Description
Done this project in Machhar Packaging Pvt. Ltd., Chittegaon, Aurangabad which is an EPS manufacturing company.
Marathwada Shikshan Prasarak Mandal’s
Deogiri Institute of Engineering and Management Studies, Aurangabad
A In-Plant Training Project Report at “Machhar Packaging & Services Pvt. Ltd.”
Submitted by Mr. Anupam N. Singh
Roll no. 49 MBA III Semester Batch 2011-2012
In partial fulfillment of the completion of MBA course of Dr. Babasaheb Ambedkar Marathwada University, Aurangabad
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Marathwada Shikshan Prasarak Mandal’s
Deogiri Institute of Engineering and Management Studies, Aurangabad
A In-Plant Training Project Report at “Machhar Packaging & Services Pvt. Ltd.”
Submitted by Mr. Anupam N. Singh Roll no. 49 MBA III semester Batch 2011-2013
In partial fulfillment of the completion of MBA course of Dr.Babasaheb Ambedkar Marathwada University, Aurangabad
Prof. Sujata Patil Mentor
Prof. Vaishali Raodeo HoD
Dr. Ulhas Shiurkar Director
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ACKNOWLEDGEMENT
I, Anupam Nandlal Singh, thanks to my project guide Mr. Baig, (HR); Mr Sandeep Rudre (Marketing Dept.); Mr. Rahul Kumar (PPC Dept.); Mr. G.M. Kulkarni (Dispatch Dept) of Machhar Packaging & Services Pvt. Ltd. Their expertise was invaluable during each step of the project from narrowing the scope of the research to theoretical development and analysis.
I also thank Prof. Chandrakant Phad (Guide); Prof. Sujata Patil (Mentor); Prof. Vaishali Raodeo (H.O.D) and Dr. Ulhas Shiurkar (Director), Deogiri Institute of Engineering and Management Studies, Aurangabad for encouraging and guiding me through the training project.
Mr. Anupam N. Singh Roll no. 49 MBA III Semester Batch 2011-2013
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Certificate
This is to certify that, Anupam N. Singh, a student of Deogiri Institute of Engineering & Management Studies, Aurangabad Batch 2011-2013, has duly completed his In-Plant Training Project (CP-402). And had submitted satisfactory report to Dr. Babasaheb Ambedkar Marathwada University, Aurangabad, in partial fulfillment of Master of Business Administration course. We wish all the best for him future endeavor.
Prof. Sujata Patil Mentor
Prof. Vaishali Raodeo HoD
Dr. Ulhas Shiurkar Director
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Certificate from the Company
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INDEX
Sr. no. 1. 2a. b. c. d. 3. 4. 5. 6. a. b. c. d. f. g. h. i. j. Topic Profile of the Company (Introduction, History, Structure, Founders, etc) Vision Mission Goals Objectives Product Profile Achievements of the company Research Methodology (primary/secondary data) Study of the Departments Production Operations Marketing HR Finance Quality PPC Materials Dispatch Research & Development Page no. 7 11 12
13 14 15 17 18 30 36 40 45 47 49 51 53
7. 8. 9. 10. 11.
SWOT Analysis Findings Suggestions & Recommendations Conclusion Bibliography
58 60 61 61 62
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INTRODUCTION OF IN-PLANT STUDY:
In-plant study is vocational training with more practical approach in field of management. The main purpose of In-plant training is to give practical exposure. The rationale behind doing an in-plant report creates a link between theoretical aspects of management education and practical working. The main purpose of in-plant is to orient MBA students with all the departments or section of an organization. In-plant training gives thorough grounding to an MBA student regarding the management education. It is nothing but detail information of an organization, its processes, functions, sections, departments, its past, present and future prospect in the form. In-plant training is also gives u s idea of how the theories we learn in syllabus are applied into practice. It gives us detail idea of how each and every department in the company are working, how they are interlinked and they communicate with each other to achieve the goals of the organization. For any MBA student, a learning combination of theory and practice is an invaluable asset, as it helps in understanding the core principles of business by way of first hand experiences. This In-plant training is a stepping stone, which will groom me for my future in the corporate world. The in-plant training also gives us brief idea of the organization culture, how the organization actually runs so that we will get good insight of different aspect of management. Hence the in-plant training is important in this regard.
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OBJECTIVES OF IN-PLANT TRAINING: ? To get an industrial exposure ? To be aware of the happening in a particular industry. ? To learn functioning and operation of different departments in an organization. ? To get knowledge about the working culture of the organization. ? To keep a watch on various policies been planned and implanted in an organization. ? To get deep knowledge about processing activity, product, how to maintain quality of product, manage employees, maintain and improvement financial performance, marketing and transport facilities, etc.
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SCOPE OF THE STUDY:
The scope of the study is not too broad; it only provides an overview of each department in trend electronics. Mainly the study enlightens the following points. ? The report contributes to the company to some micro aspects. ? The report will provide me information when I needed. ? Doing in-plant training in such renewed organization was such a delight experience to me and it will help me in future. ? Also the report will use as a further reference who needs information of the company.
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WHY PEPSICO
1.
? ? ? ? ? ?
PEPSICO HAS AN ENVIRONMENT WHICH IS DRIVEN BYDriven by Performance Strong Value base Empowered people Responsibility and Trust Sustained Growth Diversified Talent base
2.
CREATIVITY & AUTONOMY:
An individual's creativity is the basis for value creation. PepsiCo respects diversity and autonomy, allowing each of its employees to exercise their creativity to the full.
3.
EMPHASIS ON COMPETENCE:
Competence is the basis for performance. PepsiCo sees competence as the most important factor in its personnel decisions.
4.
EQUAL OPPORTUNITIES:
Equal opportunities build trust among people. PepsiCo ensures equal opportunities regardless of gender, race, age, religion, or nationality.
5.
LONG-TERM PERSPECTIVE:
Maintaining a long-term perspective is the foundation for PepsiCo 's HR policies. PEPSICO 's HR programs are designed with a long-term perspective and implemented with dedication and persistence.
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TRAINING:
PepsiCo offers diverse training programs to its employees according to position to encourage learning and development. We do this by equipping them with the professional capabilities and enabling them to apply the latest technologies at work. PepsiCo offers its employees a competitive, unique rewards system which motivates employees to perform better by helping them to enhance their quality of life.
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1) COMPANY PROFILE:
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INTRODUCTION
Machhar Packaging is EPS manufacturing firm located in Chittegaon, Aurangabad, India. For over 18 years company is been serving to their clients the EPS as per their requirements by providing cost-effective solutions to clients countrywide. This has enabled company to experience steady growth since a great deal of business is generated through referrals from satisfied customers. The company have developed and designed specialized mould of EPS which is needful for packaging of the goods. With 18 years of experience, company’s pleasure in introducing themselves as one of the largest processors of Expanded Polystyrene (Thermocole ) in India. The Machhar Group have two processing units out of which one is at Aurangabad in Maharashtra state “MACHHAR PACKAGING SERVICES PVT. LTD.” & the second one is at Karzan -Baroda (Gujarat) in the Name of “MACHHAR POLYMER PVT. LTD. One of the first company to get an ISO-9002 Certificate for TUV Cert.
The company’s total Group capacity is approximately 4000 MT per annum with a strength of skilled, semi-skilled & highly professional staff of 200 persons. The company has the most updated plant with 50 Fully Automatic Hydraulic Moulding Machine and almost construction of 1,50,000 Sq feet. The company have a state of the art Tool Room for specialized mould making.
Today Machhar Group has reached milestones in their operations dynamically and systematically and they have consolidated their position as manufacturers through sound
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strategic choices and leading edge technology. The company has one of its kind in house tool room facilities to develop moulds as per clients’ need.
The company has been trusted for best quality material with most competitive rate by many Ltd, Pvt. Ltd, & Multinational Companies. Few to mentioned as follows: VIDEOCON Group of companies, JCT Electronics, AIWA, Sansui, AKAI, Symphony Coolers, Wipro, Bajaj Auto, Voltas, Torrent Pharmaceuticals, Kenstar, Cadilla Pharmaceuticals, Wockdart Pharmaceuticals, Gujarat Guardian, Ge Lighting, Welspun Ltd, Phillips India Ltd, Patco Ceramics, Mudrika Ceramics. Reliance Industries, Sun Pharmaceuticals, Jindal Group.
Machhar Group was established in 1943 by late Shri. Ramnivashji Machhar. He was appointed as a Managing Director of Shri Maharaja Ummed Mills A Bangad Group Unit at Pali-Rajastan. Machhar Group grown rapidly in all these years in different business areas. Starting from Chemicals the activities diversified to Engineering, Packaging, Construction, Entertainment, Education and Transport. Thus company’s plants are scattered around Maharashtra, Gujarat, Orissa, Madhya Pradesh and Andhra Pradesh in India.
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MANAGEMENT STURCTURE:
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2 ) A)VISION:
The Company’s vision is to expand its business in EPS molded components and packaging butters for white goods, consumer durable and electronic industries. The Machhar Group also sees its future in making the products like Secure EPS molded box for Agro and Marine product. Starting from Chemicals the Company’s activities diversified to Engineering, Packaging, Construction, Entertainment, Education and Transport. By this, the company always tries to satisfy its clients’ needs by providing them durable and wit h effective quality of products.
