1.1.

The project goal and objectives

The purpose of this project was to design a plastic water tap. This is achieved by the following objectives: 1- To define the plastic water tap product specification and industrial application. 2- To evaluate the market requirements, by analyzing the market needs using forecasting techniques to find the required volume of production for plastic water tap. 3- To select the most desirable plastic water tap type in the market. 1.2. Product

description

Water tap is a plumbing device introduce in the water supply pipe line, the function of this device is to control water flow. This is a basic plumbing device used in the houses, in industries and in laboratories. There are various types of water taps commonly in use, generally the water tap are made of cast iron or some alloy materials. Due to the improved properties of plastics, plastic taps are common in use.

1.3. Standard related to the product

An ISO STANDARD ISO/R 265.1962 is commonly used in the design of the water pipe line fittings made of PVC plastic.

1.4. Specifications
The main specification for the water tap is the diameter of the outlet socket diameter. The selected water tap diameter is 20 mm.

2. Market analysis
2.1. Market data
2.1.1. Local production of valves cocks, etc There are three local factories producing valves, cocks, etc. The total production of these factories amounts to 214,000 units. The production data are summarized in Table 2.1 Factory Name Fire Equipments Company Al kawther Company Middle East Company Location Address Telephone number Capacity (Unit) Product name Valve, cock, etc.

P.O box 0507060795 8401 Dammam 100,000 Dammam 03 812 1092 31482 P.O box 01 4766107 4194 Riyadh 100,000 Riyadh 11491 P.O box 2321 Dammam 03 8741313 14,000 Dammam 31451 Table 2.1 Local production of valve

2.1.2. Import and Export Data A. Import quantities and Export

We obtained data from Saudi Standards, Metrology, and Quality Organization to perceive the market demand. In table 2.2 we present the imported quantities from 2000 to 2010 in Saudi Arabia.

2010 Table 2.2 Imported

29933

1005 Quantities

28928

From Table 2.2 we realize how enormous the demand in Saudi Arabia market for the parts of this product, which reflect a promising profitable business opportunity. In addition, we will present the value of this product in SR. B. Imported value In Table 2.3 we show the development of imports of valves, cocks, etc. with respect of quantity.

Imported value (1000 S.R) 2000 269335 2001 179576 2002 366446 2003 545094 2004 554755 2005 967922 2006 853609 2007 2809590 2008 2837552 2009 1547584 2010 1606995 Table 2.3 imported value

Year

2.2. Constructions and housing Unfortunately, the demand for water taps in Saudi Arabia market was not accessible. But, it gives us an idea about the demand. So we will study the real estate market, to forecast the demand. 2.2.1 New constructions and housing The main factor that affects the water tap demand is construction and housing. Thus, in Table 2.4 we show the number of construction licenses issued during the period from 2000 to 2010. Year 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 Number of licenses 32756 38742 43734 37585 44721 55369 53856 56637 70952 85047 89787

Table 2.4 Number of licenses

From Table 2.4, we can observe that the number of the issued licenses was tripled. Finally, we expect that the demand increase on water taps because it is closely-related with the increase of the number of constructions and utilities.

To obtain accurate assumptions, the previous data of new constructions and housing units is not enough because the licenses are for large, medium and small unit. Thus, we must get the buildings area to find correct assumptions. In Table 2.5 we show the new constructions and housing in Year 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 Built up Area ( ) 24800205 29865260 35659382 30714234 41365826 55524873 55428929 72979675 67546347 84416963 89003126

Table 2.5 Built up Area for new housing units 2.2.2 Restoration units The demand on water taps is not restricted to new construction. Rather it is also needed for maintaining existing units. We assume 20% of constructions need restoration yearly. In Table 2.6 we show restoration units. Year 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 Number of restoration units 4066721 813345 4105463 821093 4149197 829839 4186782 837357 4231503 846300 4286872 857375 4340728 868146 4397365 879473 4468317 893663 4553364 910672 4643151 928630 Table 2.6 Restoration units Number of constructions

2.3. Product design

The possible customer requirements for a water tap may be as follows: Aesthetically pleasing. No leakage when in off condition Little force requirement for revolving the plug Removal of sharp corners Light weight Low cost

2.4 decision making

After we analyzed the two products, we will select water tap type 1 because it is easy to produce, it has less components so it will be cost efficient, less time to assembly also it is performs the same function. In addition of that we find the customer dont want sharp angles in the body and the customer see that the handle better and more efficient than the knob.

