Airvent Fans

IMB 689
AIRVENT FANS CO.
ANSHUMAN TRIPATHY AND SHIKHA SAFAYA
Anshuman Tripathy, Professor of Production & Operations Management, and Shikha Safaya, Research Assistant, prepared this case for class
discussion. This case is not intended to serve as an endorsement, source of primary data, or to show effective or inefficient handling of decision
or business processes.
Copyright © 2018 by the Indian Institute of Management Bangalore. No part of the publication may be reproduced or transmitted in any form or
by any means – electronic, mechanical, photocopying, recording, or otherwise (including internet) – without the permission of Indian Institute of
Management Bangalore.
This document is authorized for use only in Lino Garcia's Gerencia de Produccion y Operaciones II (MDI) at Universidad Rafael Landivar (URL) from Sep 2019 to Mar 2020.
Airvent Fans Co.
As Rajan Bansal closed his eyes while sitting in his big office room, glimpses of childhood flashed before
his eyes. In the torrid afternoon heat of the Jaipur sun, he along with his father, would slice the bottoms of
used cold drink bottles, insert their necks into punched cardboards and place this setup at the windows of
their house. The hot air from the outside would pass through the narrow canal of the plastic bottle and
cool down in the process, bringing relief to the whole family. The smiles on the face of his mother and
sister had motivated Rajan to dream big, and he with his father, proceeded to successfully set up their own
ceiling fan manufacturing company Airvent Fans Co., that acted as a Tier one supplier of ceiling fans to
leading ceiling fan OEM brands in the country. Airvent made a variety of ceiling fans for its customers
(Exhibit 1). Although the company had performed steadily in the past, catering to some of the largest
players in the Indian market, the increasing demand (Exhibit 2) had Rajan worried. Given the rapid pace
at which demand for the ceiling fan market was growing, it was for certain that the production volumes
had fallen short that year (Exhibit 3). The demand was expected to reach 1.2 million in 2020, and Rajan
was sure that the plant’s capacity and setup would not be sufficient to take care of it.
The emerging set of events had left the fate of Airvent Fans Co. hanging in the balance, and it was in dire
need of a revamp of its operations. So, Rajan contacted his close childhood friend Vishwanath Shetty,
who was a senior operations consultant at OpSure in Bangalore. Vishwanath and Rajan had studied in
school together when his dad was posted in Jaipur. Looking at the urgency of the situation, Vishwanath
immediately took a flight to Jaipur to analyze Airvent’s production process.
AIRVENT FANS CO.: HISTORY
Airvent Fans Co. was established in 1988 by Rajan’s father Mukesh, with his own savings from his
kirana store business. A plot of land was bought in the Sitapura region in Jaipur itself, which later on
became a popular industrial area. The first Airvent Fans plant was completely manually operated by
workers, who operated blade and motor manufacturing machines, with the moulding processes for the
other components and painting done by hand. After some initial years of struggle trying to establish a
market for fans in Rajasthan, Airvent quickly grew to success. When Rajan took over the business, he
helped Airvent Fans Co. expand to a pan-India level. The original Sitapura factory expanded to form a
huge plant, with the latest automated machines and skilled workers, ensuring high quality products and
making Airvent a favourite among ceiling fan OEM brands in the country.
CEILING FAN MANUFACTURING PROCESS
The ceiling fan made by Airvent consists of a motor (covered with aluminum housing) that has three steel
blades attached to it with the help of iron supports and rivets (Exhibit 4). The blades have a curvature to
them to improve the air flow. The inside of the motor consists of two steel parts: a stationary stator with
copper winding and a moving rotor attached to it. Other parts like axle, capacitors, etc. are also present
and together this system is responsible for the rotation of the fan. The top of the fan has a steel hook for
mounting, and there are two plastic covers: one at the top covering the mounting hook, and the other at
the bottom, on top of the motor housing. A steel downrod connects the mounting hook to the motor.