B) MISSION:
The company’s mission is to accommodate their clients by providing high quality products and services that are tailored to meet their specific needs. In striving to ensure their success we have prided the company on not simply meeting, but exceeding client expectations. To be recognized as one of the best brands by delivering quality products at best price. To constantly innovate and develop products that add convenience, are economical and cater to the changing needs of the end users.
C) GOAL:
The company’s goal is to achieve an even more dominant and stable position in their operations. By being efficient the company is able to supply clients all over the India and their aim is to offer them competitive prices, reliable service, excellence in quality and value for
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money. To company proximity to their customers is of prime importance and also the satisfaction from the end users.
D) OBJECTIVES:
The company are endeavoured to serve the industry with full pride and honesty. Satisfying the demands of the clients, providing optimum quality and making the latest product available in the market has always been company’s prime objectives. The objective was to get out of commodities and get into the value-added space.
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4) ACHIEVEMENT OF THE COMPANY:
? With 18 years of experience, the company have pleasure in introducing themselves as one of the largest processors of Expanded Polystyrene (Thermocole) in India. ? For the first time in Gujarat, the company have introduced EPS Packing for Bone China and Ceramic Industries and today the company is doing almost 15 tones business in this area. ? The company developed packing for the transportation of heavy blades of windmills (of Suzlon & Enercon) from their manufacturing site to erection site. ? The company has developed EPS Boxes for fruits and vegetable export under the guidance of Mr. Tuse sir and Mr. Bane sir from BASF. ? The company has developed EPS packing in textile industries for the first time, where ribbon role is rolled on EPS core. ? The company has developed packing for insulin vials, which have to be transported in specific temperature.
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5) RESEARCH METHODOLOGY
There are accepted truths and theories in all fields of knowledge. The research is a systematic attempt to push back the bounds of comprehension and seek beyond the horizon of our knowledge, come truth or reality.
The Nature/ Type of the study:
The nature of study is Analytical design. The main purpose of analytical study is to use facts or information already available and analyze these to make a critical evaluation of the material so that hypothesis can be analyzed.
Sampling design:
A sample is a smaller representation of large members. Whereas, we have selected 15 respondents from employees and taken their interview as per department wise.
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The Tools and methods of Data Collection:
The sources of data collection in this research are twofold; A] Secondary data B] Primary data • Primary Data Primary data are those which are collected a fresh and for the first time and thus happen to be original. Data has been collected by interview method. • Secondary Data The data which obtained by process. Which can be collected from different origins, like Newspapers, Internet, Blog, Group Discussion, Interview, Video, Audio, Formats like previous research papered. Secondary data are those which have already been
collected by someone else and which have been already been passed through the statistical process. Where we have collected the secondary data with the use of Internet via company’s official website: http://www.utsavpolymer.com/machhar_profile.html and also the soft copies which company had provided us.
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6) STUDY OF DEPARTMENTS:
While our study, we have got the details of all the departments by their heads by personally meeting them and asking frequent questions of their respective work. The departments are as follows: 1} Productions and Operations. 2} Marketing. 3} Finance. 4} Human Resource. 5} Purchase. 6} Quality. 7} Stores and Materials. 8} R&D.
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A) PRODUCTIONS & OPERATIONS:
(Head:- Mr. Ganesh Bochre)
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The Machhar Packaging Pvt. Ltd. is an EPS manufacturing company. So, let us get familiar with what is EXPANDABLE POLYSTYRENE (EPS)? THERMOCOLE is a brand name of BASF India. Styropor is a brand name of BASF AG. The Company began with manufacture of expanded polystyrene (popularly known as Styrofoam)- a BASF AG invention. Expanded Polystyrene (EPS) is a rigid cellular plastic that is made from expandable polystyrene that contains an expansion agent. It is most commonly used for packaging foodstuffs, medical supplies, electrical consumer goods and insulation panels for building.
What's so special about EXPANDABLE POLYSTYRENE (EPS)?
Expandable Polystyrene (EPS) has many useful properties. It can be used as an insulator against heat and the cold. It is good at absorbing shocks and protecting delicate items - for example your head when used as part of a cycle crash helmet. These and other properties have led designers to specify EXPANDABLE POLYSTYRENE (EPS) as the first choice material for packaging many products and insulating buildings. EXPANDABLE POLYSTYRENE (EPS) is also odourless and non-toxic. ? Protective The outstanding shock absorbency of Expandable Polystyrene (EPS) packaging guarantees the protection of a broad range of products, from white and brown goods through to electronic components. ? Durable
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The exceptional durability of Expandable Polystyrene (EPS) means that it can effectively protect products from the factory to the home. It is abrasion resistant, yet has a relatively soft surface to protect goods against damage and dirt. ? Lightweight EXPANDABLE POLYSTYRENE (EPS) is made of 98% air, making it one of the lightest packaging materials. It adds very little to the weight of the packaging, so transport costs and fuel emissions are kept to a minimum. ? Versatile EXPANDABLE POLYSTYRENE (EPS) can be custom-shaped to protect the smallest electrical component or the largest fridge-freezer. This reduces the amount of packaging required, resulting in savings on space, distribution and damaged-goods costs. ? Insulating The thermal insulating properties of EXPANDABLE POLYSTYRENE (EPS) help keep food fresh and prevent condensation throughout the distribution chain. It is used in the fish industry for the packaging of chilled products and in the agricultural sector for seed trays and the packing of fruit and vegetables.
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? Recycled EXPANDABLE POLYSTYRENE (EPS) is being successfully and profitably recovered and recycled throughout the UK. Recycled EXPANDABLE POLYSTYRENE (EPS) is either used to make new EXPANDABLE POLYSTYRENE (EPS) insulation or packaging, or items such as replacement hardwood furniture, CD and video cases. ? Branding EXPANDABLE POLYSTYRENE (EPS) can be clearly marked with the contents or company logo, or labeling can be attached directly to the EXPANDABLE POLYSTYRENE (EPS) packaging. ? Cost Effective All these qualities add up to make EXPANDABLE POLYSTYRENE (EPS) one of the most cost effective, best value-for-money packaging materials on the market today.
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What is Expandable Polystyrene made from?
Polystyrene is extracted from oil. Thousands of small units of styrene, called monomers, link together to form large molecules of polystyrene by a process called polymerisation. The Expandable Polystyrene (EPS) production process uses a pure hydrocarbon, which does not contain any halogens and does not damage the earth's protective ozone layer, as the expansion agent.
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Manufacturing Process Of Blocks & Shape Moulding:
For the manufacture of EPS Blocks or Shapes, Expandable Polystyrene Beads are used. These beads are supplied by EPS manufacturers in different diameters, depending upon the application. EPS Beads, as such cannot be used for production of blocks or shape moulding unless pre-expanded. Hence, for the production of blocks and shapes, the following process is involved. 1. Storage of EPS Beads. 2. Pre-expansion of EPS Beads in the pre-expander. 3. Drying of expanded beads in a fluidized bed dryer. 4. Conveying and storage of beads in the storage silos, for maturation. 5. Feeding of EPS Beads either to block moulding or shape moulding machines for various shapes. 6. Cutting of EPS blocks into sheets, as per required thickness or trimming. 7. Printing (if required) packing and forwarding.
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EPS Process Flow Description And Utility Requirements:
In order to better explain the, we have attached a process flow diagram which shows the steps required for manufacturing EPS Blocks & Shape Molding. The following briefly addresses what happens during the EPS manufacturing process at each step of the process. 1. The raw material is received in 25 kgs. , 30 kgs. Bags, Octabins, Pallets, etc. 2. The raw material is blended with a lubricating powder called Zinc Stearate to improve flow properties and product release from molds. 3. Raw material is fed into a pre-expander where the material is expanded to the required density. 4. Pre-expanded material is fed into hanging bags called Silos where it is stored and used a required by the molding machines. 5. When required, material is transported to the molding machines on an “As Required” basis, where assorted packaging is made. Each machine has a mold and produces the no of moldings as per no of cavities in the mold. 6. The Automatic Shape Molding machines require electric power for controls. They also require steam, cooling water and compressed air.
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7. A minimum of two shape molding machines and one block molding machine is recommended so as achieve production economics. Furthermore the production economics improve with more machines. 8. Finished and stacked products are sealed in plastics bags and are put into cartons. Product packaging is done manually since the cost of labor is low. 9. The packaged cartons are then stored in the warehouse for shipment.
*Streaming Process*
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The utilities requirement is shown below:
Steam - approximately a boiler generating minimum 1000 kgs./hr at minimum 8 Kgs. pressure. The capacity of the boiler depends on the installed machinery & capacity of the plant. Compressed Air (Dry & Clean) – Minimum 100 cfm 100 psi. pressure. The capacity of the Compressor depends on the installed machinery & capacity of the plant. Cooling Water – Approximately 10,000 Liters per day. The water in the system is recycled using an evaporative type water-cooling unit and heat exchanger system. The quantity of water depends on the installed machinery & capacity of the plant. Electrical Power – Approx. 60 H.P. The usage by the pre-expander, screener, steam boiler, air compressor, cooling water system, etc. can only be determined once the quantity of molding machines has been established as well as the sizes of molding to be manufactured. Uninterrupted electrical power is required while the pre-expander is operating.
