Feasible study of setting medical glove factory in Vietnam.docx
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Feasible study of setting medical glove factory in Vietnam.docx
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FeasiblestudyofsettingmedicalglovefactoryinVietnam
FeasibleStudy
For
SettingUpAGloveFactoryinLongKhanhVietnam
Editor:
EddyLiou
Version:
1
Date:
06/11/2010
CONTENTS
PAGE
1.PREFACE2
2.PLANTLAYOUT&CONSTRUCTIONCOST3
2-1.LANDANDLOCATION
2-2.PLANTLAYOUT
2-3.CONSTRUCTIONCOST
3.ORGANIZATION&MANPOWERDEMAND9
3-1.MANPOWERDEMANDANDLABORCOST
3-2.ORGANIZATIONCHART
4.PRODUCTION11
4-1.PRODUCTIONPROCESSCHART&ILLUSTRATION
4-2.GLOVEDIPPINGMACHINEFLOWDRAWING
5.COSTANALYSIS15
5-1.EQUIPMENT&MACHINERYLISTANDCOST
5-2.ENERGY&UTILITIESCONSUMPTIONANDCOST
5-3.MATERIALCOST
5-4.OPERATIINGCOST
6.INVESTMENTCAPITALANDFINANCIALANALYSIS25
6-1.INVESTMENTCAPITAL
6-2.FINANCIALANALYSIS
6-3.CONCLUSIONS
1.PREFACE
WRPAsiaPacificSdnBhdisoneoftop5companiesinthegloveindustryhavingthetechnologyandreputationofmakingmedicaldevicessuchasmedicalgloves,catheter,fingercotsinMalaysia.DongNaiRubberCorpisawellknownnaturalrubberandlatexsupplierhavingplentyofresourcesinVietNam.BothpartiesjointhandstosetupajointventurecompanyforproducinglatexexaminationglovesatLotno.M1,M10ofLongKhanhIndustrialZone(LKIZ),VietNam.
Theprojectgoalisbuildingup6gloveproductionlinesinthebeginning,aftersuccessfulrunningandthenexpandinganother6productionlinesasthephaseIofproject;afterphaseIsuccessfulrunningandthenexpandinganother15productionlinesasphaseIIoftheproject;andafterphaseIIsuccessfulrunningandthenbuildingupcatheterandfingercotsproductionlinesasphaseIIIoftheproject.
AccordingtoLKIZinformation,thebasicinfrastructurewillcompleteontheendofMarch,2011.ThepresentprojectconstructionandengineeringisplanningtoembarkfromJanuary,2011toJune,2012withtotal18monthsworkingperiod.Thefactorybuildingandconstructionperiodtakesabout7monthstoaccomplish,andtheequipment&machineryinstallationperiodtakes12monthstocommission.
ThescopeofpresentfeasiblestudyisonlyincludingthephaseIoftheprojecthavingthemainfeaturesasfollowings:
InvestmentCapital:
US$24,000,000
EmployeeNo.:
460
LandSize:
3.11hector
Products:
PowderedNRLatexExaminationGlove
MaximumCapacity:
1,550,400,000piecesglove/year
Mainequipment:
12setsof99meter8tiersglovemakingmachine
WaterConsumption:
2500CMD
EnergyCoalconsumption:
166ton/dayofcoal
ElectricityCapacity:
2.28MVA
2.PLANTLAYOUT&CONSTRUCTIONCOST
2-1.LANDANDLOCATION
A.LocationGeographicalFeatures:
Thedistance
fromlocationtomainspots
2kmfromNationalHighwayNo.1A
40kmtoBienHoaCity
70kmtoHoChiMinhCity
70-80kmtoICDPortinDistric2orDistric9
4kmtoLongKhanhRailwayStation
40kmtoLongThanhInternationalAirport
Averagehumidity
85%
Averagetemperature
25.4℃
Annualaveragerainfall
2174mm
Prevailingwind
Northeastern-Southwest
Pressure–bearing
2.0kg/cm²
Locationlandsize
(CombinedM1andM10)
3.11hector,311.25Lx100Winmeter
OnthemainroadofLKIZfacetoWest
Remark:
InformationprovidedbyLKIZ
B.LandCost
ThejointventurecompanywillsetupatLKIZLotno.M1andM10withlandsize3.11hectorsforprojectPhaseI,andthereservedLotno.M2andM9withlandsize3.11hectorsforPhaseIIandIIIdevelopment.