Page 2 of 17
Airvent Fans Co.
The stator and rotor are produced by respective specialized steel stamping machines, and are joined
together to form the motor subassembly after the copper wire has been wound on the stator. For the
manufacturing of the blades, steel sheets of the appropriate size are first cut, then the proper shape is sized
before finally curving the blade to provide the right angle. Rivets and iron supports are further attached to
the blades. The downrod is made through metal extrusion which is a semi-continuous process and
involves putting in steel granules through a tube which gives the final shape. The plastic covers are made
through the process of injection moulding in which hot thermoplastic polymer is shot through the moulds
and then cooled down. The blades and other parts then go through the process of painting and drying. The
final stage involves the assembly of the right sets and storing, packaging for the customer.
AIRVENT FANS CO. AND THE CEILING FAN INDUSTRY
The Indian fan industry is an ever-growing market, given the hot weather in the country and rising
disposable incomes of households, registering a CAGR of 9-10% over the last few years.1 The total
annual sales of the Indian ceiling fan market were an estimated 50 million fans in 2016.2 Ceiling fans
make up the largest segment of the Indian electric fan industry at around 70%. The market is roughly
equally split between a few players in the organized sector (~45% market share) and a large number of
players in the unorganized sector (~55% market share) due to low barriers to entry3.
Airvent Fans Co. had a strong presence in north India and the states of Rajasthan and Gujarat, and catered
to the two main players in the region: Tropical Fans and WindStar. Both the companies were popular
because of their completely different offerings: while Tropical was known for its energy saving fan line
that not only saved electricity bills but was also affordable, WindStar offered high speed, high
performance fans. In total, Airvent manufactured 28 variants of fans based on different motor wattages,
blade sweeps and colors for its two customers at the Jaipur plant (Exhibit 1).
The plant consisted of steel stamping stations for manufacturing the stator, rotor and blades of the ceiling
fan, injection moulding setup for the plastic parts, extrusion tube setup for the downrod, a riveting shop,
two paint shops for painting of metal and plastic parts, and an assembly line for the final assembly and
packaging. Other parts such as aluminum die cast for motors, axles, capacitors, iron supports, rivets, etc.
were bought out. The plant operated for 250 days a year with two 8-hour shifts. The paint shop had excess
capacity as a result of a conscious decision taken to step up the capacities of the various stations, and
could go on a third shift if needed. The layout of the plant was in a batch production plus assembly line
type setup.
The stator and rotor differed in size according to the motor wattage. They were made in batches of 1000
and 1300, respectively, and kept as inventory before motor subassembly (Exhibit 5). Each changeover for
the two stations involved a setup time of 100 and 150 minutes, respectively. The cost of setup per
changeover was Rs. 20/min. The motor subassembly shop had machines in three parallel stations run by
three operators for fitting the stator grooves with insulation paper and winding copper to it. The machine
was automated and thus setting of different sizes of stators and wires only required changing parameters
Page 3 of 17
Airvent Fans Co.
in the machine’s control system, for which the changeover time was negligible. One operator at the next
station attached the rotor to the stator.
In parallel to rotor and stator production shop, the blade shop had 3 stations with 3 operators each for
cutting, sizing and giving angle to the blades. While the cutting of steel sheets at the right length was a
continuous process, the sizing and angling stations also worked in batches of 1000, with a setup time of
40 minutes per changeover, and rate of Rs.20/min/changeover. The riveting of blades was done at the
next station in sequence.
There was one station for downrod extrusion and two stations for injection moulding of the plastic covers.
The upper and lower plastic covers differed in sizes, with the upper plastic cover being uniform in size,