Raw Material- The major raw material required is EPS granules is adequately available in the
local market from the following: 1) BASF 3003 2) LG Polymers 522
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3) Supreme 250
Labour Requirements – One operator is required for every two molding machines. To supervise these operators one supervisor is sufficient. Besides the molding plant Operators are required for the Boiler Plant and the Compressor. Space Requirements – The size of the building required will vary with the number of molding machines. One molding machine requires approximately 1.5 m x 1.5 m (5 ft. x 5 ft.) of floor space. A typical 3-machine operation including steam generation, compressed air systems, water circulating, pumping and cooling systems together with space for raw material and product storage would be approximately 5,000 square feet. The clear ceiling height required for a typical 3-machine operation would be approximately 18-19 feet.
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Flow Diagram of EPS Processing Process.
EPS Beads in 25 kg. Bags or Octabins
Pre-expansion of EPS Material at desired density
Maturation and drying of pre-expanded material in silos
Injection by filling guns of material in mold
Manual feeding in block mold
Further expansion of material and fusion in mold material and mounted on molding machine
Further expansion of mold
fusion in block
Drying of EPS molded packing
Drying of EPS Block
Packing of dried packings in plastic rolls.
Hotwire cutting for sheets or hand fabrication.
Storage in warehouse ready for dispatch.
Storage in warehouse ready for dispatch.
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*A typical SILO Machine*
*EPS Moulding Machine*
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*The Finished Goods (EPS)*
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B} MARKETING:
(Head:- Mr. Sandeep Rudre)
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The Marketing Department is essential part of the company which helps to grow, expand and enhance the business of the company. As Machhar Packaging Pvt. Ltd. is the major vendor of Videocon and fulfills the 80% of requirement of them. The company does the business-to-business (B2B) type of marketing to expand the business in other packaging sectors.
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Business-to-business marketing is the practice of individuals, or organizations, including commercial businesses, governments and institutions, facilitating the sale of their products or services to other companies or organizations that in turn resell them, use them as components in products or services they offer, or use them to support their operations. Also known as industrial marketing, business marketing is also called B2B marketing
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The Marketing Department also takes effort in generating new product development as per demand by their client. And also company’s focuses on grow the productivity of it which will be profitable for the company.
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The new product development is done by achieving the following methods and technology: A) Neopor (Black) B) E-Por C) Periphor D) Geofoam
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A} Neopor - Innovation in Insulation
Neopor EPS foam is an innovative product from BASF® that offers a higher insulating capacity while useing less material. It is composed of small black beads of polystyrene (EPS). These black beads get expanded then formed into shapes or blocks. the formed products are a silvergrey in color and provide up to 20% better insulation performance than conventional EPS.
Up to 20% better performance with the same board thickness
The vital difference can be seen with the naked eye in the silver-grey color. In Neopor, graphite is added to the material, absorbing and reflecting heat radiation and improving the insulating performance of EPS by up to 20%.
Building with Neopor
Neopor can be used for virtually any application where you would use Styrobar whether it's roof, ceiling, or wall insulation. For new construction or the renovation of an existing building Neopor offers ideal insulation solutions for almost all components.
B} E-Por.
60 years after the invention of Styropor and 30 years after the invention of viscoelastic foams, a fundamental advancement has now been obtained in the form of E-por.
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The new approach: The scientists at BASF no longer treat foams as static mixtures of a (co-) polymer and a blowing agent. They rather developed E-por as a complex formulation comprising several ingredients that interact with each other as well as with the blowing agent.
E-por Sets New Standards At All Levels of the Value Chain Processing:
? ? ?
- Low steam requirement during processing - Foam densities of 21 g/L in the first foaming step - No conversion of EPS plants required
Properties:
? ? ?
- Elastic, crack-resistant, multishock-proof - Perfect sealing of the surface - Appealing haptical and optical properties of the moldings
Sustainability:
? ? ?
- Storage and transportation at room temperature - Low blowing agent content - Recycling and degassing at EPS plants.
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C} Periphor:
Uses? ? ? Ceiling Water resistance Temperature absorption
D} Geofoam:
? EPS Geofoam is a lightweight, rigid foam plastic that is used as a fill material in construction projects where the existing soft or loose soil is incapable of supporting increased loads.
EPS Geofoam is a lightweight fill that gives you control over your geotechnical project. Traditional earth materials are heavy and can cause settlement, instability or lateral pressures. Other lightweight fill materials such as foamed concrete, waste tires, soil, woodchips, wood fiber, etc., have higher densities, are variable in their makeup and are not engineered, due to field execution variables.
They also have limitations in handling and can be weather sensitive, thus requiring staged construction and/or preloading, surcharging and draining, etc. Foam-Control EPS Geofoam is among the most versatile lightweight materials available. EPS Geofoam maximizes onsite
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installation efficiency. EPS Geofoam can arrive at the job site prefabricated and ready to place. It is easily inventoried and handled. Installation is not delayed by weather.
*Geofoam*
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C} HUMAN RESOURCE:
(Head:- Mr. Baig)
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Human resources is the set of individuals who make up the workforce of an organization, business sector or an economy. "Human capital" is sometimes used synonymously with human resources, although human capital typically refers to a more narrow view; i.e., the knowledge the individuals embody and can contribute to an organization. Likewise, other terms sometimes used include "manpower", "talent", "labor" or simply "people".
The professional discipline and business function that oversees an organization's human resources is called human resource management (HRM, or simply HR).
Basically, in the company Security and Administration Departments come under the HR Manager.
? HRM Functions:
1. Performance Appraisal 2. Potential Appraisal 3. Career Planning 4. Training and Employee Development 5. Organization Development 6. Rewards 7. Employee Welfare and Quality of Work Life
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8. Human Resource Information
After interviewing with Mr. Baig sir, we discussed the overall facilities given to the workers and employees by the company. We also discussed the workings of all the departments working in the company and how they are interrelated with HR Department. The points discussed are as follows: ? Total number of employees 230 to 250. In which, 70 staff members are permanent and rests of the workers are on contract basis. ? ? ? Salary: Permanent 12,000 to 15,000 (as per the seniority and their designation). Wages: As per government rules according to a) Skilled b) semi-skilled c) unskilled. Bonus and Incentives: General bonus given on Diwali according to the profit of the company of the past year. And incentives are being given according to the performance of the employee or worker. ? Recruitment: According to qualification and experience of the candidate first priority is given. ? Facilities: Insurance, Company Uniform, Transport, Canteen, Shoes and Socks, Loans (Festival Advance up to Rs. 10,000). Half hour lunch or dinner break. ? ? ? Labour Law: Implemented as per rules of Government of India. Union: Internal and External Union. Appraisal, Increment: To reward the performance is checked for example, attendance, behavior and work of employee etc. The 3 months or 6 months appraisal is been given. ? Policy: Policy are implemented after discussion of the HR Manager with Director.
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Shift timing: 7 AM to 3 PM (Ist Shift), 3 PM to 11 PM (IInd Shift), 11 PM to 7 AM (IIIrd Shift), 9 AM to 5:30 (General Shift only for staff).
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Holidays: Friday week-off, Privilege Leaves (PL) 30 days, Casual Leaves (CL) 6 days, Paid leaves 8 annually.
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Employee empowerment: Suggestion and recommendation are taken by workers and employees. Involvement in meetings, ideas are taken into consideration also of low level employees.
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Employee safety: Safety measures are taken by the company by providing Mask, goggle, gloves, helmets etc.
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Employee cut-off: In case of misbehavior, irregularity, frequent absenteeism, disturbing the work flow by any employee or worker firstly warning or memo is been given by the company and if there is no positive changes in employee then finally strict measures are been taken against that employee or worker.
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D} FINANCIAL MANAGEMENT:
(Head:- Mr. R.A. Mundara)
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Financial Management means planning, organizing, directing and controlling the financial activities such as procurement and utilization of funds of the enterprise. It means applying general management principles to financial resources of the enterprise.
Scope/Elements
1. Investment decisions includes investment in fixed assets (called as capital budgeting). Investment in current assets are also a part of investment decisions called as working capital decisions. 2. Financial decisions - They relate to the raising of finance from various resources which will depend upon decision on type of source, period of financing, cost of financing and the returns thereby.
Objectives of Financial Management The financial management is generally concerned with procurement, allocation and control of financial resources of a concern. The objectives can be-
1. To ensure regular and adequate supply of funds to the concern. 2. To ensure adequate returns to the shareholders which will depend upon the earning capacity, market price of the share, expectations of the shareholders. 3. To ensure optimum funds utilization. Once the funds are procured, they should be utilized in maximum possible way at least cost. 4. To ensure safety on investment, i.e, funds should be invested in safe ventures so that adequate rate of return can be achieved.
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5. To plan a sound capital structure-There should be sound and fair composition of capital so that a balance is maintained between debt and equity capital.
Functions of Financial Management
1. Estimation of capital requirements: A finance manager has to make estimation with regards to capital requirements of the company. This will depend upon expected costs and profits and future programmes and policies of a concern. Estimations have to be made in an adequate manner which increases earning capacity of enterprise. 2. Determination of capital composition: Once the estimation have been made, the capital structure have to be decided. This involves short- term and long- term debt equity analysis. This will depend upon the proportion of equity capital a company is possessing and additional funds which have to be raised from outside parties. 3. Choice of sources of funds: For additional funds to be procured, a company has many choices likea. Issue of shares and debentures b. Loans to be taken from banks and financial institutions c. Public deposits to be drawn like in form of bonds.
