLASS CUTTING MACHINE
32
Figure 6.3.2
BENDING
MACHINE
Figure 6.3.3 WASHING AND COATING MACHINE
33
34
Figure6.3.4BAKING MACHINE
Figure 6.3.5 BEAD MOUNT MACHINE
35
Figure 6.3.6 Sealing
Machine
Figure6.3.7Fusion Machine
36
Figure 6.3i 2 ND
Fusion Machine
Figure 6.3.Exhaust Machine
37
Figure 6.3j
Ageing
Machine
38
39
6.4.3 Environmental impacts of technologies
It is necessary to implement technologies which have a smaller environmental impact to
reduce pollution of the environment. The environmental effects are evaluated by carrying
lifecycle analyses of the CFLs. The main emphasis is placed on energy consumption and
emissions linked to this during the production; operating and scrapping phases of the lamps.
On average CFLs contain 5 milligrams of mercury which is small as compared to mercury
fever thermometers.
Lifecycle analysis shows that the use of compact fluorescent lamps instead of incandescent
lamps as expected leads to reduced emissions of carbon dioxide sulphur dioxide and nitrogen
The study noted that the above organization is the most suitable for manufacturing
companies. This type of organization is called the Process-focused organization in which the
first level supervisors tend to be experts in production technology they supervise, and they
must coordinate the utilization of people, machines, and material in the manufacturing of
lamps. The firm must adopt this organisational structure because it gives stronger support to
the competitive priorities of product flexibility and quality. The costs and profit responsibility
in this type of organisation is at a high level and they have highly developed staff functions at
a higher levels in the organisation. There is a logical reflection of functions.
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7.2 Estimated overhead costs.
Year Year 1 Year 2 Year 3 Year 4 Year 5Expense CostsPower $5 000 $10 000 $10 500 $11000 $12 000Fire and insurance $500 000Heating and lighting $800Maintanance $2000Indirect material $4000Rates $4800 $2 000 $2 000 $2000 $2 000Depreciation of plant and Machinery