and the lower one varying in size as per the motor size. Hence, the injection moulding setup was multi-
mould in nature, with one side for the upper plastic cover of the fan and the other side with changing
moulds as per the differing sizes for the lower cover. So, the plastic covers would always be made in sets
according to fan size.
The plant did not make any aluminum parts, such as the motor housing, and thus sourced them from
suppliers, along with other parts such as screws, wires, axles, capacitors, copper wire, etc. All the
manufactured parts, along with the different motor housing aluminum die casts, proceeded to the two
paint shops: metal and plastic.
The plastic paint shop had two paint tank stations. The metal paint shop had eight stations in total with
three parallel lines (for the blades, motor and downrod), where the component would first be dipped in
solvent tank for pre-paint preparation and then pass to the respective line to be sprayed through the
method of electrostatic liquid painting. The components would immediately be moved to a conveyer belt
where they would dry and then be packed or moved to inventory. While the motor housing and downrod
would be moved to inventory, the blades would be checked for defects and pre-packaged in sets of 3 by 2
operators. At any point of time, there were sufficient number of blades drying on the belt and thus there
was no time spent in waiting. The fans were manufactured on a make-to-order basis, and for demand for
the month of June, say, the orders were firmed up by May 20. The production would begin much before
in March.
The final assembly line comprised four stations, that is, the final assembly of motor, its testing, packing
with other parts, picking and packaging of the right set of blades, and finally dispatch. The motor final
assembly station had one operator who fixed the axle to the motor subassembly with the help of a
machine, and then placed it on top of the motor housing bottom cover. Another operator would secure the
top lid on this structure with three screws each. The next operator would fix the capacitor and wires to the
motor, after which the motors will be tested for their rotation and wattage at the next station. The next
station would be responsible for packing the motor, downrod, mounting hook, and the plastic cover sets
(after attaching respective OEM stickers on them), and finally placing them in a box depending on the
OEM customer. The blades would be picked up, cleaned and packed into another packing material at the
Page 4 of 17
Airvent Fans Co.
next station, and together these two boxes would be dispatched to the customers. With the current setup,
the factory was capable of giving an output of 3200 fans/day, or 0.8 million fans annually, at full capacity.
PROBLEMS FACED BY AIRVENT FANS CO.
The current setup had worked very well for Airvent, as year after year, they had managed to meet the
demand (Exhibits 2, 3). The manufacturing process had been fine-tuned through the experience of several
years, and the number of stations, workers, and batch size had been fixed based on reaction to the flow of
orders. However, such a system was clearly not working anymore, and production mismatch resulted in
inability of Airvent to meet the complete demand in 2017. A backlog of orders could not be fulfilled in
the next period as the OEMs could meet their requirements from other manufacturers in the market. Lost
demand would have a negative impact on the image of the company.
As Rajan studied the yearly performance of his company at the end of quarter 4, he was worried. In front
of him lay projections for 2018 by quarter, and aggregate forecasts for the years 2019 and 2020. With the
projections only going higher, he wondered how it was even possible to meet the future demand, given
the shortfall of 2017.
He was contemplating whether to outsource some of the crucial operations in order to increase output
rate, but before embarking on that decision, he wanted a more thorough analysis by Vishwanath: whether
a productivity increase was possible using the current resources, or outsourcing was inevitable. Also, if
some operations had to be outsourced, which ones should they be?
Vishwanath flew in towards the end of quarter 4 of 2017. He needed to reflect on the scenario panning out
for Airvent in the coming years of 2018 to 2020, and devise a strategy to resolve the problem.
