Manufacturing Unit

8/3/2019 Manufacturing Unit

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Manufacturing Unit

Manufacturing involves the conversion of raw materials, usually supplied in simple or shapeless

forms, into finished products with specific shape, structure, and properties that fulfill given

requirements. This conversion into finished products is accomplished using a great variety of

processes that apply energy to produce controlled changes in the configuration properties of

materials. The energy applied during processing may be mechanical, thermal, electrical, or

chemical in nature. The results are meant to satisfy functional requirements that were defined

during the product design stage.

In the past, design, materials engineering, and manufacturing were often treated as

independent engineering specialties. However, modem manufacturing must be cost-effective

and timely. This requires that everyone involved in the entire product life cycle work together

concurrently to provide a functional product that can be produced efficiently, can be operated

reliably, and is easy to maintain and recycle (Taguchi, 1993). This report identifies a largenumber of opportunities for improving unit processes. These can be considered as future

options for the concurrent engineering teams.

Manufacturing a product or component usually requires the integration of a number of

processes. For example, the initial process may involve casting a metal into a mold to produce a

desired shape. Next, the casting may be machined with cutting tools to generate surfaces of

specified form. Finally, a surface treatment may be employed to improve the durability of the

part. Each of these three individual operationscasting, machining, and surface treatmentis

a unit manufacturing process. For brevity, in this report they will be referred to as ''unit

processes." They are the individual steps required to produce finished goods by transforming

raw material and adding value to the workpiece as it becomes a finished product.


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Asian Paints is Indias largest paint company and Asias third largest paint company, with a

turnover of Rs 77.06 billion. The group has an enviable reputation in the corporate world for

professionalism, fast track growth, and building shareholder equity. Asian Paints operates in 17

countries and has 24 paint manufacturing facilities in the world servicing consumers in over 65

countries. Besides Asian Paints, the group operates around the world through its subsidiaries

Berger International Limited, Apco Coatings, SCIB Paints and Taubmans.

Forbes Global magazine USA ranked Asian Paints among the 200 Best Small Companies in the

World for 2002 and 2003 and presented the 'Best under a Billion' award, to the company. Asian

Paints is the only paint company in the world to receive this recognition. Forbes has also ranked

Asian Paints among the Best under a Billion companies in Asia In 2005, 06 and 07.

The company has come a long way since its small beginnings in 1942. Four friends who were

willing to take on the world's biggest, most famous paint companies operating in India at that

time set it up as a partnership firm. Over the course of 25 years Asian Paints became a

corporate force and India's leading paints company. Driven by its strong consumer-focus andinnovative spirit, the company has been the market leader in paints since 1968. Today it is

double the size of any other paint company in India. Asian Paints manufactures a wide range of

paints for Decorative and Industrial use.

In Decorative paints, Asian Paints is present in all the four segments v.i.z Interior Wall Finishes,

Exterior Wall Finishes, Enamels and Wood Finishes. It also introduced many innovative concepts

in the Indian paint industry like Colour Worlds (Dealer Tinting Systems), Home Solutions

(painting solutions Service), Kids World (painting solutions for kids room), Colour Next

(Prediction of Colour Trends through in-depth research) and Royale Play Special Effect Paints,

just to name a few.

Asian Paints has always been ahead when it comes to providing consumer experience. It has set

up a Signature Store in Mumbai where consumers are educated on colours and how it can

change their homes.


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COMPANY PROFILE

Asian Paints India Ltd.

Asian Paints, incorporated in 1942, is Indias largest paint company and the third largest paint

company in Asia (Source: Crisil). The company currently operates in 21 countries has 29 paintmanufacturing facilities all over the world and is servicing consumers in over 65 countries.

Apart from Indian operations, the group operates around the world through its subsidiaries

Berger International Limited, Apco Coatings, SCIB Paints and Taubmans.

Asian Paints Ltd.

Asian Paints Ltd. (APL) is involved in the manufacturing of decorative paints and chemical

business i.e. Phthalic Anhydride and Pentaerythritol. The decorative & chemical business

contributes together contributes 77% of the total consolidated revenue.

Asian PPG Ltd.

Asian PPG Ltd. handles the automotive and industrial paints business. It was incorporated in

year 1997, as a 50:50 Joint Venture between Asian Paints Ltd., and Pittsburgh Paints and Glass

Industries (PPG), USA. The JV was formed primarily to obtain Cathodic Electro Deposition (CED)

technology, later the whole auto furnish business of PPGs Indian operation was transferred to

the JV. After acquisition ofICI Indias 2k auto furnishes business, the company has become the

largest player in this segment in the domestic market.

