Design and Fabrication of Inline Fuel Injection System

Power up your performance with Inline Fuel Injection System

The Business Plan

Submitted by:
Muhammad Muneeb 2001386-035
Meer Hamza 20013386-046
Muhammad Azeem 20013386-052

BSc Mechanical Engineering Technology

(2020-2024)
Submitted to

Engr. Hasnain Raza

March 8, 2023
 Table of Contents

1 Executive Summary
2 The industry, the company, the product and service
2.1 The Industry
2.2 The Opportunity
2.3 Our Products and Services
2.4 The company: Mission, Vision, Values

3 Market Analysis

3.1 The Clients

3.11 Customer Segmentation

3.12 Market Size

3.2 The Environment

3.2.1 Macro-environment: PESTEL Analysis

3.2.2 Macro-environment: Porters Five Forces Model

4 Marketing Plan

4.1 Product: Features, Positioning, Branding

4.2 Pricing Strategy

4.3 Place, Distribution Channels

4.4 Promotions and Customers Relationships

5 Operations Plan

5.1 Facilities

5.2 Operations, Key Processes and Activities

 5.3 Key Resources

5.4 Key Partners: Outsourcing, Alliances

6 Human Resources and Entrepreneurial team

6.1 Entrepreneurial team: Competences, Abilities

6.2 Employment Projections

7 Financial Plan

7.1 Finance sources

7.2 Cash Flow Forecasting

7.3 Income Statement

7.4 Breakeven Analysis and Profitability

8 Conclusions
9 Annexures (if any)
10 References
1 Executive Summary

The design and fabrication of an inline fuel injection system involves the development of a
system that can deliver fuel to an internal combustion engine in a controlled manner. The system
typically includes a fuel pump, fuel injectors, fuel lines, and an electronic control unit (ECU) to
manage fuel delivery.

The design process begins with determining the fuel flow rate requirements of the engine and
selecting an appropriate pump to meet those requirements. The fuel injectors are then chosen
based on the desired spray pattern and fuel delivery rate.

Once the components have been selected, they are assembled and tested for functionality and
performance. The fuel lines are carefully routed and secured to prevent leaks or damage.

The ECU is programmed to monitor and control fuel delivery based on various sensor inputs
such as throttle position, engine speed, and air temperature. The system is then tested under
various operating conditions to ensure it meets performance and emissions standards.

Overall, the design and fabrication of an inline fuel injection system is a complex process that
requires careful attention to detail and a thorough understanding of engine dynamics and fuel
system components. When done correctly, it can significantly improve engine performance and
fuel efficiency.
 3 The industry, the company, the product and service
3.1 The Industry

The design and fabrication of inline fuel injection systems is a specialized area of the
automotive and manufacturing industries. These systems are essential for delivering fuel to an
engine's combustion chambers at the precise time and in the correct amount to optimize
performance and fuel efficiency.

The industry of designing and fabricating inline fuel injection systems involves a range of skills
and expertise, including mechanical and electrical engineering, computer-aided design and
manufacturing (CAD/CAM), precision machining, and quality control. Professionals in this field
typically work for automotive manufacturers, engine builders, or fuel system manufacturers.

The design and fabrication of fuel injection systems require specialized knowledge of fuel flow
dynamics, fuel atomization, and combustion processes. Engineers and designers must consider
factors such as fuel pressure, injector size and placement, fuel pump capacity, and injection
timing. They use computer simulation software to model fuel flow and combustion processes,
and they work closely with engine designers to optimize fuel injection performance.

Once the design is finalized, fabrication begins. Fuel injection system components are typically
manufactured using high-precision machining tools such as CNC (computer numerical control)
machines. Quality control is critical at every stage of fabrication, as even small variations in fuel
injector dimensions or fuel flow rates can affect engine performance.

Overall, the industry of design and fabrication of inline fuel injection systems is a highly
specialized and technically advanced field that plays a critical role in optimizing engine
performance, fuel efficiency, and emissions control in modern vehicles.

2.2 The opportunity

 Better fuel efficiency

 Improved performance
 Easier cold starting
 Reduced emissions.
 Lower maintenance.
2.3 Our Product
 Improved fuel efficiency: Inline fuel injection systems can deliver precise amounts of
fuel to the engine, resulting in improved fuel efficiency and better gas mileage.