VISHWANATH’S ANALYSIS
Vishwanath visited the manufacturing plant and took an overview of the manufacturing process, noting
down the broad outline of the process flow (Exhibit 5). At the face of it, the operations looked efficient
and Vishwanath understood why it was difficult for Rajan to identify where the problem really was. He
had to dig deeper, and so he asked the planning and design & engineering departments to compile a
detailed bill of materials for the complete fan (Exhibit 6A) and the motor separately (Exhibit 6B) (as the
motor itself consisted of various subcomponents). He asked the engineering department to also put
together a detailed sequence of steps for the manufacturing of fan along with process times (Exhibit 7),
and the sales department for the complete demand data: past and future forecasts (Exhibit 2). The
planning department also kept records of the holding costs of the various inventories and setup costs for
the different machines, and was required to provide the same. The annual holding costs for the stator
production station was Rs.140 and for each of the rotor and blade stamping stations was Rs.250.
Vishwanath wanted to analyze the gap between the production capacity of the company and the projected
demand.
Page 5 of 17
Airvent Fans Co.
A bill of materials for the motor had never been put together before, nor had the process sequence been
clearly noted down. It thus took 48 hours for the various departments to present the reports to
Vishwanath. In addition, he also assembled the heads of the design & engineering team, planning team,
sales team, and the operations manager along with Rajan in the board room for a meeting, so that he could
take personal feedback from all the people regarding the manufacturing process and where they thought
the problematic areas and potential sources of waste were.
The first glimpse of data brought some clarity to Vishwanath. He felt that the immediate need for Airvent
factory was to bring its production process in sync, and there was also a need to invest some capital or
outsource some operations. The total amount of data was a lot for Vishwanath to immediately process and
come up with a concrete response, so he asked Rajan for some time in order to go through the information
and come up with a detailed proposal to help resolve Airvent’s problems. Bidding his friend goodbye,
Vishwanath landed at Bangalore and resumed office. A new hiree had joined OpSure and Vishwanath
handed him the data to perform detailed calculations to analyze the process in detail.
Page 6 of 17
Airvent Fans Co.
Exhibit 1
Fan Variants Manufactured by Airvent Fans Co.
Fans → S06XTr N12XTr N12XWs N14XWs H12XTr H12XWs H14XWs
Customer
Tropical (Tr) ✓ ✓ ✓
WindStar (Ws) ✓ ✓ ✓ ✓
Motors
30-watt energy ✓
saver (S)
60-watt normal ✓ ✓ ✓
(N)
75-watt high ✓ ✓ ✓
speed (H)
Blade Sweeps
600 mm (06) ✓
1200 mm (12) ✓ ✓ ✓ ✓
1400 mm (14) ✓ ✓
All the 7 models of fans are available in 4 colors: White (W), Ivory (I), Brown (B), Maroon (M). X in the model
variant can take any of these four color codes.
For simplification: downrod length is only one = 400 mm
Source: Developed by case writers
Page 7 of 17
Airvent Fans Co.
Exhibit 2
Airvent Fans Co.: Ceiling Fan Demand Data
Fan Code 2014 2015 2016 2017 2018 2019E 2020E
Q1 Q2 Q3 Q4 Total Q1E Q2E Q3E Q4E Total
S06XTr 234,500 241,000 253,500 69,000 63,000 68,000 67,000 267,000 71,000 74,000 78,000 80,000 303,000 330,000 375,000
N12XTr 80,000 65,400 74,000 19,000 18,000 19,500 21,000 77,500 20,500 21,500 22,000 23,000 87,000 92,500 98,000
N12XWs 73,330 82,000 85,000 21,000 21,500 22,000 23,000 87,500 23,500 23,000 24,500 26,000 97,000 106,000 110,000
N14XWs 85,000 94,000 98,500 23,000 24,000 23,500 25,500 96,000 27,000 28,500 29,000 26,500 111,000 120,000 138,000
H12XTr 69,000 59,000 87,500 22,000 23,000 24,000 24,000 93,000 24,000 26,000 23,500 26,000 99,500 106,000 115,000
H12XWs 50,000 40,000 23,500 5,000 5,500 6,000 6,000 22,500 8,000 8,500 10,000 10,000 36,500 38,000 52,000
H14XWs 120,000 139,000 145,000 37,000 39,500 37,000 41,000 154,500 40,000 42,000 42,500 43,000 167,500 192,000 220,000
Total 711,830 720,400 767,000 196,000 194,500 200,000 207,500 798,000 214,000 223,500 229,500 234,500 901,500 984,500 1,108,000
Page 8 of 17
Airvent Fans Co.
Exhibit 3
Airvent Fans Co.: Ceiling Fan Supply Data
Fan Code 2014 2015 2016 2017

