How to open a metal door production: a detailed guide. We bring the business idea for the manufacture of metal doors to life Plan of the workshop for the production of doors

Production of metal doors: main advantages + manufacturing technology from 8 stages. Equipment for production: complex or separately + basic expenses and business profitability.

Capital expenditures: from 7,340,000 rubles.
Approximate payback period: about 3.5 years.

1. We analyze the demand for the production of metal doors

It makes sense to participate in various exhibitions, put up tents with product samples in construction hypermarkets, as well as in construction markets.

All this will lead to the fact that people who are in this moment are busy with repairs, they will also think about putting new door maybe not even one.

8. Costs of setting up a business

The costs required to open your own factory for the production of metal doors are divided into capital and monthly.

It is worth considering that important fact that the first time (1-2 months) monthly expenses will not pay off with profit, so they must be considered when calculating the main amount of opening costs.

Capital expenditures

PS. The calculation takes into account the cost of the complex for production, since this is the most suitable and stable option for large-scale production.

Monthly expenses

There is also an option with the purchase of premises for the workshop. The amount of capital costs from this increases, but at the same time, the amount of monthly expenses decreases several times.

As a result, it will bring much more benefits than renting.

However, it is important to evaluate your prospects sensibly, because the benefits will be tangible only if the business quickly pays off and becomes profitable.

9. Profit and profitability of door production

In the case of the manufacture of economy class doors, the approximate profit will be about 1 250 000 rubles per month.

It should be understood that such figures will become a reality after a few months (at best), since a sufficient volume of orders will not begin to arrive immediately.

You will need to "accelerate", launch an active advertising campaign and build a customer base.

Given these figures, we can conclude that the production of metal doors will pay off only in 2.5-3.5 years, with optimistic forecasts.

The profitability of manufacturing specifically metal doors is much lower than that of the idea of ​​\u200b\u200bmanufacturing ordinary ones.

A novice entrepreneur should not think that a business will become successful if he does not understand the nuances of production and business promotion.

Personal experience is the strongest motivator in all endeavors.

How a 22-year-old guy earns up to 300,000 rubles a month

in the production of metal doors - in this video:

Conclusion about metal door manufacturing business in Russia

In order for the business to become even more profitable, it must be expanded from conventional production to the installation of doors. After all, the installation itself is not a particularly complicated process that does not require much time.

Therefore, you can easily include it in the range of services provided by the manufacturer.

This will have a positive effect on the development of door production, as it is always much more convenient for customers to do everything with one master. It will also bring additional profit, since most often the margin for such services is about 300%.

On average, door installation will take 1.5 hours. This means that one installer will be able to install about 3 doors in a working day.

Each installation will bring from 7,000 rubles. For a month you will get a good amount, as for additional income.

In this case production of metal doors will pay off faster, and in the future it can be expanded by adding new services and products.

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The popularity of steel entrance structures is largely due to their impressive performance and aesthetic parameters. However, achieving such characteristics is far from easy and is possible only with careful observance of the quality of work at all technological stages production. Its final stage is the assembly of metal doors. Obviously, the release of a reliable and durable product is simply impossible without proper installation. individual elements, parts and parts into a single design.

The sequence of manufacturing steel doors

For all the importance technological operations that occur when the metal door is assembled and welded, the manufacturing process begins much earlier. It consists of several sequentially performed actions, each of which determines the success of the final result.

Technologically, the production of a steel entrance structure consists of the following main stages:

• preparatory work:

1. creation of a general sketch and product design;
2. development of each individual element, part and assembly;
3. writing software for CNC machines

• manufacture:

1. preparation of steel sheets of the required size;
2. making holes for hinges, locks and other components on CNC machines;
3. production on a stamping press of the main load-bearing structural elements, which include a box, racks, stiffeners and racks;

• assembly of entrance metal doors;
• finishing products ready for installation.

Each of the operations described above is a complex technological process, which, in turn, can also be broken down into successive steps. At the same time, it should be taken into account that the above scheme assumes the manufacture of a typical input structure. If it is required to produce a metal door of non-standard dimensions, even more operations are required.

Basic steps in the build process

The assembly of a metal door is deservedly considered one of the most responsible and significant stages of production. It is performed in two stages:

• installation of individual elements and structural parts into a single product;
• the so-called straightening, which involves giving the product a marketable appearance before finishing.