 Better throttle response: Fuel injection systems can deliver fuel to the engine quickly and
accurately, resulting in better throttle response and faster acceleration.

 Lower emissions: Fuel injection systems can more precisely control the air/fuel mixture
going into the engine, resulting in lower emissions.

 Consistent performance: Fuel injection systems can maintain a consistent air/fuel mixture
throughout a range of operating conditions, resulting in consistent performance and better
drivability.

 Easy to diagnose: Fuel injection systems have sensors that can detect problems with the
system, making them easier to diagnose and repair compared to carburetors.

 Flexibility: With the help of Electronic Control Unit (ECU) fuel injection system can be
programmed to work in a wide range of engine conditions such as high altitudes, hot and
cold climates, and extreme driving conditions.

2.4 The company: Mission, Vision, Values

Mission
The mission of an inline fuel injection system is to precisely deliver fuel to the engine at the
correct time and in the correct amount, ensuring efficient combustion and optimal engine
performance. The system must maintain a constant flow of fuel under varying engine speeds and
loads, while also taking into account factors such as air temperature and pressure.

Vision
Our vision for an inline fuel injection system would be to create a highly efficient and precise
system that maximizes the engine's performance while minimizing fuel consumption and
emissions. This could be achieved through various technological advancements, such as:

 Advanced Fuel Injectors:

 Electronic Control Unit (ECU
 Hybrid Fuel System.
 Real-time Monitoring

Overall, the vision for an inline fuel injection system is to create a highly efficient,
precise, and environmentally friendly fuel delivery system that maximizes the engine's
performance and reduces emissions.

Values

 Consistent performance: Since the fuel-air mixture is precisely controlled, inline fuel
injection systems provide more consistent engine performance, which translates to a
smoother and more reliable driving experience.

 Reduced emissions: Inline fuel injection systems can reduce emissions of harmful
pollutants such as carbon monoxide and nitrogen oxides, which is especially important
for meeting modern emissions standards.

 Better cold starting: Fuel injection systems provide better cold starting than carburetors,
which can be particularly useful in colder climates.

 Increased power output: Inline fuel injection systems can deliver more fuel to the engine,
which can increase power output and improve acceleration.

 Lower maintenance requirements: Inline fuel injection systems require less maintenance
compared to carburetors since they have fewer moving parts and do not require
adjustments as frequently.

 Overall, inline fuel injection systems offer improved fuel efficiency, consistent
performance, reduced emissions, better cold starting, increased power output, and lower
maintenance requirements, making them a popular choice in modern vehicles.
3 Market Analysis

Inline fuel injection is expected to grow steadily in the coming years, driven by the increasing
demand for fuel-efficient and high-performance vehicles. However, the market is also facing
several challenges, including high costs and increasing competition from alternative technologies
such as electric and hybrid vehicles.

3.1 The Clients

3.1.1 Customer Segmentation

1. Automotive manufacturers: This customer segment would be interested in purchasing

inline fuel injection systems in bulk for use in the production of their vehicles. They
would require systems that meet their specifications for performance, efficiency, and
durability.

2. Aftermarket automotive parts retailers: These retailers cater to customers who are looking
to upgrade or repair their vehicles. They would be interested in carrying a range of inline
fuel injection systems that are compatible with different makes and models of cars.

3. Performance enthusiasts: This customer segment is made up of people who are interested
in improving the performance of their vehicles. They would be looking for high-
performance inline fuel injection systems that can deliver increased power and
acceleration.

4. Classic car enthusiasts: This segment of customers is interested in restoring and

maintaining vintage or classic cars. They may be interested in purchasing inline fuel
injection systems that are designed to replicate the performance and look of original
systems.

5. Industrial equipment manufacturers: Inline fuel injection systems are also used in
industrial equipment, such as generators and pumps. This customer segment would
require systems that are designed to meet the specific requirements of their equipment.

