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Aligarh’s lock manufacturing history is fascinating. A gentleman from England founded Johnson and Company almost 125 years ago, in 1870, to import locks from England for sale in Aligarh. Johnson and Company began regular lock production on a small scale in 1890, cutting the sheets and shaping them. Aside from England, sheet metal locks began to be imported from Germany for sale in Aligarh.
Johnson and Company and a few other companies began producing sheet metal locks in 1930, based on German locks. These locks are known as Aligarh locks since they were made in Aligarh. However, due to a family feud, this world-famous lock manufacturing company has closed its doors. When the company went bankrupt in 1975, the engineer, contractors, mechanics, and labourers who worked for it started up their small-scale lock units. Aligarh has recently become India’s largest lock manufacturing centre. The origins of the lock business in Aligarh have been interpreted in several ways. Regarding its origin, Jain offered one theory.
Aligarh’s lock business dates back over a century and is considered a traditional occupation of Aligarh residents. At least 5,000 lock manufacturing units’ employ about 2 lakh people, either directly or indirectly. The majority of craftspeople in this industry are Muslims, but Hindus and Muslims jointly own large industrial units and corporate companies. Muslim artists make approximately 80% of Aligarh’s locks. They work as labourers and make things for major corporations.
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The lock industry’s entire structure can be classified into three categories:
Small Scale Factories. Units that produce forty to eighty percent of the components themselves are registered with the District Industries Centre and hire outside labour.
Cottage or household units. Cottages or housing units serve as residences and workplaces for the production and distribution of lock parts to small industries. Family labour and simple tools are used to carry out the majority of their manufacturing operations.
The traders or commission Agents. The commission agents purchase all of the components of locks from household units and assemble them before selling them under their brands.
Aligarh is the leading manufacturer of locks for the national market, accounting for 80% of the Indian lock industry’s turnover. Because this industry falls under the small-scale sector, it benefits from the government’s facilities and discounts for small-scale businesses. Even then, the industry was beset by issues relating to finance, raw materials, marketing, and so on. Because it is still not operated on modern lines, it is unable to compete effectively in the international market. In this study, an attempt was made to give a critical analysis of the industry, in which the industry’s structure and current situation were analysed.
The industry’s challenges have been explored, and appropriate treatments for bringing the industry out of its current state of stagnation.
Locks are not only important for safety in Aligarh, Uttar Pradesh old city; they also open the entrance to a craft history. Consider a fish-shaped lock suspended from a rod-shaped like a seated camel or an owl with large round eyes. These brass locks have a triple locking mechanism and are handcrafted. They were on display at a recent exhibition in Delhi. As indirect exports, some Aligarh-based lock makers sell their locks to merchant exporters in Delhi, Mumbai, and Chennai. Some lock manufacturers sell their products to hardware exporters who include them in larger shipments of hardware. Because of a developing market where price realisation is faster, and the industry is more organised, the shift from handcrafted to machine-made locks is taking place.
Handcrafted locks are costly, and the volume of manufacture cannot compete with that of machines. “Handmade locks used to have a 50 to 60 percent market share, but now they barely have a 5% market share.”
The lock industry, which employs over 6,000 cottage and mid-scale lock units in Aligarh and generates over Rs 210 crore in annual revenue from the export of locks and other brass hardware, is the city’s economic backbone.
A lock is a mechanical fastening device that restricts access to the space or property enclosed by a door, vehicle, or container. It’s usually unlocked by a key or a combination of keys.
This product comes under the ambit of small-scale industries, so the basic quality standard of manufacturing should be maintained. Also, it is advisable to check your local laws as per your state or area to complete all compliances. Still, some basic points are explained here while we go for compliances:
REGISTRATION OF BUSINESS
We can start with a proprietorship or partnership firm.
When an entrepreneur starts a firm, they always have a business plan, also known as a project report, on hand, and you can quickly compute financial figures from this project report. If you need a location to work but don’t have one, consider renting one, as we say during the early stages of your firm. Renting a space allows you to avoid making large investments in land and buildings. You will, nevertheless, need to invest fixed cash in the acquisition of machines.