Q1 Q2 Q3 Q4 Total
S06XTr 234,500 241,000 253,500 70,000 63,000 68,000 67,000 268,000
N12XTr 80,000 65,400 74,000 19,500 19,500 20,500 19,000 78,500
N12XWs 73,330 82,000 85,000 21,000 22,000 22,000 22,000 87,000
N14XWs 85,000 94,000 98,500 23,500 24,000 23,500 22,000 93,000
H12XTr 69,000 59,000 87,500 22,000 23,000 22,000 24,000 91,000
H12XWs 50,000 40,000 23,500 6,000 6,000 6,000 6,000 24,000
H14XWs 120,000 139,000 145,000 34,000 36,500 36,500 39,000 146,000
Total 711,830 720,400 767,000 196,000 194,000 198,500 199,000 787,500
Exhibit 4
Ceiling Fan Design
Page 9 of 17
Exhibit 5
Nuts, Screws, Wires etc.

Stator
Airvent Fans Co.
Production
Motor Sub-Assembly
(rotor+stator+winding) WIP
WIP

Rotor
Pack
Steel Sheets
Production Pick and
Motor Motor Motor and Dispatch
Pack
Assembly Testing Other
Motor Housing Blades
Parts
Copper Wire, Insulation Paper Lids- top and
bottom
Metals Paint
Incoming
Material Rivets, Iron Supports
Motor Housing
Painted Sets
Blade Blade Extrusion Rod, Plastic Cover Sets

Blade Riveting
Stamping Packaging Blade Sets
Steel Sheets
WIP
WIP
Stee l Granu les

Steel Rod
Extrusion
Factory Layout (initial)
WIP
Plastics Paint
Plastic
Thermop last ic Po lymer

Injection
WIP
Moulding
Page 10 of 17
Airvent Fans Co.
Exhibit 6A
Bill of Materials – Final Fan
Parts Usage
Part no. Part name Sourcing
N12XWs
N14XWs
S06XTr
N12XTr
H12XTr
H12XWs
H14XWs
MOU001 Steel Bought 1 1 1 1 1 1 1
mounting out
hook
PCU001 Plastic In-house 1 1 1 1 1 1 1
cover:
upper
PCL001S Plastic In-house 1
cover:
lower S
PCL001N Plastic In-house 1 1 1
cover:
lower N
PCL001H Plastic In-house 1 1 1
cover:
lower H
OEM100Tr OEM Bought 1 1 1
sticker Tr out
OEM101Ws OEM Bought 1 1 1 1
sticker Ws out
DR400 Steel In-house 1 1 1 1 1 1 1
downrod
MOT30S Motor S Assembly 1
in-house
MOT60N Motor N Assembly 1 1 1
in-house
MOT75N Motor H Assembly 1 1 1
in-house
BLD06 Blade 06 In-house 3
BLD12 Blade 12 In-house 3 3 3
BLD14 Blade 14 In-house 3 3 3
IS624 Iron Bought 3 3 3 3 3 3 3
supports out
RIV003 Rivets Bought 9 9 9 9 9 9 9
out
BLD06PP Blade 06 Bought 1
pre- out
packaging
material
BLD12PP Blade 12 Bought 1 1 1
pre- out
packaging
material
Page 11 of 17
Airvent Fans Co.
Exhibit 6A (Contd.)
BLD14PP Blade 14 Bought 1 1 1
pre- out
packaging
material
PCS001PP Plastic Bought 1
cover set S out
pre-
packaging
material
PCN001PP Plastic Bought 1 1 1
cover set N out
pre-
packaging
material
PCH001PP Plastic Bought 1 1 1
cover set H out
pre-
packaging
material
DM401PP Downrod Bought 1 1 1 1 1 1 1
and out
mounting
hook pre-
packaging
material
BOXS100Tr Motor S Bought 1
packing out
box Tr
BOXN100Tr Motor N Bought 1
packing out
box Tr
BOXN101Ws Motor N Bought 1 1
packing out
box Ws
BOXH100Tr Motor H Bought 1
packing out
box Tr
BOXH100Ws Motor H Bought 1 1
packing out
box Ws
PK06100Tr Blade Bought 1
packing out
box 06 Tr
PK12100Tr Blade Bought 1 1
packing out
box 12 Tr
PK12101Ws Blade Bought 1 1
packing out
box 12 Ws
PK14101Ws Blade Bought 1 1
packing out
box 14Ws
Page 12 of 17
Airvent Fans Co.
Exhibit 6A (Contd.)
Note: BOM above is exclusive of color specifications
Code
DR400 X, PCU001 X X= White (W)/Ivory (I)/Brown (B)/Maroon (M)
OEM Y Y= 100Tr/101Ws
PCL001 B, PC B001PP B= S/N/H
PCL001 BX, BOX BY
BLD D, BLD DPP D= 06/12/14
BLD DX, PK DY
MOT GPP G= 30S/60N/75H
MOT GX
Exhibit 6B
Bill of Materials – Motor
Parts Usage
Part no. Part Name Sourcing Motor S Motor N Motor H
STR12S Stator S In-house 1