3.1.2 Market Size

In general, the inline fuel injection system market has been growing steadily in recent years due
to the increasing demand for fuel-efficient vehicles, stringent emission norms, and technological
advancements in fuel injection systems. According to a market research report by
MarketsandMarkets, the global fuel injection system market size is projected to reach USD 78.9
billion by 2025, growing at a CAGR of 5.5% from 2020 to 2025.

3.2 The Environment

3.2.1 Macro-environment:

PESTEL Analysis

Political:

Political action related to fuel injection systems might involve advocating for stricter emissions
standards for cars and other vehicles, promoting the use of cleaner fuels, or supporting research
into new technologies that can further reduce emissions. This might involve lobbying elected
officials, organizing public awareness campaigns, or working with industry groups and other
stakeholders to develop and implement new policies and practices.

Economic:

The use of inline fuel injection systems can have both economic and environmental benefits for
Pakistan, but there may be challenges to their widespread adoption that need to be addressed.
Political action that promotes the use of cleaner fuels and incentivizes the adoption of fuel-
efficient technologies could help to overcome these barriers and support a more sustainable and
prosperous economy in Pakistan.

Social:

Social media can be a source of information on fuel prices, fuel efficiency, and other factors that
can affect vehicle performance. People can share their experiences with different fuel injection
systems and provide tips on how to keep them running smoothly.
Social media can also be a platform for people to discuss their experiences with mechanics and
repair shops that work on fuel injection systems. This can be helpful for those looking for
trustworthy mechanics or seeking advice on how to repair their vehicles.

Overall, social media can have a positive impact on the maintenance and performance of inline
fuel injection systems by providing people with valuable information and resources.

Technology

1. Increased fuel efficiency: Inline fuel injection systems deliver fuel more precisely and
accurately than carburetors, resulting in better fuel efficiency.

2. Improved engine performance: The precise delivery of fuel to the engine allows for
improved performance, including faster acceleration and better responsiveness.

3. Reduced emissions: Inline fuel injection systems can reduce emissions by delivering fuel
more efficiently and burning fuel more completely, resulting in fewer harmful pollutants
being released into the environment.

4. Enhanced diagnostics: Inline fuel injection systems are equipped with sensors that
monitor engine performance, allowing for easier diagnostics and maintenance.

5. Improved reliability: Inline fuel injection systems are more reliable than carburetors,
which can suffer from issues such as flooding and vapor lock.

Overall, inline fuel injection systems have had a positive impact on the automotive industry,
improving performance, efficiency, and environmental friendliness.

Environmental:

 An inline fuel injection system can be more environmentally friendly than other types of
fuel delivery systems for several reasons:

 Increased fuel efficiency

 Reduced emissions.

 Improved engine performance

  Compatibility with alternative fuels

Overall, an inline fuel injection system can help reduce the environmental impact of an
engine by improving fuel efficiency, reducing emissions, and enabling the use of
alternative fuels.

4 Marketing Plan

4.1 Product: Features, Positioning, Branding

Features:

 Fuel injectors: These are small electric valves that spray fuel directly into the engine's
intake manifold or combustion chamber in precise amounts and at precise times. The fuel
is atomized into a fine mist for efficient combustion.

 Fuel pump: An electric fuel pump delivers fuel from the tank to the injectors at the
required pressure.

 Fuel pressure regulator: This maintains the fuel pressure within the fuel injection system
to ensure consistent fuel delivery.

 Throttle body: This controls the amount of air entering the engine and is also responsible
for the positioning of the fuel injectors.

 Electronic control unit (ECU): This is the "brain" of the fuel injection system, which
receives input from various sensors and controls the fuel injectors and other components.
Positioning:

Inline fuel injection systems are typically positioned in the intake manifold or directly in the
combustion chamber of the engine. The fuel injectors are placed at precise locations to ensure
even fuel distribution and efficient combustion.

Branding:

There are several brands that manufacture inline fuel injection systems, including Bosch, Delphi,
Denso, and Siemens. These brands may have their own unique features and technologies, but
they all generally function in the same way and offer similar benefits. The branding may be
visible on the fuel injectors themselves or on the electronic control unit (ECU) that controls the
fuel injection system.