At the first stage, the supporting frame is first assembled steel structure, which ends with the installation of stiffeners and welding of the web. Next, locks and other protective devices, such as anti-removable pins, are mounted. Then, the internal cavity of the sash and, if necessary, the elements of the box are filled with insulation, which also acts as sound insulation. After that, the canvas is sheathed with two steel sheets, and at the end of the stage, the installation of the front elements and parts of the product is performed.

At the leveling stage, which always ends with the assembly of an entrance metal door, welds, joints of structural parts are processed, scale is removed, surfaces are leveled, and burrs are removed. After that, the product is ready for finishing.

Necessary equipment

A prerequisite for the assembly of an entrance metal door to be completed successfully and with proper quality is the use of modern high-precision equipment. pledge efficient operation Almost all the most serious domestic companies engaged in the production of steel entrance structures are constantly improving the technologies used, which is simply impossible without regular modernization of machines and other tools.

Moreover, in addition to the already mentioned CNC equipment, many Russian companies use semi-automatic production lines for the assembly of steel water structures. They usually consist of:

• machine for cutting metal;
• powerful welding machine;
• special press brake.

To work on such semi-automatic high-precision equipment, highly qualified and well-trained personnel are required, the presence of which is another prerequisite production of competitive products on the modern construction market.

The door direction in Russia is considered traditional, because it came out of handicraft. Despite the fact that there are many such industries, this niche remains attractive for start-up entrepreneurs. The door business is good because there are many of its directions: there are interior doors, entrance doors, wooden, metal and others. One workshop usually specializes in the production a certain kind doors. Therefore, an entrepreneur, if he analyzes this segment in his city and looks at the work of competitors, he will be able to choose his niche, which will not yet be occupied by anyone. The demand for doors is very high. We bring to your attention a business plan for the production of doors, which will allow you to do this. interesting business and receive from it not only pleasure, but also material benefits.

Project Summary

A business plan for the production of doors with calculations has the following goals:

• Opening of a shop for the production of doors in a small town.
• Offering customers a wide range of products.
• Expansion of business and access to other cities.
• Getting the maximum profit.

We chose the format of a large workshop because, although a businessman will need a lot of investments to open it, such a production facility will be able to quickly adapt to new technologies, update the line of models and get the most profit.

There are many directions in the field of door production, and every year their number increases. The selection options are:

1. Veneered interior doors. This is the most demanded direction, such products are bought very quickly and are not stale in the warehouse. The only problem is that in this segment there is the biggest competition, which will not be easy to overcome.
2. Metal entrance doors. This is the second most popular destination. The release of metal doors is usually an automated process.
3. Doors from MDF. Products are made from fibreboard, which is obtained by pressing wooden waste. They are cheap, so they are in demand, although their quality is quite low.
4. aluminum doors. Warm profile aluminum is used as raw material.
5. Plastic doors. They were in great demand a couple of years ago, but now the demand for them is stable. Used in offices, on balconies and in manufacturing plants.

Room selection

For door production, you will need a workshop, which should be looked for outside the city, in an industrial area, where rent will be cheaper. The area of ​​​​the room should be large, because it should accommodate special equipment, work tables and the doors themselves. It is best to start from an area of ​​​​200 square meters. m as from the minimum. If there is more space, it is better, because you can allocate space for a warehouse and a showroom.

It is best to divide the area into 2 workshops (wooden and metal), a raw material storage and shipment area, premises for raw materials and finished products. Finished products must be stored at a constant temperature and in compliance with required level air humidity. In this case, the doors will retain their original characteristics longer. If we talk about communications, then the workshop should have gas, water supply, electricity and a ventilation system.

Parking for cars should be provided on the street, and it is important that there are convenient access roads. The rent of the premises will cost about 100 thousand rubles a month. It is important to note that the premises must be assessed fire brigade and Rospotrebnazdor.

Sales of products

As for sales, there can be several directions:

• Construction teams specialized in construction work and renovation of residential premises.
• Shops selling building materials.
• Private persons.