STR20N Stator N In-house 1
STR32H Stator H In-house 1
ROT005S Rotor S In-house 1
ROT005N Rotor N In-house 1
ROT005H Rotor H In-house 1
CW27 Copper winding 27 SWG* Bought out 1
CW36 Copper winding 36 SWG Bought out 1
CW41 Copper winding 41 SWG Bought out 1
INSP02 Insulation paper 0.2 mm Bought out 12 20 32
AX010 Axle Bought out 1 1 1
CAP020 Capacitor 2 uF Bought out 1
CAP025 Capacitor 2.5 uF Bought out 1
CAP050 Capacitor 5 uF Bought out 1
WIRE005 Connection wire 0.5 m Bought out 3
WIRE010 Connection wire 1 m Bought out 3
WIRE020 Connection wire 2 m Bought out 3
MHU001S Motor housing top lid S Bought out 1
Page 13 of 17
Airvent Fans Co.
Exhibit 6B (Contd.)
MHL001S Motor housing bottom lid S Bought out 1

MHU001N Motor housing top lid N Bought out 1
MHL001N Motor housing bottom lid N Bought out 1
MHU001H Motor housing top lid H Bought out 1
MHL001H Motor housing bottom lid H Bought out 1
MOT30SPP Pre-packaging material motor S Bought out 1
MOT60NPP Pre-packaging material motor N Bought out 1
MOT75HPP Pre-packaging material motor H Bought out 1
SCRW0078 Motor housing screws Bought out 3 3 3
* SWG = Standard Wire Gauge is measurement of wire size by cross-sectional area

Note: BOM above is exclusive of color specifications
Code
STR A A= 12S/20N/30H
ROT005 B, MHU001 B, MHL001 B B= S/N/H
MHU001 BX, MHL001 BX
CW C C= 27/36/41
CAP E E= 020/025/050
WIRE F F= 005/010/020
Page 14 of 17
Airvent Fans Co.
Exhibit 7
Process Sequence – Ceiling Fan Manufacturing
# Operation Process Pre- Parts (used/mfrd.)

Time requisite
(secs) step
Stator 1 Layers of steel 9.9 -
Production sheet stamped STR A
together in
batches based on
motor size, cut
into circular
shapes, and given
grooves by
machine
Rotor 2 Steel sheet sliced 9 - ROT005 B
Production and coiled into
hollow discs, with
diameter based on
motor size
Motor sub 3 Approproate size 8 1 STR A INSP02
assembly stator chosen,
grooves fitted
with insulation
paper
4 Copper wire 39 3 CW C
wound on stator
depending on its
size
5 Rotor fitted with 9 2, 4 ROT005 B
stator manually
Blade 6 Steel sheet cut at 1.2 -
stamping the right length
by machine,
based on blade BLD D
sweep
7 Cut sheet given 3.3 6
shape of blade by
machine
according to
blade sweep
8 3 holes punched 2.1 7
into each blade
9 Shaped blade 3 8
given curvature
by machine
according to
blade sweep
Blade 10 1 iron support 3.6 9 IS624 RIV003
riveting placed on each
blade and 3 rivets
per blade attached
(9 rivets per fan
set)
Downrod 11 Steel granules fed 7.2 - DR400
extrusion into extrusion
tube to produce
downrod
Page 15 of 17
Airvent Fans Co.
Exhibit 7 (Contd.)
Plastic 12 Thermoplastic 9 - PCU001 PCL001 B
injection polymers shot into
moulding mould at high
temperature: one
mould side makes
upper plastic
cover (uniform
size), other side
mould makes
lower plastic
cover according to
motor size (set of
2 covers per fan)
Metal 13 Fan blades, rods, 6.5 10, 11,12 BLD D DR400 MHU001 MHL001
paint motor housing- B B
shop top and bottom
lids dipped in
solvent for pre-
paint preparation
14 Fan blades painted 9.1 13 BLD DX
through
electrostatic liquid
painting according
to color
15 Downrods spray 5 13 DR400 X
painted according
to color
16 Motor housing- 7.7 - MHU001 MHL001
top and bottom lid BX BX
spray painted
according to fan
color
Plastic 17 Plastic cover- 10.5 12 PCU001 PCL001
paint upper and lower X BX
shop spray painted
according to fan
color
18 Drying of all continous 14,15,16,17 BLD DX DR400 X MHU001 MHL001 PCU001 PCL001
painted BX BX X BX
components on
conveyer belt
19 Blades quality 12 18 BLD DX
check performed
manually
20 Blades pre- 7.2 19 BLDDPP
packaged in sets
of three according
to blade length
Assembly 21 Fix axle to motor 8 5 AX010
subassembly
22 Place motor 4 18, 21 MHL001
subassembly on BX
motor housing
bottom based on
size
23 Place appropriate 7 22 MHU001 SCRW0078
motor housing top BX
lid and secure
with screws (3
screws per motor)
Page 16 of 17
Airvent Fans Co.
Exhibit 7 (Contd.)
24 Fix capacitor and 6.5 23 CAP E WIRE F