You can readily invest in raw materials, employing people, licencing and registration, administrative fees, and transportation with working capital support. However, you’ll need to set aside money for advertising and promotion. This business approximately needs;
Capital investment: 25 – 30 Lakhs…Depending upon the production and business model, profit earned can be 9 to 10 percent.
Land Required: 1500 – 1800 square feet area.
Electricity Load required: 15 – 18 kilowatt load.
Manpower required: We can start this manufacturing business with 12 to 15 artisans, including 2 – 3 machine operators, 3-4 skilled labour, 3 – 4 unskilled labour & office staff.
Brass is the base material for these handcrafted locks (60 percent copper and 40 percent zinc). The moulds are made of brass. In the sand casting process, this is utilised for shaping. Standard five-tumbler key locks are constructed of a variety of durable metals. Locks’ interior mechanisms are usually composed of brass or zinc die-cast. Steel or stainless steel is commonly used for the cam, the tongue protruding from the lock to secure it. Brass, chrome, steel, nickel, or any other robust metal or alloy can be used for a lock’s exterior casing. The average cost of raw materials for a set of Door Locks is Rs. 320-390 (Approx.). So majorly following raw materials required:
Table of Contents
| Sr. No. | Particulars |
| 1 | Purpose Of The Document |
| 2 | Introduction |
| 3 | Market Potential |
| 4 | Product Description |
| 5 | Product Uses |
| 6 | Raw Material |
| 7 | Manufacturing Process |
| 8 | Project Components |
| 9 | Land |
| 10 | Civil Work |
| 11 | Machinery & Equipments |
| 12 | Miscellaneous Asset |
| 13 | Power Requirement |
| 14 | Man Power Requirement |
| 15 | Financial Aspects |
| 16 | Balance Sheet |
| 17 | Profitability Statement |
| 18 | Cash Flow Statement |
| 19 | Repayment Schedule |
| 20 | Depreciation Schedule |
| 21 | Computation Of Sale |
| 22 | Production And Raw Material Consumed |
| 23 | Closing Stock |
| 24 | Computation Of Working Capital |
| 25 | Computation Of Electricity |
| 26 | Salary & Wages |
| 27 | Financial Indicators |
| 28 | Break-Even Analysis |
| 29 | Dscr |
| 30 | License & Approvals |
| 31 | Swot Analysis |
| 32 | Assumptions |
Apart from this, all the information is being provided. To help in preparing project reports.
Q1. Which factors affect the pricing of the product?
Ans. Following factors affect:
New product- as it is a new product and in the market, its name is not established. Therefore the prices are less.
Product cost- cost fixed after considering all operating expenses and profit margins.
Penetration Pricing- always tries to keep prices low to capture a large market.
The extent of competition in the market- seeing the intense competition with other competitors and keep your prices low.
Q2. What types of channels are used for the distribution of locks manufactured?
.Ans. Sold through two-level channels, i.e. Manufacturer-Wholesaler-Retailer-Consumer. This is used to cover some large market areas.
The physical movement of the product- means locks manufactured in one area and transported to the rest of India.
Q3.How much profit can a lock manufacturer make?
Ans. The lock manufacturing business is not so big that it can provide you with so huge amount of profits, but it provides handsome income by giving some smart efforts like contacting small furniture traders or manufacturers. Provide free samples at local retail or hardware shops to highlight your business. Profit earned can be 9 to 10 percent.
In our project report format, we cover technology details, its diagrams, flow chart etc. as and when required or deemed fit to include. Also, prepare in-depth financial calculations which is necessary for the Investor/bank.
You will get the report data l Lock Manufacturing Business in PDF or MS word. Which you can use easily. You can also modify the information according to your need. You will be able to access the data easily according to the your requirement. Additionally you can easily convert the data to PDF format.
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