FollowinginformationisprovidedbyLKIZ:
A.Landrentalfee:
GovernmenthireLKIZis1500VND/m²/year,willbeadjustedinaccordancewithregulationinforce.Atpresent,landrentalfeethatGovernmenthireLKIZisfree.
B.Infrastructurefee:
Annualpayment:
US$1.60/m²
Onetimepayment:
US$30.00/m²/48years
Thispriceisonlyappliedforinvestorreleaselandwithareaover50000m².Usinginfrastructurefeewillbeadjustedinaccordancewithareaandlocationoflandrental.Landrentaldurationis48years.
2-2.PLANTLAYOUT
A.BuildingFloorSize:
Floorsize(M)
Remarks
Mainbuilding
Lobby
Mainoffice
Productionarea
Packingroom
Chemicalstorage
Lab.
Formerstorage
Partsstorage
Aircompressor,chillerroom
W.C.andLockerroom
Personentrance
Productionoffice
Waterleakingtestroom
Q.C.room
Warehouse:
including
Finishedgoodsstorage
Packagingmaterialstorage
200Lx62Wx12.5H
30Lx9.9W
30Lx24W
120Lx50W
46.1Lx30W
30Lx12W
16Lx12W
12Lx12W
12Lx12W
30Lx12W
16Lx12W
12Lx4W
10Lx6W
10Lx6W
10Lx6W
2812M²
24Lx12W
Lightsteelframestructure
Lobbyisatthe1stfloornexttopackingarea
Officeisonthe2ndfloorabovethepackingarea
AccessoryBuilding
Coalstorage
Boilerroom
Canteen
WWTP
Guardhouse
Generatorroom
Weighbridge
40Lx30Wx12.5H
24Lx20Wx12.5H
24Lx24Wx5H
40Lx30W
9Lx9W
12Lx12Mx6M
15Lx3M
Lightsteelframestructure
Lightsteelframestructure
RCstructure
Brickstructure
Lightsteelfromstructure
RCstructure
Others
Containerdock
Carparkinglot
Motorcycleparkinglot
Intracommunicationroad
Greenbelt
Fence
600M²
60M²
500M²
5240M²
8000M²
2044M²
6Nos.
10lots
200lotswithroofing
Circulararoundmainbuilding
B.PlantLayoutDrawing
C.ConstructionandEngineeringSchedule
2-3.CONSTUCTIONCOST
Description
Size(M²)
UnitCost
(US$/M²)
Amount(US$)
Lightsteelframestructure
Mainfactorybuilding
Coalstorage
Boilerroom
Canteen
Guardhouse
Generatorroom
12416
1212.5
850
480
32
288
180
180
180
180
180
180
2,234,880
218,250
153,000
86,400
5,760
51,840
RCstructure
WWTP
Weighbridge
800
45
350
350
280,000
15,750
Groundconstruction
Containerdock
Carparkinglot
Motorcycleparkinglot
Intracommunicationroad
600
60
500
5240
12
12
12
12
7,200
720
6,000
62,880
Others
Greenbelt
Fence
8000
2044
5
50
40,000
102,200
Total
32467.5
US$3,264,880
3.ORGANIZATION&MANPOWERDEMAND
3-1MANPOWERDEMANDANDLABORCOST
JobDescription
Nos.