Choice of factor will depend on relative merits and demerits of each source and period of financing.
4. Investment of funds: The finance manager has to decide to allocate funds into profitable ventures so that there is safety on investment and regular returns is possible.
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5. Disposal of surplus: The net profits decision have to be made by the finance manager. This can be done in two ways: a. Dividend declaration - It includes identifying the rate of dividends and other benefits like bonus. b. Retained profits - The volume has to be decided which will depend upon expansional, innovational, diversification plans of the company. 6. Management of cash: Finance manager has to make decisions with regards to cash management. Cash is required for many purposes like payment of wages and salaries, payment of electricity and water bills, payment to creditors, meeting current liabilities, maintainance of enough stock, purchase of raw materials, etc. 7. Financial controls: The finance manager has not only to plan, procure and utilize the funds but he also has to exercise control over finances. This can be done through many techniques like ratio analysis, financial forecasting, cost and profit control, etc.
In Machhar Packaging; ? ? Indirect cost: 10% to 15%. Sales hike: Sales hike is been observed in festive season so that more capital is been required and the production is increased. To increase production, efforts are taken to do extreme marketing and special efforts are been taken by Finance Department to increase the marketing level. ? Efforts are taken to reduce the unwanted cost by various methods.
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E} QUALITY DEPARTMENT
(Head:- Mr. A.B. Mangoli )
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Machhar Packaging is able to maintain its market credentials due to their uncompromising adherence to quality policy. The professionals make sure that the products are at par with international standards and meet the requirements of the clients. Initiating from procurement process till final delivery, company’s quality controllers maintain a stringent approach at all levels. Thats why Machhar Packaging are an ISO 9002 Certified Company. The company’s quality controllers make sure that business operations adhere to the quality policy underlying the following important points:
? ? ? ?
Using best raw material, latest technology & processes. Developing products of consistent high quality Serving customers better every time and continuing to be the best Being eco-friendly and conserving energy.
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F} PRODUCTION PLANNING & CONTROL DEPARTMENT:-
(Head:- Mr. Rahul Kumar)
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?
The orders by clients are been taken by using electronic mail. The clients such as Videocon, Bajaj etc.
?
The following steps are been involved in it: 1. Taken purchase order by client. 2. Plan gathering. 3. Data collecting. 4. According to demand from clients planning of raw material is made. 5. Production planning is made. 6. Production. (Formation of finished goods i.e. EPS) 7. Packaging as per requirement (Production depend on quantity) 8. Dispatch. (One day before dispatch method is been used i.e D-1 method)
?
Useful application used in the company are: A) Tally B) MS-Excel C) Outlook for mailing purpose.
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G} MATERIALS & STORES DEPARTMENT:
(MR. Naikwade)
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?
The materials department is handled by Production Department itself. And the main thing here in this department is to manage the raw material and its stock.
? As it is the EPS manufacturing company so it requires polymer for manufacturing EPS as
per requirement of clients. Polystyrene is an Aromatic Polymer made from monomer styrene (a liquid hydrocarbon that is manufactured by petroleum by chemical industry. ? The raw materials basically used i.e. BASF 3003, LG 522 and Supreme 250 these are the types of polymer which are used for manufacturing different types of EPS required by the clients. ? Location to get the raw materials are Visakhapatnam, Delhi, Mumbai, Chennai.
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H} DISPATCH DEPARTMENT (MR. G.M. Kulkarni)
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Dispatching of Goods
Dispatch
Finished Goods (Godown).)
Logistics
? ? ?
Dispatch- 2 employees Godown- 3 employees Logistic- 1 employee
? 6.5 tons daily dispatching of EPS ? JIT Technique is used. ? Daily reporting to the General Manager Mr. Tapadiya. The step-by-step methods involve in dispatching the finished goods: Design of Mold Sample Mold Approval Final Planning Purchase Order Planning using codes and applying on machine
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I} RESEARCH & DEVELOPMENT:
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The term R&D or research and development refers to a specific group of activities within a business. The activities that are classified as R&D differ from company to company, but there are two primary models. In one model, the primary function of an R&D group is to develop new products; in the other model, the primary function of an R&D group is to discover and create new knowledge about scientific and technological topics for the purpose of uncovering and enabling development of valuable new products, processes, and services. Under both models, R&D differs from the vast majority of a company's activities which are intended to yield nearly immediate profit or immediate improvements in operations and involve little uncertainty as to the return on investment (ROI). The company is taking more and more efforts in R&D Department to grow their business in sectors as follows: ? The new product development is done by achieving the following methods and technology: A) Neopor (Black) B) E-Por C) Periphor D) Geofoam
A} Neopor - Innovation in Insulation
Neopor EPS foam is an innovative product from BASF® that offers a higher insulating capacity while useing less material. It is composed of small black beads of polystyrene (EPS). These
59
black beads get expanded then formed into shapes or blocks. the formed products are a silvergrey in color and provide up to 20% better insulation performance than conventional EPS.
Up to 20% better performance with the same board thickness
The vital difference can be seen with the naked eye in the silver-grey color. In Neopor, graphite is added to the material, absorbing and reflecting heat radiation and improving the insulating performance of EPS by up to 20%.
Building with Neopor
Neopor can be used for virtually any application where you would use Styrobar whether it's roof, ceiling, or wall insulation. For new construction or the renovation of an existing building Neopor offers ideal insulation solutions for almost all components.
B} E-Por.
60 years after the invention of Styropor and 30 years after the invention of viscoelastic foams, a fundamental advancement has now been obtained in the form of E-por.
The new approach: The scientists at BASF no longer treat foams as static mixtures of a (co-) polymer and a blowing agent. They rather developed E-por as a complex formulation comprising several ingredients that interact with each other as well as with the blowing agent.
E-por Sets New Standards At All Levels of the Value Chain Processing:
?
- Low steam requirement during processing
60
? ?
- Foam densities of 21 g/L in the first foaming step - No conversion of EPS plants required
Properties:
? ? ?
- Elastic, crack-resistant, multishock-proof - Perfect sealing of the surface - Appealing haptical and optical properties of the moldings
Sustainability:
? ? ?
- Storage and transportation at room temperature - Low blowing agent content - Recycling and degassing at EPS plants.
C} Periphor:
Uses? ? ? Ceiling Water resistance Temperature absorption
D} Geofoam:
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?
EPS Geofoam is a lightweight, rigid foam plastic that is used as a fill material in construction projects where the existing soft or loose soil is incapable of supporting increased loads.
EPS Geofoam is a lightweight fill that gives you control over your geotechnical project. Traditional earth materials are heavy and can cause settlement, instability or lateral pressures. Other lightweight fill materials such as foamed concrete, waste tires, soil, woodchips, wood fiber, etc., have higher densities, are variable in their makeup and are not engineered, due to field execution variables.
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7) SWOT ANALYSIS:
Strength:? ? ? ? ? ? ? ? ? Second largest EPS manufacturing company in India. No localized competitor. Excellent quality as compared to other EPS manufacturing company. Experienced staff available 27/7. Daily reporting to seniors. Conducting meeting every week to take effective decisions to increase profit level. Total satisfaction of clients. Positive aspect on every decision making. Good relations between company and raw material providers.
Weakness:? ? Majority of workers are on contractual basis. Maintenance of machines at regular intervals.
Opportunities:? ? Improvement in R&D department can enhance the profitability. Scope in future i.e. the uses of EPS in various sectors will be increased.
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?
Extreme B2B marketing can help to manufacture various types of EPS products will be helpful for making new clients.
?
New product development as per requirement as we are observing growth in industrial sector in Aurangabad.
Threats:? ? ? Increase in fuel cost, which leads to increase the transportation cost. The company is majorly dependent on one company i.e. 80% on Videocon. No awareness between people of uses of EPS products in different-different field.
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8) FINDINGS:
? In Machhar Packaging, we observed that satisfaction of clients is the basic priority given by the company and all that efforts are been taken to improve the quality of EPS products. ? In Machhar Packaging, JIT method is been implemented so that it avoids the wastage of raw material, it saves time and effort of employees. ? In Machhar Packaging, we observed that waste management is done by doing proper recycling of the damaged EPS products instead of throwing them. ? In Machhar Packaging, we also observed that Agro base fuel efficient Boiler, electropneumatic steam flow control system is been used that is eco friendly. Whereas smoke is less harmful for the environment. ? Security is also given priority as not one can be entered or leave without permission of Head of the Department.
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9) SUGGETION AND RECCOMANDATIONS:
? Enhancing of R&D department is to be done so that it can increase the profitability level of the company by making new-new products of EPS. ? If there is an improvement in B2B marketing initiative so that it can make more and more clients in future. So, extreme level of marketing should be done is various sectors.
10) CONCLUSION:
We conclude that, Machhar Packaging is the popular and only EPS manufacturing company in Aurangabad. As compared to other similar EPS manufacturing companies, Machhar Packaging provides a good quality EPS products to their clients as per there requirements. The feedback given by company’s clients is always good and they are happy with the work and services provided by Machhar Packaging.
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11) BIBLIOGRAPHY:
www.utsavpolymer.com/ www.bseindia.com/bseplus/AnnualReport/506979/5069790311.pdf www.google.co.in
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68
doc_726240266.docx
Done this project in Machhar Packaging Pvt. Ltd., Chittegaon, Aurangabad which is an EPS manufacturing company.