Registration

When the workshop is found and the lease agreement is signed, you can proceed to the registration of the business. To officially engage in this activity, you will need to register as an individual entrepreneur, for which you need to come to your tax office. You will need to pay a state fee of 800 rubles, and the documents will be ready within one week.

Many large supermarkets do not cooperate with entrepreneurs, therefore, in order to deal with them, you will have to become a legal entity and form an LLC. In order for the tax service to know what your company does, indicate OKVED codes 16.23 "Manufacture of other wooden building products” and 25.12 “Production of metal doors and windows”.

Purchase of equipment

The next step will be the purchase of the equipment necessary for the operation of the workshop. Which equipment to choose depends on the specialization. Our example is focused on the operation of two workshops: wood and metal, respectively, equipment is purchased for both. Consider the costs in the table:

To purchase equipment, you will need to spend 780 thousand rubles, and this will be the main item of expenditure. It is desirable to take the equipment new so that it is operated longer, without the need for maintenance and repair. You also need to buy raw materials from which the doors will be made. This includes glue and wood. For everything in a month will take about 100 thousand rubles.

Staff

In order for the shop to work properly, people need to be hired. If the functions of the production manager at first will be performed by the entrepreneur himself, then administrative and technical personnel will not be required. However, in this case, he simply will not have time to negotiate deliveries and work with clients. Therefore, it is worth hiring a qualified engineer to manage the production. 3 people will work in each workshop according to the 5/2 schedule. With an increase in volumes, it is planned to switch to shift work and increase the number of staff.

It is necessary to allocate 260 thousand rubles for the salary fund.

Advertising

Production is focused on wholesale, so the focus is on active sales- in the first months, the director personally works on the basis of hardware stores and specialized departments for the sale of doors and offers his products. For a successful presentation, the following tools are offered:

• Creation of a business card website with a product catalog (50 thousand rubles) or an online store if you plan to launch your own retail direction (200 thousand rubles).
• Creation of printed catalogs for presentation to potential partners (35 thousand rubles).
• Production of printed advertising for placement in trading floor door stores to conduct joint campaigns with them (150 thousand).

At the first stage, from 250 to 500 thousand rubles are allocated for these purposes.

Financial plan

Starting injections

The profitability of the business will depend, among other things, on the investments that the entrepreneur makes at the very beginning. Let's count them in the table:

Thus, the creation of a business will require at least 1.5 million rubles.

Monthly infusions

There will also be monthly expenses. They are the following:

Each month, therefore, about 400 thousand rubles will be spent (office, unforeseen and other small expenses are not taken into account in the table). In addition, raw material costs will be required, more on that later.

Revenue

For the first year, we will set a release plan interior doors 100 pieces per month (MDF) and 100 pieces (veneer) plus 50 metal doors. The average wholesale price of a metal door is 8 thousand rubles, MDF doors - 1,500, veneered - 4,000. The share of raw materials costs, on average, will be 20% from the position.

Taking into account monthly expenses, raw material costs and tax payments, we get a result of about 100 thousand rubles. To start it can be considered acceptable. In the future, funds will be used to purchase additional, higher quality equipment, which will make it possible to produce high-quality doors and systematically increase margins.

The profitability of the business will be about 25%. The investment will pay off in about 2 years. At first, there will be few customers and you will need to unwind in order to reach a good income.

Eventually

The door manufacturing business gives the entrepreneur a wide choice of directions. This business is not seasonal, the doors are selling well all year round. If you strictly follow the business plan, you will be able to competently organize a small workshop, which you will expand over time, and come out on a fundamentally new level! All investments will pay off. We wish you good luck in this interesting and, most importantly, profitable business.

The championship of the most easily opened locks is headed by a pin cylinder lock with a cross-shaped key. The presence of such a lock in the door does not protect it, but, on the contrary, attracts the thief by the simplicity of opening it. Opened with a Phillips screwdriver.

The opening time by criminals is 2-3 minutes. /A The second place is shared by the two most common types of locks: a pin cylinder lock, popularly called “English”, and a cylinder disk lock. "English" is opened using the selection of keys, and the disk one is opened with a locksmith's tool.