2.3. Prices There is a difference in prices in accordance with quality, raw material, finishing and place of sale Table 2.7 we show the selling price on the Saudi market. Models Made Price Wholesale Operational price specification

available in

China

Inch

China

4.5

1/2 Inch

Table 2.7 The selling price on the Saudi market

2.4. Estimation of current demand To estimate current demand from Table 2.5 we assumed one water tap for each 30 in new

unit. Also we assume three water taps for each restoration unit from Table 2.6. In Table 2.8 we

show the yearly demand. Figure 2.1we show total estimated water tap.

Year

2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

Estimated Total Estimated Water taps Estimated water taps Water taps For For new Restoration construction 826673 2440033 3266706 995508 2463278 3458786 1188646 2489518 3678164 1023808 2512069 3535877 1378861 2538902 3917763 1850829 2572123 4422952 1847631 2604437 4452068 2432656 2638419 5071075 2251545 2680990 4932535 2813899 2732018 5545917 2966771 2785891 5752661 Table 2.8 Estimated currant demand

Trend Analysis Plot for Total estimated water tap

Linear Trend Model Yt = 2831531 + 255874*t

6000000 Total estimat ed water tap 5500000 5000000 4500000 4000000 3500000 3000000
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

Variable A ctual F its A ccuracy Measures MAPE 3.87105E+00 MAD 1.60859E+05 MSD 3.05947E+10

Year

Figure 2.1Trend analysis plot for total estimated water tap

3.1. Estimation of future demand After estimated the demand for last ten years, the future estimation demand for next ten years (in unit) is calculated by using forecast techniques on MINITAB. In Figure 2.2 we present the graph of the forecast.
Trend Analysis Plot for Total estimated water tap
Linear Trend Model Yt = 2831531 + 255874* t 8000000 Total est imat ed wat er t ap 7000000 6000000 5000000 4000000 3000000
Variable A ctual F its Fo recasts A ccuracy Measures MA PE 3.87105E+00 MA D 1.60859E+05 MSD 3.05947E+10

Year

Figure 2.2 Forecast analyses for water taps The trend of demand as shown in Figure 2.2 is increasing year after year, and this gives u s the impression of the possibility to entry this market.

In Table 2.9 we present the forecast calculated by the software

Year Forecast (units) 2011 5902016 2012 6157889 2013 6413763 2014 6669637 2015 6925511 2016 7181384 2017 7437258 2018 7693132 2019 7949006 2020 8204879 Table 2.9 Forecast of future demand 3.2. Average demand The average demand gives u s the idea about the amount of product missing to fulfill the requirements. In Table 2.10 we show the average units.
Year 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 Forecast, units 5902016 6157889 6413763 6669637 6925511 7181384 7437258 7693132 7949006 8204879 7053448 Average

Table 2.10 Average demand

3.3. Market share The yearly average forecast is 7,053,448 units. Therefore, our aim to reach about 10% from the average forecast. So, our production will be about 800,000 units/year.