Marathwada Shikshan Prasarak Mandal’s
Deogiri Institute of Engineering and Management Studies, Aurangabad
A In-Plant Training Project Report at “Machhar Packaging & Services Pvt. Ltd.”
Submitted by Mr. Anupam N. Singh
Roll no. 49 MBA III Semester Batch 2011-2012
In partial fulfillment of the completion of MBA course of Dr. Babasaheb Ambedkar Marathwada University, Aurangabad
1
Marathwada Shikshan Prasarak Mandal’s
Deogiri Institute of Engineering and Management Studies, Aurangabad
A In-Plant Training Project Report at “Machhar Packaging & Services Pvt. Ltd.”
Submitted by Mr. Anupam N. Singh Roll no. 49 MBA III semester Batch 2011-2013
In partial fulfillment of the completion of MBA course of Dr.Babasaheb Ambedkar Marathwada University, Aurangabad
Prof. Sujata Patil Mentor
Prof. Vaishali Raodeo HoD
Dr. Ulhas Shiurkar Director
2
ACKNOWLEDGEMENT
I, Anupam Nandlal Singh, thanks to my project guide Mr. Baig, (HR); Mr Sandeep Rudre (Marketing Dept.); Mr. Rahul Kumar (PPC Dept.); Mr. G.M. Kulkarni (Dispatch Dept) of Machhar Packaging & Services Pvt. Ltd. Their expertise was invaluable during each step of the project from narrowing the scope of the research to theoretical development and analysis.
I also thank Prof. Chandrakant Phad (Guide); Prof. Sujata Patil (Mentor); Prof. Vaishali Raodeo (H.O.D) and Dr. Ulhas Shiurkar (Director), Deogiri Institute of Engineering and Management Studies, Aurangabad for encouraging and guiding me through the training project.
Mr. Anupam N. Singh Roll no. 49 MBA III Semester Batch 2011-2013
3
Certificate
This is to certify that, Anupam N. Singh, a student of Deogiri Institute of Engineering & Management Studies, Aurangabad Batch 2011-2013, has duly completed his In-Plant Training Project (CP-402). And had submitted satisfactory report to Dr. Babasaheb Ambedkar Marathwada University, Aurangabad, in partial fulfillment of Master of Business Administration course. We wish all the best for him future endeavor.
Prof. Sujata Patil Mentor
Prof. Vaishali Raodeo HoD
Dr. Ulhas Shiurkar Director
4
Certificate from the Company
5
INDEX
Sr. no. 1. 2a. b. c. d. 3. 4. 5. 6. a. b. c. d. f. g. h. i. j. Topic Profile of the Company (Introduction, History, Structure, Founders, etc) Vision Mission Goals Objectives Product Profile Achievements of the company Research Methodology (primary/secondary data) Study of the Departments Production Operations Marketing HR Finance Quality PPC Materials Dispatch Research & Development Page no. 7 11 12
13 14 15 17 18 30 36 40 45 47 49 51 53
7. 8. 9. 10. 11.
SWOT Analysis Findings Suggestions & Recommendations Conclusion Bibliography
58 60 61 61 62
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INTRODUCTION OF IN-PLANT STUDY:
In-plant study is vocational training with more practical approach in field of management. The main purpose of In-plant training is to give practical exposure. The rationale behind doing an in-plant report creates a link between theoretical aspects of management education and practical working. The main purpose of in-plant is to orient MBA students with all the departments or section of an organization. In-plant training gives thorough grounding to an MBA student regarding the management education. It is nothing but detail information of an organization, its processes, functions, sections, departments, its past, present and future prospect in the form. In-plant training is also gives u s idea of how the theories we learn in syllabus are applied into practice. It gives us detail idea of how each and every department in the company are working, how they are interlinked and they communicate with each other to achieve the goals of the organization. For any MBA student, a learning combination of theory and practice is an invaluable asset, as it helps in understanding the core principles of business by way of first hand experiences. This In-plant training is a stepping stone, which will groom me for my future in the corporate world. The in-plant training also gives us brief idea of the organization culture, how the organization actually runs so that we will get good insight of different aspect of management. Hence the in-plant training is important in this regard.
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OBJECTIVES OF IN-PLANT TRAINING: ? To get an industrial exposure ? To be aware of the happening in a particular industry. ? To learn functioning and operation of different departments in an organization. ? To get knowledge about the working culture of the organization. ? To keep a watch on various policies been planned and implanted in an organization. ? To get deep knowledge about processing activity, product, how to maintain quality of product, manage employees, maintain and improvement financial performance, marketing and transport facilities, etc.
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SCOPE OF THE STUDY:
The scope of the study is not too broad; it only provides an overview of each department in trend electronics. Mainly the study enlightens the following points. ? The report contributes to the company to some micro aspects. ? The report will provide me information when I needed. ? Doing in-plant training in such renewed organization was such a delight experience to me and it will help me in future. ? Also the report will use as a further reference who needs information of the company.
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WHY PEPSICO
1.
? ? ? ? ? ?
PEPSICO HAS AN ENVIRONMENT WHICH IS DRIVEN BYDriven by Performance Strong Value base Empowered people Responsibility and Trust Sustained Growth Diversified Talent base
2.
CREATIVITY & AUTONOMY:
An individual's creativity is the basis for value creation. PepsiCo respects diversity and autonomy, allowing each of its employees to exercise their creativity to the full.
3.
EMPHASIS ON COMPETENCE:
Competence is the basis for performance. PepsiCo sees competence as the most important factor in its personnel decisions.
4.
EQUAL OPPORTUNITIES:
Equal opportunities build trust among people. PepsiCo ensures equal opportunities regardless of gender, race, age, religion, or nationality.
5.
LONG-TERM PERSPECTIVE:
Maintaining a long-term perspective is the foundation for PepsiCo 's HR policies. PEPSICO 's HR programs are designed with a long-term perspective and implemented with dedication and persistence.
6.
TRAINING:
PepsiCo offers diverse training programs to its employees according to position to encourage learning and development. We do this by equipping them with the professional capabilities and enabling them to apply the latest technologies at work. PepsiCo offers its employees a competitive, unique rewards system which motivates employees to perform better by helping them to enhance their quality of life.
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1) COMPANY PROFILE:
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INTRODUCTION
Machhar Packaging is EPS manufacturing firm located in Chittegaon, Aurangabad, India. For over 18 years company is been serving to their clients the EPS as per their requirements by providing cost-effective solutions to clients countrywide. This has enabled company to experience steady growth since a great deal of business is generated through referrals from satisfied customers. The company have developed and designed specialized mould of EPS which is needful for packaging of the goods. With 18 years of experience, company’s pleasure in introducing themselves as one of the largest processors of Expanded Polystyrene (Thermocole ) in India. The Machhar Group have two processing units out of which one is at Aurangabad in Maharashtra state “MACHHAR PACKAGING SERVICES PVT. LTD.” & the second one is at Karzan -Baroda (Gujarat) in the Name of “MACHHAR POLYMER PVT. LTD. One of the first company to get an ISO-9002 Certificate for TUV Cert.
The company’s total Group capacity is approximately 4000 MT per annum with a strength of skilled, semi-skilled & highly professional staff of 200 persons. The company has the most updated plant with 50 Fully Automatic Hydraulic Moulding Machine and almost construction of 1,50,000 Sq feet. The company have a state of the art Tool Room for specialized mould making.
Today Machhar Group has reached milestones in their operations dynamically and systematically and they have consolidated their position as manufacturers through sound
12
strategic choices and leading edge technology. The company has one of its kind in house tool room facilities to develop moulds as per clients’ need.
The company has been trusted for best quality material with most competitive rate by many Ltd, Pvt. Ltd, & Multinational Companies. Few to mentioned as follows: VIDEOCON Group of companies, JCT Electronics, AIWA, Sansui, AKAI, Symphony Coolers, Wipro, Bajaj Auto, Voltas, Torrent Pharmaceuticals, Kenstar, Cadilla Pharmaceuticals, Wockdart Pharmaceuticals, Gujarat Guardian, Ge Lighting, Welspun Ltd, Phillips India Ltd, Patco Ceramics, Mudrika Ceramics. Reliance Industries, Sun Pharmaceuticals, Jindal Group.
Machhar Group was established in 1943 by late Shri. Ramnivashji Machhar. He was appointed as a Managing Director of Shri Maharaja Ummed Mills A Bangad Group Unit at Pali-Rajastan. Machhar Group grown rapidly in all these years in different business areas. Starting from Chemicals the activities diversified to Engineering, Packaging, Construction, Entertainment, Education and Transport. Thus company’s plants are scattered around Maharashtra, Gujarat, Orissa, Madhya Pradesh and Andhra Pradesh in India.
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MANAGEMENT STURCTURE:
14
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2 ) A)VISION:
The Company’s vision is to expand its business in EPS molded components and packaging butters for white goods, consumer durable and electronic industries. The Machhar Group also sees its future in making the products like Secure EPS molded box for Agro and Marine product. Starting from Chemicals the Company’s activities diversified to Engineering, Packaging, Construction, Entertainment, Education and Transport. By this, the company always tries to satisfy its clients’ needs by providing them durable and wit h effective quality of products.