Opening time with a master key is 5-10 minutes. c) The last place in this rating is occupied by a cylinder lock with a perforated key or with laser sharpening. Without special overlays, this lock is also quickly opened by master keys or by breaking the cylinder out of the lock with an adjustable wrench. But the armor plates installed on the lock complicate and slow down the work of thieves up to 30-40 minutes, but, unfortunately, they do not stop. Here comes much more serious data.
“My house is my fortress” – this is what each of us thinks today. But the statistics are ruthless, they say otherwise.

| §Ъ The above information suggests that you should not rely on the protection of your home only on the lock, here you need comprehensive measures: a reliable expensive lock and a high-quality metal door. It is such a tandem that will round the attacker from the execution of the perfidious plan.

After all, no matter what the super-secret lock may be, if you install it in the old entrance wooden door he won't help. But cheap obsolete locks are not even installed in a good metal door. Yes, the criminal situation is pushing the owners to protect their home, and more and more people are acquiring new metal doors.

This situation, in turn, affects the demand and expansion of the Ukrainian metal door market.

Moreover, market players use frightening criminal statistics to attract buyers. Many metal door companies have an exciting story in store for customers about how intruders ransacked several apartments on stairwell by hacking, but it was their door, the branded one, that remained impregnable. And each of the market operators thinks that his PR story is unique. Although in fact this bike is used by everyone who sells doors. It seems to be a trifle, but it shows how little the participants in this market know about each other.

Yes, and marketers did not bother to analyze the Ukrainian market of metal doors, so our review will be based on the conclusions of market participants and the opinion of independent experts.

OVERVIEW OF THE UKRAINE MARKET

The Ukrainian market of steel doors began to form back in the distant 90s. AT early XXI century, it rapidly developed until a crisis broke out, one way or another affecting all sectors of the economy. For some subjects of the steel market
door sales drop led to disastrous consequences, many operators left the market. But by the beginning of 2010, the Ukrainian market of steel doors began to gradually revive. To date, the number of operators is approximately 300 companies. And only about 20 of them are large and have a hyped trademark metal doors.

It should be noted right away that the main market participants are Ukrainian manufacturers and importers of Chinese doors. It is difficult to name the proportion of the ratio, but the order is somewhere around 15-85% (in wholesale prices).
The share of imports from other countries (Poland, Russia, Turkey, Italy) is small and does not affect the overall picture.

As you can see from the diagram [on page 47), Chinese doors have taken over the market. But according to the consumers themselves, who managed to buy a made in China door, cheap Chinese doors are money thrown away. Indeed, until 2009, Chinese doors were present on the market in only one price segment - up to $125. To date, the price range for Chinese doors starts at $60 per unit and reaches $315 per door.

But here, too, there is a problem (in terms of security): the thickness sheet metal at a door of Chinese origin does not exceed an average of 1.5 mm. Some market participants joke that this is due to the fact that thieves in China are being shot and the problem of crime in China is close to a final solution. Although attractive appearance of these doors seems to indicate that they were produced on quite modern equipment.

-> HOW TO BECOME A METAL DOORS MARKET OPERATOR

The market itself shows how you can organize your business for the production of metal doors: from a garage mini-workshop to a large factory. And you can do without own production, significantly reducing the initial investment in the purchase of equipment, and become a dealer of a large and well-known manufacturer. Each method has its own advantages.
4 OWN WORKSHOP

To organize a mini-factory for the production of metal doors, you will need at least $ 10,000-15,000. This amount includes the cost of renting premises, equipment, components, advertising and wages workers (in the first month of work).

Rental of premises for the production of doors

The success of a business largely depends on finding the right premises.
Minimum area production premises should be at least 200-250 m2. Workshops of former factories or hangars are ideal for production. The cost of renting a hangar ranges from $1100-1500 per month, capital premises cost from $1800. These are the prices of the capital.

It is clear that many novice entrepreneurs cannot afford them. Therefore, most firms operating in the metropolitan market of cheap metal doors place their production facilities
news in the regions. There, the rental price is much lower.

Mini-factory equipment

The minimum set of equipment for a door production plant includes welding machines, grinder saws, a guillotine for cutting metal, turning, milling and other machines. You can save money by buying used units. The number of equipment depends on the volume of products produced.