4.2 Pricing Strategy

Pricing strategy for the industry of inline fuel injection requires careful consideration of various
factors. By understanding the market, analyzing the competition, determining production costs,
setting profit margins, and choosing an appropriate pricing strategy, companies can establish a
competitive pricing strategy that meets their goals and customer needs.

4.3 Place, Distribution Channels

Ace could be a distribution channel since is one of our methods of payment. We would prefer
using our own payment channel after some months and after we have grown enough, because
Ace would also take a commission by each transfer and would make our services more
expensive.

4.4 Promotion and Customer Relationships

Promoting and managing customer relationships in the inline fuel injection system industry
requires a multi-faceted approach that includes digital marketing, promotions, customer service,
and customer feedback.
5 Operations Plan

5.1 Facilities

1. Production facility: You will need a production facility with sufficient space for
manufacturing inline fuel injection systems, including assembly lines, testing equipment,
and storage for raw materials and finished products.

2. Skilled workforce: Hiring a skilled and experienced workforce is crucial for the success
of your business. You should consider hiring engineers, technicians, assemblers, and
quality control personnel.

3. Raw materials: You will need to secure a steady supply of raw materials such as fuel
injectors, fuel rails, sensors, and electronic components.

4. Machining equipment: You will need high-quality machining equipment, such as CNC
machines, lathes, and grinders, to manufacture precision parts for your fuel injection
systems.

5. Quality control equipment: Quality control is essential in the fuel injection industry. You
will need testing equipment such as flow benches, pressure testers, and leak detectors to
ensure that your products meet industry standards.

6. Research and Development: A good R&D team is necessary for developing and
improving products. Investment in R&D equipment, software and tools is crucial to
develop advanced technology.

7. Legal compliance: You will need to comply with local and national regulations, obtain
necessary licenses and certifications, and adhere to industry standards.

8. Marketing and sales: Marketing and sales team are essential to spread the word about
your products and services, identify customers and achieve the sales targets.
5.2 Operations, Key Processes and Activities

5.1 Operations

1. Design and development: This involve creating and testing new fuel injection systems
and their components, such as fuel pumps, injectors, pressure regulators, and sensors.

2. Manufacturing: This involves producing fuel injection components and systems at scale
using advanced manufacturing techniques such as CNC machining, 3D printing, and
injection molding.

3. Assembly: This involves assembling fuel injection systems and components, which
requires precise calibration and alignment of the various parts to ensure optimal
performance.

4. Testing and calibration: This involves testing and calibrating fuel injection systems and
components to ensure they meet industry standards and perform as expected under
various operating conditions.

5. Maintenance and repair: This involve repairing or replacing faulty fuel injection
components and systems and performing regular maintenance to ensure optimal
performance and prevent breakdowns.

6. Research and development: This involve researching new technologies and materials to
improve the performance, efficiency, and reliability of fuel injection systems, as well as
developing new applications for the technology.

7. Training and education: This involve providing training and education to engineers,
technicians, and mechanics on the proper installation, maintenance, and repair of fuel
injection systems and their components.

5.3 Key Resources

1. Skilled Labor: The industry of inline fuel injection system requires skilled labor, such as
engineers, machinists, assemblers, and testers. These professionals play a crucial role in
designing, manufacturing, and testing fuel injection systems.
 2. Manufacturing Equipment: To produce high-quality fuel injection systems, the industry
requires advanced manufacturing equipment, such as CNC machines, lathes, grinders,
and injection molding machines.

3. Materials: The industry requires a variety of materials to manufacture fuel injection

systems, such as metals, plastics, and rubber. These materials must meet strict quality
standards and be sourced from reliable suppliers.

4. Research and Development: The industry must invest in research and development to
stay ahead of competitors and develop new fuel injection technologies. This may involve
developing new materials, testing new designs, and exploring new manufacturing
processes.

5. Marketing and Sales: The industry requires effective marketing and sales resources to
reach customers and promote its products. This may involve creating advertising
campaigns, attending industry trade shows, and building relationships with distributors
and retailers.

6. Supply Chain: The industry requires a reliable supply chain to ensure timely delivery of
materials, components, and finished products. This may involve working with suppliers,
logistics companies, and transportation providers to manage the flow of goods and
materials.