3.4. Investment opportunity

Expected selling price of a water tap = 800,000*4 = 3,200,000 SR/year Expected profit = 20% of selling price = 3,200,000*0.2 = 640,000 SR/year Production cost = selling price profit = 3,200,000 640,000= 2,560,000 SR/year

4. Product drawing and specification

4.1. Assembly drawing The assembly drawing for the product is produced by assembling the individual parts of the product, created by using the reverse engineering concept. SOLID WORKS 2012 is used for the creation of the drawings. The assembled models for type 1and type 2 water taps are shown in Figures 4.1 and 4.2, the exploded assemblies are shown in Figures 4.3and 4.4

TITLE: Water Tap PART: Assembly Drawing MATERIAL: QUATITY: Figure 4.1Assembled model for type 1 water tap

TITLE: Water Tap PART: Assembly Drawing MATERIAL: QUATITY: Figure 4.2 Assembled model for type 2 water tap

TITLE: Water Tap PART: Exploded Assembly Drawing MATERIAL: QUATITY:

Figure 4.3 Exploded assembly drawing for type 1 water tap

TITLE: Water Tap PART: Exploded Assembly Drawing MATERIAL: QUATITY: Figure 4.4 Exploded assembly drawing for type 1 water tap

4.2 Detailed part drawings and Bill of Materials (BOM) The individual part drawings for the type 1 water tap and their dimensions are shown in Figures 4.5 to 4.9

TITLE: Water Tap PART: Body MATERIAL: Plastic QUATITY: 1 Figure 4.5 Part drawing for the type 1 water tap

TITLE: Water Tap PART: Plug MATERIAL: Plastic QUATITY: 1 Figure 4.6 Part drawing for the type 1 water tap

TITLE: Water Tap PART: Adapter MATERIAL: Plastic QUATITY: 1

Figure 4.7 Part drawing for the type 1 water tap

TITLE: Water Tap PART: Handle MATERIAL: Plastic QUATITY: 1

Figure 4.8 Part drawing for the type 1 water tap

TITLE: Water Tap PART: Standard Parts MATERIAL: Plastic QUATITY: 1 Figure 4.9 Part drawing for the type 1 water tap

The bill of materials for the type 1 is shown on Table 4.1 Part No. 1 2 3 4 5 6 7 Part Designation Material Quantity Weight (grams) 12 8 5 6 2 2 -

Body Plastic 1 Plug Plastic 1 Adapter Plastic 1 Handle Plastic 1 Nylon Washer Nylon 1 O Ring Rubber 1 Screw Steel 1 Table 4.1 Bill of materials for the type 1 water tap

The part drawings for the type 2 water tap are shown in Figures 4.10 to 4.14

TITLE: Water Tap 2 PART: Body MATERIAL: Plastic QUATITY: 1 Figure 4.10 Part drawing for the type 2 water tap

TITLE: Water Tap 2 PART: Plug MATERIAL: Plastic QUATITY: 1 Figure 4.11 Part drawing for the type 2 water tap

TITLE: Water Tap 2 PART: Cock MATERIAL: Plastic QUATITY: 1 Figure 4.12 Part drawing for the type 2 water tap

TITLE: Water Tap 2 PART: Knob MATERIAL: Plastic QUATITY: 1 Figure 4.13 Part drawing for the type 2 water tap

TITLE: Water Tap 2 PART: Standard Parts MATERIAL: Plastic QUATITY: 1 Figure 4.14 Part drawing for the type 2water tap

The bill of materials is shown as Table 4.2 Part No. 1 2 3 4 5 6 7 Part Designation Material Quantity Weight (grams) 15 6 5 5 -

Body Plastic 1 Cock Plastic 1 Seat Plastic 1 Knob Plastic 1 Nylon Washer Nylon 1 O Ring Rubber 1 Screw Steel 1 Table 4.2 Bill of material for the type 2 water tap

4.3. Part structure The part structure gives the idea about the levels of assembly to get the product. It starts from the complete assembly and start decomposition to sub-assemblies and parts. The parts structure diagram for the type 1 water tap are presented in Figure 4.15 and for the type 2 in Figure 4.16.

Figure 4.15 Part structure for the type 1 water tap

Figure 4.16 Part structure for type 2 water tap