Staff

The number of employees depends on the production capacity of the plant. The average welder can “weld” two or three doors per day. Thus, a company producing 300 doors per month,

According to the production technology, domestic doors can be divided into two main groups:

1 Doors made in a handicraft way outside of industrial production.

This is the largest group of steel doors on the market. The design is extremely simple; in most cases, such doors require the installation of a conventional overhead lock. There are not even very approximate statistics on the number of door manufacturers in this group. And this is understandable: it is difficult to keep records welding machines, and doors can be made in any premises, including garages.

2 Doors made by manufacturers using technological equipment.

Steel doors belonging to this group are made in mixed production using less sophisticated equipment, but using highly skilled manual labor (hence the relatively low prices).

Although it should be noted that many manufacturers of high-quality prestigious entrance metal doors in recent times are seriously modernizing their production, introducing modern technologies from the best Western companies. Already today we can say that from the point of view of finishing, domestic doors of the elite class, according to
quality and assortment came close to imported ones, and sometimes they seriously surpass them in their characteristics.

This group of serious manufacturers who have been operating on the market for more than one year. There are few of them: for example, in Kyiv, according to various estimates, from 7 to 10, and throughout Ukraine there are no more than 20 such firms.

at least 5 welders will be required. Measurer and installer functions in small firms usually performed by one person. In addition, small producers usually do not have their own fleet. Therefore, measurers-installers have to be also drivers operating their own cars. Installation of one door takes 1.5-2 hours. That is, in a day, taking into account moving from client to client, one installer can complete 2-3 orders.

SALARY FOR EMPLOYEES

IS ABOUT 30% OF ALL

COSTS FOR ONE DOOR.

Another costly part is hiring highly qualified sales managers, which are not cheap. However, these investments are justified. True professionals will be able to explain to the client that an expensive door is not only distinguished by its external beauty, but also is effective protection dwellings.

Profitability

A production that produces at least 200-300 products per month is considered profitable.

The fact is that the prices for products are initially low and there is no way to raise them due to fierce competition. In the cost scheme, imported components occupy about 30-40%, another 30% goes to salaries of employees, the rest is eaten up by advertising and rent.

There is only one way out: to increase production and reduce the cost of production. And therefore, most entrepreneurs involved in this business invest most of their income in the purchase of new equipment.

More profit with lower sales volumes are received by firms engaged in the manufacture of expensive products: doors finished with laminated panels,
MDF, artificial or natural veneer valuable breeds tree. The cost of such products is higher, but they also cost 100-2000% more. Yes, the door MDF finish costs $280, and finished with oak veneer - all $800. The high cost is due not only to exterior trim, but also with expensive fittings and locks, mainly of Italian production.

The demand for such doors is lower, but the profitability is higher. Such production can turn out to be profitable, producing already 60-100 products per month.

The cost of raw materials, components and wages of workers is about a third of the cost of an expensive door.
According to market players, the profitability of this business depends on the price segment in which the company operates. If doors with expensive finishes are sold, then you can count on 25-30%, but if the average cost of the order is low, then the profitability will be lower than -10-12%.

Having become acquainted with all the intricacies of this type of door manufacturing business, we can summarize: it is so interesting to do this business. So, the turnover of a small enterprise will be a maximum of $105,000 per month. The net income of the workshop owner is $10,500.

Is this not enough? Need to earn more? Then you can open a more powerful enterprise.
OWN ZAVVD
The initial investment in this case will be at least $110,000-$!50,000. Approximately half will have to be spent on the purchase of equipment. In addition to welding machines, large-scale production all kinds of presses, guillotines, lathes, milling and grinding machines, automatic hacksaws, as well as bending machines that allow bending metallic profile. Another $50,000-$70,000 will be spent on renting premises, purchasing vehicles, organizing exhibitions, advertising and paying staff in the first months of operation.

Properties for the production of doors

Since the production of doors is full complex operations connected to each other, then, accordingly, there should be several rooms:

Hi Administrative building(office).

Shop for work with rolled metal products (marking, cutting, bending, filing).

Painting and drying shop.

Door assembly workshop: complete
locks, handles, eyes, heaters.

Storage warehouse.

Staff

The staff list consists of more than 50 people with higher or secondary technical education.

CEO.

Hi Chief accountant.

Head of planning and economic department.

Sales manager.

Director of operations.

Hi Master, drivers, workers.