B) MISSION:
The company’s mission is to accommodate their clients by providing high quality products and services that are tailored to meet their specific needs. In striving to ensure their success we have prided the company on not simply meeting, but exceeding client expectations. To be recognized as one of the best brands by delivering quality products at best price. To constantly innovate and develop products that add convenience, are economical and cater to the changing needs of the end users.
C) GOAL:
The company’s goal is to achieve an even more dominant and stable position in their operations. By being efficient the company is able to supply clients all over the India and their aim is to offer them competitive prices, reliable service, excellence in quality and value for
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money. To company proximity to their customers is of prime importance and also the satisfaction from the end users.
D) OBJECTIVES:
The company are endeavoured to serve the industry with full pride and honesty. Satisfying the demands of the clients, providing optimum quality and making the latest product available in the market has always been company’s prime objectives. The objective was to get out of commodities and get into the value-added space.
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4) ACHIEVEMENT OF THE COMPANY:
? With 18 years of experience, the company have pleasure in introducing themselves as one of the largest processors of Expanded Polystyrene (Thermocole) in India. ? For the first time in Gujarat, the company have introduced EPS Packing for Bone China and Ceramic Industries and today the company is doing almost 15 tones business in this area. ? The company developed packing for the transportation of heavy blades of windmills (of Suzlon & Enercon) from their manufacturing site to erection site. ? The company has developed EPS Boxes for fruits and vegetable export under the guidance of Mr. Tuse sir and Mr. Bane sir from BASF. ? The company has developed EPS packing in textile industries for the first time, where ribbon role is rolled on EPS core. ? The company has developed packing for insulin vials, which have to be transported in specific temperature.
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5) RESEARCH METHODOLOGY
There are accepted truths and theories in all fields of knowledge. The research is a systematic attempt to push back the bounds of comprehension and seek beyond the horizon of our knowledge, come truth or reality.
The Nature/ Type of the study:
The nature of study is Analytical design. The main purpose of analytical study is to use facts or information already available and analyze these to make a critical evaluation of the material so that hypothesis can be analyzed.
Sampling design:
A sample is a smaller representation of large members. Whereas, we have selected 15 respondents from employees and taken their interview as per department wise.
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The Tools and methods of Data Collection:
The sources of data collection in this research are twofold; A] Secondary data B] Primary data • Primary Data Primary data are those which are collected a fresh and for the first time and thus happen to be original. Data has been collected by interview method. • Secondary Data The data which obtained by process. Which can be collected from different origins, like Newspapers, Internet, Blog, Group Discussion, Interview, Video, Audio, Formats like previous research papered. Secondary data are those which have already been
collected by someone else and which have been already been passed through the statistical process. Where we have collected the secondary data with the use of Internet via company’s official website: http://www.utsavpolymer.com/machhar_profile.html and also the soft copies which company had provided us.
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6) STUDY OF DEPARTMENTS:
While our study, we have got the details of all the departments by their heads by personally meeting them and asking frequent questions of their respective work. The departments are as follows: 1} Productions and Operations. 2} Marketing. 3} Finance. 4} Human Resource. 5} Purchase. 6} Quality. 7} Stores and Materials. 8} R&D.
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A) PRODUCTIONS & OPERATIONS:
(Head:- Mr. Ganesh Bochre)
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The Machhar Packaging Pvt. Ltd. is an EPS manufacturing company. So, let us get familiar with what is EXPANDABLE POLYSTYRENE (EPS)? THERMOCOLE is a brand name of BASF India. Styropor is a brand name of BASF AG. The Company began with manufacture of expanded polystyrene (popularly known as Styrofoam)- a BASF AG invention. Expanded Polystyrene (EPS) is a rigid cellular plastic that is made from expandable polystyrene that contains an expansion agent. It is most commonly used for packaging foodstuffs, medical supplies, electrical consumer goods and insulation panels for building.
What's so special about EXPANDABLE POLYSTYRENE (EPS)?
Expandable Polystyrene (EPS) has many useful properties. It can be used as an insulator against heat and the cold. It is good at absorbing shocks and protecting delicate items - for example your head when used as part of a cycle crash helmet. These and other properties have led designers to specify EXPANDABLE POLYSTYRENE (EPS) as the first choice material for packaging many products and insulating buildings. EXPANDABLE POLYSTYRENE (EPS) is also odourless and non-toxic. ? Protective The outstanding shock absorbency of Expandable Polystyrene (EPS) packaging guarantees the protection of a broad range of products, from white and brown goods through to electronic components. ? Durable
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The exceptional durability of Expandable Polystyrene (EPS) means that it can effectively protect products from the factory to the home. It is abrasion resistant, yet has a relatively soft surface to protect goods against damage and dirt. ? Lightweight EXPANDABLE POLYSTYRENE (EPS) is made of 98% air, making it one of the lightest packaging materials. It adds very little to the weight of the packaging, so transport costs and fuel emissions are kept to a minimum. ? Versatile EXPANDABLE POLYSTYRENE (EPS) can be custom-shaped to protect the smallest electrical component or the largest fridge-freezer. This reduces the amount of packaging required, resulting in savings on space, distribution and damaged-goods costs. ? Insulating The thermal insulating properties of EXPANDABLE POLYSTYRENE (EPS) help keep food fresh and prevent condensation throughout the distribution chain. It is used in the fish industry for the packaging of chilled products and in the agricultural sector for seed trays and the packing of fruit and vegetables.
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? Recycled EXPANDABLE POLYSTYRENE (EPS) is being successfully and profitably recovered and recycled throughout the UK. Recycled EXPANDABLE POLYSTYRENE (EPS) is either used to make new EXPANDABLE POLYSTYRENE (EPS) insulation or packaging, or items such as replacement hardwood furniture, CD and video cases. ? Branding EXPANDABLE POLYSTYRENE (EPS) can be clearly marked with the contents or company logo, or labeling can be attached directly to the EXPANDABLE POLYSTYRENE (EPS) packaging. ? Cost Effective All these qualities add up to make EXPANDABLE POLYSTYRENE (EPS) one of the most cost effective, best value-for-money packaging materials on the market today.
?
What is Expandable Polystyrene made from?
Polystyrene is extracted from oil. Thousands of small units of styrene, called monomers, link together to form large molecules of polystyrene by a process called polymerisation. The Expandable Polystyrene (EPS) production process uses a pure hydrocarbon, which does not contain any halogens and does not damage the earth's protective ozone layer, as the expansion agent.
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Manufacturing Process Of Blocks & Shape Moulding:
For the manufacture of EPS Blocks or Shapes, Expandable Polystyrene Beads are used. These beads are supplied by EPS manufacturers in different diameters, depending upon the application. EPS Beads, as such cannot be used for production of blocks or shape moulding unless pre-expanded. Hence, for the production of blocks and shapes, the following process is involved. 1. Storage of EPS Beads. 2. Pre-expansion of EPS Beads in the pre-expander. 3. Drying of expanded beads in a fluidized bed dryer. 4. Conveying and storage of beads in the storage silos, for maturation. 5. Feeding of EPS Beads either to block moulding or shape moulding machines for various shapes. 6. Cutting of EPS blocks into sheets, as per required thickness or trimming. 7. Printing (if required) packing and forwarding.
27
EPS Process Flow Description And Utility Requirements:
In order to better explain the, we have attached a process flow diagram which shows the steps required for manufacturing EPS Blocks & Shape Molding. The following briefly addresses what happens during the EPS manufacturing process at each step of the process. 1. The raw material is received in 25 kgs. , 30 kgs. Bags, Octabins, Pallets, etc. 2. The raw material is blended with a lubricating powder called Zinc Stearate to improve flow properties and product release from molds. 3. Raw material is fed into a pre-expander where the material is expanded to the required density. 4. Pre-expanded material is fed into hanging bags called Silos where it is stored and used a required by the molding machines. 5. When required, material is transported to the molding machines on an “As Required” basis, where assorted packaging is made. Each machine has a mold and produces the no of moldings as per no of cavities in the mold. 6. The Automatic Shape Molding machines require electric power for controls. They also require steam, cooling water and compressed air.
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7. A minimum of two shape molding machines and one block molding machine is recommended so as achieve production economics. Furthermore the production economics improve with more machines. 8. Finished and stacked products are sealed in plastics bags and are put into cartons. Product packaging is done manually since the cost of labor is low. 9. The packaged cartons are then stored in the warehouse for shipment.
*Streaming Process*
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The utilities requirement is shown below:
Steam - approximately a boiler generating minimum 1000 kgs./hr at minimum 8 Kgs. pressure. The capacity of the boiler depends on the installed machinery & capacity of the plant. Compressed Air (Dry & Clean) – Minimum 100 cfm 100 psi. pressure. The capacity of the Compressor depends on the installed machinery & capacity of the plant. Cooling Water – Approximately 10,000 Liters per day. The water in the system is recycled using an evaporative type water-cooling unit and heat exchanger system. The quantity of water depends on the installed machinery & capacity of the plant. Electrical Power – Approx. 60 H.P. The usage by the pre-expander, screener, steam boiler, air compressor, cooling water system, etc. can only be determined once the quantity of molding machines has been established as well as the sizes of molding to be manufactured. Uninterrupted electrical power is required while the pre-expander is operating.