Wage
(US$/month)
Total(US$/month)
6LINE
12LINE
6LINE
12LINE
GeneralManager
1
1
3,000
3,000
3,000
ProductionVP
1
1
2,000
2,000
2,000
SeniorManager
8
8
1,000
8,000
8,000
2ndManager
3
3
700
2,100
2,100
JuniorManager
8
8
500
4,000
4,000
Seniorstaff
5
5
350
1,750
1,750
Generalstaff
12
17
250
3,000
4,250
Engineer
3
3
600
1,800
1,800
Supervisor
7
7
400
2,800
2,800
Technician
2
2
300
600
600
Skilledworker
15
23
250
3,750
5,750
Non-skilledworker
200
382
120
24,000
45,840
Sub-total
265
460
56,000
81,890
SocialInsurance
Employercontribute16%ofwages
8,960
13,102
MedicalInsurance
Employercontribute2%ofwages
1,120
1,638
Otherallowances
Estimated6%ofwages
3,360
4,913
Total(US$/month)
69,440
101,543
Remarks:
1.AccordingtoDecreeNo.98/2009/ND-CP:
Minimumwagesis1.190.000VND/monthforforeigninvestmententerprice..
2.Theestimatedforeignexchangerate:
US$1=VND20000
3.Thewagesareincludingover-timeworkinghourcompensation
3-2.ORGANIZATIONCHART
4.PRODUCTION
4-1.PRODUCTIONPROCESSCHART&ILLUSTRATION
PRODUCTIONPROCESSILLUSTATION
RawMaterials&ChemicalsPreparingandLatexCompounding:
Thesolidformchemicalsaregrindedintofinepowderbyabeanorballmillforeasydispersingmixwithlatex,thecompoundinglatexiscontinuouslyagitating12-18hourstopre-matureorper-vulcanizethelatex;andthensendtolatextankformakingglovebygravitywithlevelingcontrolsystemtocontroltheeffluentvolume.Thecoagulantagentcontainscalciumnitrate,calciumcarbonateandwettingagentthatiswellmixedandagitatingtopreventfromsedimentationandsendtocoagulanttankformakinggloves.
ManufacturingProcedure:
On-LineProcedure:
Ceramicgloveformerconnectedwithdiskholderandjointontoamotordrivenconveyorchainwhichiscontinuouslyrotatedmovingalongwithtracktopassthroughformercleaningsectionincludingacidandalkalitreatment,rounddiskandplatebrushingandfurtherwithhotwaterrinseprocesstocleantheresidueleftontheformersurface;andthenpassthroughadryingoventodryoutwaterandheatuptheformertemperature;andthendipintoajacketedcoagulanttankwhichismaintainedabout50℃tocoatalayerofcoagulantagent;andthenpassthrougha150℃dryingoventodryoutthecoatedcoagulantagent;andthendipintoajacketedlatextankwhichiscirculatedwithcoolingwaterandmaintainabout28℃tocoatadesiredthicknesslayeroflatexfilmontoformer;andthenpassthrough100℃dryingoventosemi-drythelatexfilm;andthendipintoabout50℃pre-leachingtanktowashingouttheimpuritiesandproteinofthelatexfilm;andthenpassthroughbeadingstationtobrushrollingtheupportionfilmintoabead;andthenpassthroughthe110-135℃mainoventodryoutandcurethelatexfilm;andthendipinto50℃post-leachingtanktofurtherwashouttheimpuritiesfromthecuredfilm,andthendipintoslurrytanktocoatstarchpowderonthegloveforlubricating;andthenapre-strippingbrushrollingdowntheglovecuff;andthengloveisstrippedofffromformerbyaautopeelingmachineandthenformercontinuouslyreturntorepeatthewholeprocess.
Off-LineProcedure:
Thestrippedglovesaresenttotumblerdryerforpost-curingandevenoutthepowderdistribution;andthensenttoQ.C.forsamplingcheckthequalities;andthequalifiedglovesaresentforpackingasfinishedgoods.
(Thenexttwopagedrawingsaretheglovedippingmachineflowchart)
5.COSTANALYSIS
5-1.EQUIPMENT&MACHINERYLISTANDCOST
A.PRODUCTIONEQUIPMENT
Description
Unit
Cost(US$)
1
Energy&System:
ThermalOil(ton)
6,000,000Kcalcoalfiringthermaloilboiler
eachwith
50HpOilcirculationpump
15HpFeedingchainmotor
2HpAs
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