In order for the production of doors not to stop, it is necessary to regularly sell products, thanks to which employees receive their salaries on time, and it is also possible to pay for the purchase of rolled metal and components for further production activities.

In such firms there is a special department: marketing. It is he who organizes promotions, calls potential clients, offering its products, concludes contracts with hardware stores and bases of building materials.
On the Internet, it is effective to have your own website that tells

production of doors with real photo and video materials, as well as phone numbers and company address.

Start-up costs

The initial start-up costs are:

workshop rent - approximately $ 9300; purchases necessary equipment, that is, fixed assets: a sheet bending mechanism, a welding machine, a corner cleaning machine - a total of $ 60,000.

Monthly expenses will consist of:

rent (if rented) - $9300;

transportation costs - $3000;

utility bills (water, heat, electricity) - $2,100; security — $900;

salaries and other expenses - $25,000;

other expenses - $3,300. Total: $9,300+3,000+2,100+900+ 25,000+3,300 = $43,600.

Potential Income

If we produce daily 50 doors of various price ranges, when calculating the average cost of doors $ 250, we calculate:

50 * $250 * 22 = $275,000 Conclusion: $275,000 - $43,600 = $231,400 profit.

Door production is a complex business, but quite profitable. Dare!

Article Source: Make Money Magazine 2013

In this article:

For the house to be truly a fortress, the entrance to it must be blocked by reliable metal doors - protection from uninvited guests, cold winds and street noise. Entrance doors made of durable steel are a standard requirement that every inhabitant makes today for his own home.

Although market competition entrance doors is quite high, you can still find a niche here: recently, the demand has grown not only for the quality and reliability of door panels, but also for a spectacular appearance (especially in elite new buildings, well-guarded entrances and cottage settlements). Therefore, having thought over an interesting, stylish design and an assortment range of several models, you can enter the middle price niche on a par with branded manufacturers.

However, as practice shows, the decisive factor when buying from 80% of consumers is the price. Therefore, even "garage production" - with the help of hand tools and machine tools, is quite capable of making a profit in as soon as possible which will allow you to take a step to the next stage of business development.

• GOST 31173-2003 - Steel door blocks. Specifications;
• GOST 23118-99 Steel building structures;
• GOST 5089-97 - Locks and latches for doors. Specifications.

Steel door production equipment

1. Automatic lines

Used in large factories high performance from 200 doors/day and more. The technological process is fully automated, for the manufacture of one door leaf takes about 2 minutes. High-precision technology ensures the same geometry of the product, forming profiles, drilling holes for fittings and connecting fasteners, painting the door leaf and filling internal voids - everything happens automatically, with minimal manual intervention.

The welding of the product is also automated, thanks to the use of special welding robots. Strong weld seam connections do not require additional manual cleaning and grinding.

Pros: automated lines allow the production of 500-600 finished products per day with minimal risk of marriage.

Minuses: high price and the cost of maintenance (the lines are made to order, the cost starts from 6 million rubles). For full-fledged work such equipment requires a large production area (from 1500 m 2), where, in addition to the workshop itself, it is necessary to provide significant areas for storing raw materials and finished products.

2. Semi-automatic lines (using manual labor)

A set of equipment and machines for opening a partially automated production:

• Semi-automatic guillotine or metal cutting machine (plasma - Fig. 4, laser) - from 120,000 rubles;
• Press brake - 70,000 rubles;
• Welding machines (includes spot welding, door leaf welding, tong welding, final welding in the environment carbon dioxide) - from 100,000 rubles. Can be replaced by conventional welding machines;
• Painting equipment (paint gun, compressor).

Rice. 4 (Plasma)

With this equipment, you can produce 15-20 doors per day. The required area of ​​the premises is not less than 250 m 2 .

Pros: the cost is quite lifting for medium-sized businesses - the price of a semi-automatic line completely depends on the configuration (from 400,000 rubles). But some machines can be replaced more than simple equipment, which will significantly reduce the start-up capital, but increase the amount of manual labor and, accordingly, the cost of wages to workers.

Minuses: "human factor" - the less automation, the higher the number of defects. In addition, highly qualified craftsmen, trained to work both on machines and manually, will be required to ensure the correct implementation of the production technology at all its stages.