Raw Material- The major raw material required is EPS granules is adequately available in the
local market from the following: 1) BASF 3003 2) LG Polymers 522
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3) Supreme 250
Labour Requirements – One operator is required for every two molding machines. To supervise these operators one supervisor is sufficient. Besides the molding plant Operators are required for the Boiler Plant and the Compressor. Space Requirements – The size of the building required will vary with the number of molding machines. One molding machine requires approximately 1.5 m x 1.5 m (5 ft. x 5 ft.) of floor space. A typical 3-machine operation including steam generation, compressed air systems, water circulating, pumping and cooling systems together with space for raw material and product storage would be approximately 5,000 square feet. The clear ceiling height required for a typical 3-machine operation would be approximately 18-19 feet.
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Flow Diagram of EPS Processing Process.
EPS Beads in 25 kg. Bags or Octabins
Pre-expansion of EPS Material at desired density
Maturation and drying of pre-expanded material in silos
Injection by filling guns of material in mold
Manual feeding in block mold
Further expansion of material and fusion in mold material and mounted on molding machine
Further expansion of mold
fusion in block
Drying of EPS molded packing
Drying of EPS Block
Packing of dried packings in plastic rolls.
Hotwire cutting for sheets or hand fabrication.
Storage in warehouse ready for dispatch.
Storage in warehouse ready for dispatch.
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*A typical SILO Machine*
*EPS Moulding Machine*
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*The Finished Goods (EPS)*
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B} MARKETING:
(Head:- Mr. Sandeep Rudre)
35
?
The Marketing Department is essential part of the company which helps to grow, expand and enhance the business of the company. As Machhar Packaging Pvt. Ltd. is the major vendor of Videocon and fulfills the 80% of requirement of them. The company does the business-to-business (B2B) type of marketing to expand the business in other packaging sectors.
?
Business-to-business marketing is the practice of individuals, or organizations, including commercial businesses, governments and institutions, facilitating the sale of their products or services to other companies or organizations that in turn resell them, use them as components in products or services they offer, or use them to support their operations. Also known as industrial marketing, business marketing is also called B2B marketing
?
The Marketing Department also takes effort in generating new product development as per demand by their client. And also company’s focuses on grow the productivity of it which will be profitable for the company.
?
The new product development is done by achieving the following methods and technology: A) Neopor (Black) B) E-Por C) Periphor D) Geofoam
36
A} Neopor - Innovation in Insulation
Neopor EPS foam is an innovative product from BASF® that offers a higher insulating capacity while useing less material. It is composed of small black beads of polystyrene (EPS). These black beads get expanded then formed into shapes or blocks. the formed products are a silvergrey in color and provide up to 20% better insulation performance than conventional EPS.
Up to 20% better performance with the same board thickness
The vital difference can be seen with the naked eye in the silver-grey color. In Neopor, graphite is added to the material, absorbing and reflecting heat radiation and improving the insulating performance of EPS by up to 20%.
Building with Neopor
Neopor can be used for virtually any application where you would use Styrobar whether it's roof, ceiling, or wall insulation. For new construction or the renovation of an existing building Neopor offers ideal insulation solutions for almost all components.
B} E-Por.
60 years after the invention of Styropor and 30 years after the invention of viscoelastic foams, a fundamental advancement has now been obtained in the form of E-por.
37
The new approach: The scientists at BASF no longer treat foams as static mixtures of a (co-) polymer and a blowing agent. They rather developed E-por as a complex formulation comprising several ingredients that interact with each other as well as with the blowing agent.
E-por Sets New Standards At All Levels of the Value Chain Processing:
? ? ?
- Low steam requirement during processing - Foam densities of 21 g/L in the first foaming step - No conversion of EPS plants required
Properties:
? ? ?
- Elastic, crack-resistant, multishock-proof - Perfect sealing of the surface - Appealing haptical and optical properties of the moldings
Sustainability:
? ? ?
- Storage and transportation at room temperature - Low blowing agent content - Recycling and degassing at EPS plants.
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C} Periphor:
Uses? ? ? Ceiling Water resistance Temperature absorption
D} Geofoam:
? EPS Geofoam is a lightweight, rigid foam plastic that is used as a fill material in construction projects where the existing soft or loose soil is incapable of supporting increased loads.
EPS Geofoam is a lightweight fill that gives you control over your geotechnical project. Traditional earth materials are heavy and can cause settlement, instability or lateral pressures. Other lightweight fill materials such as foamed concrete, waste tires, soil, woodchips, wood fiber, etc., have higher densities, are variable in their makeup and are not engineered, due to field execution variables.
They also have limitations in handling and can be weather sensitive, thus requiring staged construction and/or preloading, surcharging and draining, etc. Foam-Control EPS Geofoam is among the most versatile lightweight materials available. EPS Geofoam maximizes onsite
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installation efficiency. EPS Geofoam can arrive at the job site prefabricated and ready to place. It is easily inventoried and handled. Installation is not delayed by weather.
*Geofoam*
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C} HUMAN RESOURCE:
(Head:- Mr. Baig)
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Human resources is the set of individuals who make up the workforce of an organization, business sector or an economy. "Human capital" is sometimes used synonymously with human resources, although human capital typically refers to a more narrow view; i.e., the knowledge the individuals embody and can contribute to an organization. Likewise, other terms sometimes used include "manpower", "talent", "labor" or simply "people".
The professional discipline and business function that oversees an organization's human resources is called human resource management (HRM, or simply HR).
Basically, in the company Security and Administration Departments come under the HR Manager.
? HRM Functions:
1. Performance Appraisal 2. Potential Appraisal 3. Career Planning 4. Training and Employee Development 5. Organization Development 6. Rewards 7. Employee Welfare and Quality of Work Life
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8. Human Resource Information
After interviewing with Mr. Baig sir, we discussed the overall facilities given to the workers and employees by the company. We also discussed the workings of all the departments working in the company and how they are interrelated with HR Department. The points discussed are as follows: ? Total number of employees 230 to 250. In which, 70 staff members are permanent and rests of the workers are on contract basis. ? ? ? Salary: Permanent 12,000 to 15,000 (as per the seniority and their designation). Wages: As per government rules according to a) Skilled b) semi-skilled c) unskilled. Bonus and Incentives: General bonus given on Diwali according to the profit of the company of the past year. And incentives are being given according to the performance of the employee or worker. ? Recruitment: According to qualification and experience of the candidate first priority is given. ? Facilities: Insurance, Company Uniform, Transport, Canteen, Shoes and Socks, Loans (Festival Advance up to Rs. 10,000). Half hour lunch or dinner break. ? ? ? Labour Law: Implemented as per rules of Government of India. Union: Internal and External Union. Appraisal, Increment: To reward the performance is checked for example, attendance, behavior and work of employee etc. The 3 months or 6 months appraisal is been given. ? Policy: Policy are implemented after discussion of the HR Manager with Director.
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?
Shift timing: 7 AM to 3 PM (Ist Shift), 3 PM to 11 PM (IInd Shift), 11 PM to 7 AM (IIIrd Shift), 9 AM to 5:30 (General Shift only for staff).
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Holidays: Friday week-off, Privilege Leaves (PL) 30 days, Casual Leaves (CL) 6 days, Paid leaves 8 annually.
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Employee empowerment: Suggestion and recommendation are taken by workers and employees. Involvement in meetings, ideas are taken into consideration also of low level employees.
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Employee safety: Safety measures are taken by the company by providing Mask, goggle, gloves, helmets etc.
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Employee cut-off: In case of misbehavior, irregularity, frequent absenteeism, disturbing the work flow by any employee or worker firstly warning or memo is been given by the company and if there is no positive changes in employee then finally strict measures are been taken against that employee or worker.
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D} FINANCIAL MANAGEMENT:
(Head:- Mr. R.A. Mundara)
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Financial Management means planning, organizing, directing and controlling the financial activities such as procurement and utilization of funds of the enterprise. It means applying general management principles to financial resources of the enterprise.
Scope/Elements
1. Investment decisions includes investment in fixed assets (called as capital budgeting). Investment in current assets are also a part of investment decisions called as working capital decisions. 2. Financial decisions - They relate to the raising of finance from various resources which will depend upon decision on type of source, period of financing, cost of financing and the returns thereby.
Objectives of Financial Management The financial management is generally concerned with procurement, allocation and control of financial resources of a concern. The objectives can be-
1. To ensure regular and adequate supply of funds to the concern. 2. To ensure adequate returns to the shareholders which will depend upon the earning capacity, market price of the share, expectations of the shareholders. 3. To ensure optimum funds utilization. Once the funds are procured, they should be utilized in maximum possible way at least cost. 4. To ensure safety on investment, i.e, funds should be invested in safe ventures so that adequate rate of return can be achieved.
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5. To plan a sound capital structure-There should be sound and fair composition of capital so that a balance is maintained between debt and equity capital.
Functions of Financial Management
1. Estimation of capital requirements: A finance manager has to make estimation with regards to capital requirements of the company. This will depend upon expected costs and profits and future programmes and policies of a concern. Estimations have to be made in an adequate manner which increases earning capacity of enterprise. 2. Determination of capital composition: Once the estimation have been made, the capital structure have to be decided. This involves short- term and long- term debt equity analysis. This will depend upon the proportion of equity capital a company is possessing and additional funds which have to be raised from outside parties. 3. Choice of sources of funds: For additional funds to be procured, a company has many choices likea. Issue of shares and debentures b. Loans to be taken from banks and financial institutions c. Public deposits to be drawn like in form of bonds.