Asian Paints Industrial Coating Ltd. (APICL)

Asian Paints Industrial Coatings Ltd. (APICL), wholly-owned subsidiary of the company handles

powder coating business. APCIL has tied up with Protech Chemicals, one of the top ten powder

coating companies in the world, for obtaining technological know-how for powder coatings.


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Currently, the company ranks as third largest player in this segment. Besides the company also

started is operations in Protective Coatings, Road Markings, Floor Coatings and General

Industrial Liquid Paints.


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Paints Industry

Paint is defined as the group of emulsions, consisting of pigments suspended in a

liquid medium, for use as decorative or protective coatings. Paint ranges from

the broad group of environmentally-sound latex paints used to decorate and protect

homes and the translucent coatings that line the interior of food containers, to the

chemically-complex, multi-component finishes that automobile manufacturers apply

on the assembly line.

Market Structure

The size of the Indian paint industry is valued at Rs.112 bn . Indian Paints Industry can be classifi

ed into two sub-segments:


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Demand Supply Dynamics

The Indian Paint Industry grew by 18% from Rs. 95 bn. in FY06 to Rs. 112 bn in FY07 (Source:

Company). The industry has a positive correlation with GDP as both have same drivers for

growth. Demand for paints is both, derived as well as direct. The demand for decorative paints

is a direct demand whereas the demand for industrial paints is a derived demand.


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Raw Materials

Liquid paints is a composite of a finely divided pigment dispersed in aliquid composed of a resin

or binder and a volatile solvent. Therefore, paints are manufactured from three main

constituents; pigments, binders, and solvents (thinners), in addition to many other additives

togive the paints specific properties for specific purposes or applications.The liquid portion of

the paints is known as the vehicle. Vehicles arecomposed of nonvolatile and volatile parts:

Nonvolatile;-Solvent-based paints: oils and/ or resins plus driers and additives

Lacquers: celluloses, resins, plasticizers, and additives.-Water-based paints: styrene-

butadiene, polyvinyl acetate,acrylic, other polymers and emulsions, copolymers plusadditives.

VolatileKetones, esters, alcohol, aromatics, and aliphatics


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Paint manufacturing process

Major Products and Services

Asian Paints manufactures and markets industrial and decorative coatings. The company's key

products and brands include the following:


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Products:

Decorative paints: Interior wall paints Exterior wall paints Wood surface paints Metals surface

paints

Industrial coatings: Protective coatings Floor coatings Road markings

Automotive: Body coatings Plastic coatings

Brands: Ace & Apex Apcolite Apex Apex Ultima Asian Paints Colour Next Premium Gloss Enamel

Royale Royale Play Touchwood Tractor Emulsion Utsav

Paint Manufacture and Sustainability

Just because a paint is classed as 'Low-VOC' does not mean it is environmentally preferable. It is

important to consider the entire manufacturing process of a product, and its' environmental impact.


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Another problem with synthetic paints is post-application wastage and disposal. The petrochemical

paints that currently dominate the market are predominately derived from oil, a non-renewable

resource. In most paints up to 20% of a tin by volume can be the pigment Titanium Dioxide, a product

that can have a very high environmental impact load associated with it. Waste needs to be specially

treated to avoid adverse environmental impacts.

The manufacture of petrochemical based paint is energy-intensive, and the production of of 1 tonne of

solvent-based paint can produce 10-30 tonnes of toxic waste, much of which is non-degradable

Plant and Mineral-based paints are made using naturally occurring ingredients, and therefore do not

require high levels of processing. Many of the ingredients are made from renewable resources, such as

linseed oil, and citrus oil, and therefore avoid contributing to greenhouse gas emissions over the life of

the product. 'Natural' paints use plant-derived solvents and binders instead of synthetic ones, and

usually have low VOC levels. It results in better health outcomes, and uses renewable resources for the


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most sustainable living.

Consumers and specifiers should also consider the carbon-emissions produced by manufacturers in the

production of paint products. Paints are now available that have been independently certified carbon-

neutral.

Eco-labels can help you identify eco-preferable products. To obtain an eco-

label, manufacturers must undergo independant assessment by an eco-

labeling body such as Good Environmental Choice Australia. The GECA

program conducts a comprehensive life cycle based assessment of product

compliance to voluntary environmental declaration standards. It is a member

of the Global Ecolabelling Network.

Documents

Manufacturing Unit