6 Human Resources and Entrepreneurial team

6.1 Entrepreneurial team: Competences, Abilities

 Technical Lead:

 Manufacturing and Supply Chain Lead:

 Sales and Marketing Lead:

 Financial and Business Lead

Other important skills that could be beneficial for members of the entrepreneurial team
include:
  Project Management: Someone with experience in project management could help keep
the team organized and on track.

 Design and UX/UI: A designer could help create a user-friendly interface for the fuel
injection system, which could be an important selling point for customers.

 Customer Service: Someone with experience in customer service could help ensure that
customers are satisfied with the product and address any issues that arise.

6.2 Employment Projections

For the first two years the projection for the number of employees is the following:

 One Accountant / Manager

 One Agent representative

For the long run, our company has planned to expand the amount of its employee and the size of
its market

7 Financial Plan

7.1 Hypothesis and Assumptions

We assume that the first month we will be able to promote our solution sufficiently to have 50
subscribers by the end of the month. The months to come we estimate that, in the worst scenario,
we will only increase the number of clients by 20.

 The verification fee is estimated to be around 2 clients per month the first two quarters of the
year 1 and then it will increase at a rate of 3 clients per month. Since no other competitor at the
moment is offering this service, there is no information available in the market to make
estimation, we assume a prudent amount of sales for this product.

 The projection for the number of clients that will advertise their products or businesses in our
website is 41 regular customers by the end of the first year. We estimate that this amount of
clients will be maintained in the year to come.

 We estimate that 20% of the subscriptions will become a commission for contracts through the
website.
 We estimate that for the service for Consultation about accommodation, we will not have
clients the first quarter. The next quarters we will have an increase of 2 clients per month.

Revenue

 The fees for monthly subscription, Advertising and Commission for contracts through website
were estimated accordingly to the market average. In Table 1 the estimations can be consulted.

 The verification fees is a cost based estimation.

7.2 Finance Sources

A bank loan will be necessary to cover the investment expenses and the operation expenses for
the first year. An amount of 54,020 € will be finance by Santander Bank at an annual rate of
interest of 10% in a two-year term. A monthly payment of 225 for the interest expenses is
considered for 24 months.

Conclusions

To make a business viable and grow with well-organized structure and high-oriented in the
future, the enterprise should have its own business plan. Aware of its importance, Injex Pro team
did a business plan for establishing an enterprise of providing inline fuel pump injection based
on our own research, surveys, calculation and forecast about this market sector. We recognized
that though this industry is not new, it has large potential to develop in the next coming years due
to the fact that there has an amazing increase in number of international customers who come to
inline fuel injection pump each year as well as their difficulties they may face in finding
appropriate pump with ease and cheap price. By doing surveys as well as considering the
internal, external market factors, we have drawn a picture of Pakistan’s environment with the
help of PESTEL analysis, SWOT analysis, Porter´s 5 forces model which finally lead us to the
conclusion that the renting market is still interesting for new entrant enterprise. Although they
will face some difficulties such as: the high competitiveness, existing rival companies, capital
issues, not a new idea, etc. However, Injex Pro has its own special features that are different
from others and Injex Pro can take them as the advantages to entry the markets, such as low fees
and high number of offers, also addressing a wide range of customers who need to settle in new
cities. At the same time, we made our marketing strategies based on the 4Ps model which are
price, product, place and promotion as well as the plan to exploit the resources. Last but not
least, financial plan was made to predict the profits, expenses of new established enterprise so on
and so forth and from this point clarify the abilities to expand its size and markets by assuming,
sale forecasting, etc. it seems that we would face budget shortage for the first year, hoping that
we could ask for a loan for the first year and after that making profit due to our competitive
advantage and honesty. we try to implicitly tell our customers that we really understand their
need for room, their economic situation and we are not here only to make profit, but also to make
a pleasant stay for young people in foreign cities. To sum up, Injex Pro has large potential in
developing successful operation with high profit in inline fuel injection pump and has
opportunities to expand its operation in many large cities in Pakistan such as Lahore, Islamabad.
The market outside Pakistan such as France, Italy, Sweden are also our long-term target markets.