Choice of factor will depend on relative merits and demerits of each source and period of financing.
4. Investment of funds: The finance manager has to decide to allocate funds into profitable ventures so that there is safety on investment and regular returns is possible.
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5. Disposal of surplus: The net profits decision have to be made by the finance manager. This can be done in two ways: a. Dividend declaration - It includes identifying the rate of dividends and other benefits like bonus. b. Retained profits - The volume has to be decided which will depend upon expansional, innovational, diversification plans of the company. 6. Management of cash: Finance manager has to make decisions with regards to cash management. Cash is required for many purposes like payment of wages and salaries, payment of electricity and water bills, payment to creditors, meeting current liabilities, maintainance of enough stock, purchase of raw materials, etc. 7. Financial controls: The finance manager has not only to plan, procure and utilize the funds but he also has to exercise control over finances. This can be done through many techniques like ratio analysis, financial forecasting, cost and profit control, etc.
In Machhar Packaging; ? ? Indirect cost: 10% to 15%. Sales hike: Sales hike is been observed in festive season so that more capital is been required and the production is increased. To increase production, efforts are taken to do extreme marketing and special efforts are been taken by Finance Department to increase the marketing level. ? Efforts are taken to reduce the unwanted cost by various methods.
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E} QUALITY DEPARTMENT
(Head:- Mr. A.B. Mangoli )
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Machhar Packaging is able to maintain its market credentials due to their uncompromising adherence to quality policy. The professionals make sure that the products are at par with international standards and meet the requirements of the clients. Initiating from procurement process till final delivery, company’s quality controllers maintain a stringent approach at all levels. Thats why Machhar Packaging are an ISO 9002 Certified Company. The company’s quality controllers make sure that business operations adhere to the quality policy underlying the following important points:
? ? ? ?
Using best raw material, latest technology & processes. Developing products of consistent high quality Serving customers better every time and continuing to be the best Being eco-friendly and conserving energy.
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F} PRODUCTION PLANNING & CONTROL DEPARTMENT:-
(Head:- Mr. Rahul Kumar)
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?
The orders by clients are been taken by using electronic mail. The clients such as Videocon, Bajaj etc.
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The following steps are been involved in it: 1. Taken purchase order by client. 2. Plan gathering. 3. Data collecting. 4. According to demand from clients planning of raw material is made. 5. Production planning is made. 6. Production. (Formation of finished goods i.e. EPS) 7. Packaging as per requirement (Production depend on quantity) 8. Dispatch. (One day before dispatch method is been used i.e D-1 method)
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Useful application used in the company are: A) Tally B) MS-Excel C) Outlook for mailing purpose.
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G} MATERIALS & STORES DEPARTMENT:
(MR. Naikwade)
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?
The materials department is handled by Production Department itself. And the main thing here in this department is to manage the raw material and its stock.
? As it is the EPS manufacturing company so it requires polymer for manufacturing EPS as
per requirement of clients. Polystyrene is an Aromatic Polymer made from monomer styrene (a liquid hydrocarbon that is manufactured by petroleum by chemical industry. ? The raw materials basically used i.e. BASF 3003, LG 522 and Supreme 250 these are the types of polymer which are used for manufacturing different types of EPS required by the clients. ? Location to get the raw materials are Visakhapatnam, Delhi, Mumbai, Chennai.
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H} DISPATCH DEPARTMENT (MR. G.M. Kulkarni)
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Dispatching of Goods
Dispatch
Finished Goods (Godown).)
Logistics
? ? ?
Dispatch- 2 employees Godown- 3 employees Logistic- 1 employee
? 6.5 tons daily dispatching of EPS ? JIT Technique is used. ? Daily reporting to the General Manager Mr. Tapadiya. The step-by-step methods involve in dispatching the finished goods: Design of Mold Sample Mold Approval Final Planning Purchase Order Planning using codes and applying on machine
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I} RESEARCH & DEVELOPMENT:
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The term R&D or research and development refers to a specific group of activities within a business. The activities that are classified as R&D differ from company to company, but there are two primary models. In one model, the primary function of an R&D group is to develop new products; in the other model, the primary function of an R&D group is to discover and create new knowledge about scientific and technological topics for the purpose of uncovering and enabling development of valuable new products, processes, and services. Under both models, R&D differs from the vast majority of a company's activities which are intended to yield nearly immediate profit or immediate improvements in operations and involve little uncertainty as to the return on investment (ROI). The company is taking more and more efforts in R&D Department to grow their business in sectors as follows: ? The new product development is done by achieving the following methods and technology: A) Neopor (Black) B) E-Por C) Periphor D) Geofoam
A} Neopor - Innovation in Insulation
Neopor EPS foam is an innovative product from BASF® that offers a higher insulating capacity while useing less material. It is composed of small black beads of polystyrene (EPS). These
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black beads get expanded then formed into shapes or blocks. the formed products are a silvergrey in color and provide up to 20% better insulation performance than conventional EPS.
Up to 20% better performance with the same board thickness
The vital difference can be seen with the naked eye in the silver-grey color. In Neopor, graphite is added to the material, absorbing and reflecting heat radiation and improving the insulating performance of EPS by up to 20%.
Building with Neopor
Neopor can be used for virtually any application where you would use Styrobar whether it's roof, ceiling, or wall insulation. For new construction or the renovation of an existing building Neopor offers ideal insulation solutions for almost all components.
B} E-Por.
60 years after the invention of Styropor and 30 years after the invention of viscoelastic foams, a fundamental advancement has now been obtained in the form of E-por.
The new approach: The scientists at BASF no longer treat foams as static mixtures of a (co-) polymer and a blowing agent. They rather developed E-por as a complex formulation comprising several ingredients that interact with each other as well as with the blowing agent.
E-por Sets New Standards At All Levels of the Value Chain Processing:
?
- Low steam requirement during processing
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? ?
- Foam densities of 21 g/L in the first foaming step - No conversion of EPS plants required
Properties:
? ? ?
- Elastic, crack-resistant, multishock-proof - Perfect sealing of the surface - Appealing haptical and optical properties of the moldings
Sustainability:
? ? ?
- Storage and transportation at room temperature - Low blowing agent content - Recycling and degassing at EPS plants.
C} Periphor:
Uses? ? ? Ceiling Water resistance Temperature absorption
D} Geofoam:
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?
EPS Geofoam is a lightweight, rigid foam plastic that is used as a fill material in construction projects where the existing soft or loose soil is incapable of supporting increased loads.
EPS Geofoam is a lightweight fill that gives you control over your geotechnical project. Traditional earth materials are heavy and can cause settlement, instability or lateral pressures. Other lightweight fill materials such as foamed concrete, waste tires, soil, woodchips, wood fiber, etc., have higher densities, are variable in their makeup and are not engineered, due to field execution variables.
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7) SWOT ANALYSIS:
Strength:? ? ? ? ? ? ? ? ? Second largest EPS manufacturing company in India. No localized competitor. Excellent quality as compared to other EPS manufacturing company. Experienced staff available 27/7. Daily reporting to seniors. Conducting meeting every week to take effective decisions to increase profit level. Total satisfaction of clients. Positive aspect on every decision making. Good relations between company and raw material providers.
Weakness:? ? Majority of workers are on contractual basis. Maintenance of machines at regular intervals.
Opportunities:? ? Improvement in R&D department can enhance the profitability. Scope in future i.e. the uses of EPS in various sectors will be increased.
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?
Extreme B2B marketing can help to manufacture various types of EPS products will be helpful for making new clients.
?
New product development as per requirement as we are observing growth in industrial sector in Aurangabad.
Threats:? ? ? Increase in fuel cost, which leads to increase the transportation cost. The company is majorly dependent on one company i.e. 80% on Videocon. No awareness between people of uses of EPS products in different-different field.
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8) FINDINGS:
? In Machhar Packaging, we observed that satisfaction of clients is the basic priority given by the company and all that efforts are been taken to improve the quality of EPS products. ? In Machhar Packaging, JIT method is been implemented so that it avoids the wastage of raw material, it saves time and effort of employees. ? In Machhar Packaging, we observed that waste management is done by doing proper recycling of the damaged EPS products instead of throwing them. ? In Machhar Packaging, we also observed that Agro base fuel efficient Boiler, electropneumatic steam flow control system is been used that is eco friendly. Whereas smoke is less harmful for the environment. ? Security is also given priority as not one can be entered or leave without permission of Head of the Department.
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9) SUGGETION AND RECCOMANDATIONS:
? Enhancing of R&D department is to be done so that it can increase the profitability level of the company by making new-new products of EPS. ? If there is an improvement in B2B marketing initiative so that it can make more and more clients in future. So, extreme level of marketing should be done is various sectors.
10) CONCLUSION:
We conclude that, Machhar Packaging is the popular and only EPS manufacturing company in Aurangabad. As compared to other similar EPS manufacturing companies, Machhar Packaging provides a good quality EPS products to their clients as per there requirements. The feedback given by company’s clients is always good and they are happy with the work and services provided by Machhar Packaging.
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11) BIBLIOGRAPHY:
www.utsavpolymer.com/ www.bseindia.com/bseplus/AnnualReport/506979/5069790311.pdf www.google.co.in
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doc_726240266.docx