3. Manual labor and machine tools

Minimum set of equipment:

• Bulgarian;
• mechanical guillotine for cutting metal (Fig. 5);
• milling machine;
• lathe;
• auxiliary hand tool.

Pros: minimum costs for the purchase of equipment (from 60,000 rubles) and the rental of premises (60-80 m 2).

Minuses: 2-3 doors a day is the maximum productivity for such equipment. Such a mini-production can only be oriented to low price segment. To avoid a large number marriage, we need specialists who can work on metal.

Workshop for the manufacture of metal doors

All the main processes of steel door manufacturing technology must be carried out in separate rooms. Therefore, the production area should provide:

• shop for acceptance and preparation of metal;
• workshop for processing steel sheets and rolled profiles;
• assembly and welding shop;
• paint shop;
• decorative and finishing (and if the finish is made directly at the enterprise, and is not purchased ready-made, then separate room for the technological line for its production) (Fig. 7);
• assembly and control shop;
• finished products warehouse.

Of the special requirements - the presence of a system fire safety, finishing with non-combustible materials of walls and floors, good ventilation.

Technological process of production of metal doors

Manufacturing technology steel door includes a certain sequence of actions prescribed in a special document (technological or route map), indicating:

• requirements for the quality of materials;
• rules for their transportation, storage and acceptance;
• sequential process of converting raw materials into steel door block, its painting and assembly;
• complex technical requirements for each process
• quality control and verification methods;
• method of transportation, storage of finished products and other technical specifications (production specifications), which are compiled in accordance with the requirements of GOST 31173-2003.

Main steps technological process production of steel doors

1. Metal preparation

Before going to production, the metal is sorted. The marking, the presence of deformations after rolling or transportation is checked, corrosion and scale are removed. In the warehouse of raw materials and materials, rolled metal is stored stacked or on stable racks (at least 2.5 m high).

2. Marking and cutting blanks

Making doors starts with cutting sheet metal according to the templates applied with the help of center punches. For cutting rolled metal use:

• mechanical equipment (guillotine shears, presses, saws);
• oxygen method (cutting on stationary machines with gas cutting or hand cutters);
• laser, plasma cutting.

3. Processing of workpieces

Profile for door frame it is made on bending equipment, where, under the pressure of a press, a metal plate is given a shape bent at the required angle.

It can be either a standard rectangular design or an arched model. In the second case, the arcuate profile of the upper part of the door is passed through a rolling machine to give the desired shape. After rolling, the profile is cut into the desired parts.

The blanks are sawn off - to eliminate irregularities and the burr is removed upper layer metal at the cutting points. Sawdust is performed manually, with the help of files or on special sawdust machines. After processing, the blanks are sent to a stamping machine, where holes of various diameters are punched for locks and fittings in accordance with the prepared maps.

4. Assembly and welding

The assembly of the door leaf is carried out using resistance welding, which eliminates the deformation of the leaf and ensures the absence of welding seams. The sheets are welded to the frame, a 15-20 mm indent is left on the front side, which will serve as a vestibule. In the manufacture of metal doors, a multi-seam type of welding is used. The density of the fabric structure is achieved by installing special stiffeners.

Door locks are installed simultaneously with stiffeners, in places reinforced with metal plates (the so-called "technological pockets"). Between the door leafs, non-combustible basalt slab (alternatives: wood, mineral wool, glass wool, polyurethane foam, polypropylene).

To assembled door hinges are manually welded, observing the necessary gaps between the canvas and door frame. The assembly is carried out according to several types (by marking, in conductors, by copiers) and is controlled at each stage for compliance with the geometry in order to correct the defect if necessary.

5. Treatment with paints and varnishes

After assembly, the door blank is sent for painting. The paint is applied to a cleaned, sanded and degreased surface using one of the following methods:

• jet douche;
• pneumatic spraying (Fig. 13);
• spraying in an electrostatic field.

Used nitro, powder, graphite, hammer paint different colors - this coating forms good protection protecting the door from corrosion and light mechanical damage. After drying, the thickness of the applied layer is controlled and there are no visual defects - air bubbles, unpainted areas, cracks, stains.

6. Sheathing with decorative elements

To give high wear resistance and an original decorative effect, additional protective covering- molded or laminated finishing panels, which are manufactured in the enterprise by cutting (automatic or semi-automatic) according to ready-made templates or purchased in bulk.