wires (different
lengths based on
motor size) to
motor
25 Motor testing of 14.4 24 MOT GX
rotation and
wattage
26 Pack motor (pre- 9.3 25 MOTGPP
packgaging
material based on
size)
27 Pick plastic cover 3.5 18 PCU001 X PCL001 OEM Y
sets (based on BX
motor size) and
place OEM sticker
on upper cover
28 Pack plastic cover 6 27 PCB001PP
set according to
motor size (pre-
packaging
material)
29 Pack downrod and 5 18 DM401PP
mounting hook
(pre-packaging
material)
30 Place motor, 5 26,28,29 BOXBY
downrod and
mouting hook,
plastic cover set in
appropriate box
(based on motor
size and OEM)
31 Pick blade set, 12 20 PKDY
clean and pack in
final packaging
material (based on
blade sweep and
OEM)
32 Dispatch motor continous 30, 31 BOXBY PKDY
pack box with
blade set
Key
A= 12S/20N/32H
B= S/N/H
C= 27/36/41
D= 06/12/14
E= 020/025/050
F= 005/010/020
G= 30S/60N/75H
X= White (W)/Ivory(I)/Brown(B)/Maroon(M)
Y= 100Tr/101Ws

Page 17 of 17

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IMB 689

AIRVENT FANS CO.

ANSHUMAN TRIPATHY AND SHIKHA SAFAYA

AIRVENT FANS CO.: HISTORY

CEILING FAN MANUFACTURING PROCESS

AIRVENT FANS CO. AND THE CEILING FAN INDUSTRY

PROBLEMS FACED BY AIRVENT FANS CO.

Fans → S06XTr N12XTr N12XWs N14XWs H12XTr H12XWs H14XWs

Source: Developed by case writers

Fan Code 2014 2015 2016 2017 2018 2019E 2020E

Q1 Q2 Q3 Q4 Total Q1E Q2E Q3E Q4E Total

Source: Developed by case writers

Fan Code 2014 2015 2016 2017

Source: Developed by case writers

Source: Developed by case writers

Nuts, Screws, Wires etc.

Source: Developed by case writers

Blade Blade Extrusion Rod, Plastic Cover Sets

Stee l Granu les

Thermop last ic Po lymer

Source: Developed by case writers

STR12S Stator S In-house 1

MHL001S Motor housing bottom lid S Bought out 1

* SWG = Standard Wire Gauge is measurement of wire size by cross-sectional area

Source: Developed by case writers

# Operation Process Pre- Parts (used/mfrd.)

24 Fix capacitor and 6.5 23 CAP E WIRE F

Source: Developed by case writers

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