Types of skins:

• leather, leatherette, vinyl leather;
• wooden lining;
• chipboard;
• natural wood;
• thermal film plain or with imitation of wood of various species;
• forging elements;
• veneer.

7. Installation of locks, fittings, quality control of the finished product

Inserting fittings and checking locks is done manually. To avoid the characteristic knock of metal on metal when the door is closed, a special shock-absorbing material is glued to the door leaf to enhance heat and sound insulation - rubber compressor rubber or silicone.

To control the quality of the assembly and the tightness of the door leaf to the frame, the finished product is installed on a control stand. If all requirements are met, the door is packed and sent to the finished product warehouse.

Raw materials for making steel doors

There are two technologies for manufacturing steel doors:

• pipe-coal, using rolled pipes fastened by electric arc welding;
• profile bending - using bent rolled profiles.

Today, the second technology is most successfully used in production, where the raw materials for the manufacture of doors are finished sheets of metal. Many believe that the thicker steel sheet in a metal door, the better. And this is not entirely true. Too heavy doors can lead to a lot of problems, for example, difficulty in opening / closing due to heavy weight, rapid wear of the loops due to high load. Therefore, 2 mm is the upper "bar" for standard apartment doors. Each additional millimeter adds about 8 kg of weight.

Required accessories:

• locks;
• loops;
• latches/latches;
• pens;
• additional (closers, eyes, clamps, blocking devices).

Business plan for the production of metal doors

1. It is planned to open a mini-factory for the production of steel entrance doors. The target group of consumers are construction companies and private households.

2. For the legal registration of business, an LLC was created on common system taxation, indicating the following types of OKVED:

• 28.75.21 "Production of armored or reinforced safes, fireproof cabinets and doors";
• 45.25.4 "Installation of metal building structures".

For the production of metal doors and the provision of services for their installation, it is necessary to issue a license in accordance with SNiP 11-23-81. The cost of processing packages of documents and obtaining a license is about 35,000 rubles.

3. The production workshop is planned to be located on 100 m 2 of non-residential leased premises. Rental price - 15,000 rubles / month.

4. Costs for the purchase of equipment - 125,000 rubles:

• guillotine crank shears NK3418A;
• sheet bending mechanism MGL-2500;
• drilling machine 2116K;
• abrasive cutting machine;
• welding machine TDM-403;
• spray gun;
• Bulgarian;
• additional equipment (hand tools, racks, exhibition stand).

5. Calculation of the cost of 1 product - a metal door with a size of 2180 * 1040 mm.

• sheet steel 2mm - 0.098 t * 31,600 rubles = 3096.80 rubles;
• insulation (mineral wool) - 0.2 m 3 * 1475 rubles = 295 rubles.
• electrodes - 4 kg * 43 rubles = 172 rubles;
• mortise lock - 820 rubles;
• loops, handle, peephole - 550 rubles;
• cutting wheels, grinding wheels - 420 rubles;
• primer - 4 l * 87 rubles = 348 rubles;
• solvent - 2l * 210 rubles = 420 rubles;
• paint - 2 kg * 460 rubles = 960 rubles.

Total: 7081.80 rubles

6. Income from sales

It is planned to manufacture and install 3 doors per day with a 21-day working day. The selling price of the product is determined by the method of carrying out comparative analysis market prices and is equal to 12,500 rubles. Installation cost - 1200 rubles.

Projected revenue per month: 63 pieces * 13,700 rubles = 863,100 rubles / month.

Material costs - 63 pieces * 7081.8 rubles = 446 153.4 rubles / month.

7. Other costs of doing business:

• rent - 15,000 rubles;
• electricity - 1200 rubles;
• depreciation of fixed assets - 5750 rubles;
• advertising - 15,000 rubles;
• staff salary (director, 5 workers and a sales manager) - 65,000 rubles;
• payroll taxes -24,375 rubles;
• income tax - 58,124.32 rubles.

Total: 184,449.32 rubles / month.

8. Financial results

Net profit: 863,100 rubles - 446,153.4 rubles - 184,449.32 rubles = 232,497.28 rubles / month.

The initial investment (equipment + license + material costs for 1 month of work + other costs) will pay off in 4 months of work.