A

Project Report

On

“Total Consumption Of Polymer In Automobile Sector In Pune

Region”

With Special Reference To

Submitted To

In Partial Fulfillment Of The Requirement

For The Award Of Degree Of

Master Of Business Administration

By

Under The Guidance Of

Mr.

(Professor,)

A!Q

1

CERTIFICATE OF SUMMER TRAINING COMPLETION

This is to certify that Project Report titled “Total Consumption Of Polymer in Automobile

Sector In Pune Region” has been completed satisfactorily in partial fulfillment of Master Of

Business Administration course for the academic year 2004-2006 by Mrinal Khajuria, Student of

“Vishwakarma institute of management” pune-37.

Place: Pune Director,

Date: Vim, pune-37

2

GUIDE CERTIFICATE

This is to certify that Mr. Mrinal Khajuria “student of Master of business administration course

with specialization in Marketing, for the session August 2004- July 2006 prepared project report

entitled “Total Consumption Of Polymer in Automobile Sector In Pune Region” at Aalekh

polymers PVT. Limited. From15th June to 30th July under my guidance and supervision.

I wish him all success in life.

Prof. Yuvraj lahoti

(Marketing)

3

4

TABLE OF CONTENTS

S.No TOPIC PAGE No.

1. INTRODUCTION 10-11

2. COMPANY PROFILE 13-14

3. PRODUCT PROFILE 16-20

4. OBJECTIVES OF THE STUDY 22

5. RESEARCH METHODOLOGY 24

6. OBSERVATIONS AND FINDINGS 26-45

7. CONCLUSIONS & SUGGESTIONS 47-49

8. ANNEXURES 51-56

5

ACKNOWLEDGEMENT

I take the occasion to thank “Aalekh polymers private Limited” for giving me the opportunity to

work on this project, which has immensely helped in gaining & developing my knowledge &

experience. I would like to thank my institute VIM as well as Director sir Dr. Sharad L Joshi to

provide me such a wonderful opportunity.

I especially thank my project guide Mr.Yuvraj Lahoti (professor, VIM) for his valuable guidance,

co-operation & encouragement throughout the project.

I am also Grateful to Mr.Arun Sharma (senior head marketing) and Mr.Inder Jain (CEO) for

providing their valuable thoughts and inputs throughout the project & kindly accepting the

suggestions & recommendations given by me.

I am very thankful to god as well as my family who really helped me during the project work

without there ally and support it its not possible to study here in a very pleasant atmosphere.

Lastly I would like to specially thank the subordinates & their superiors for their co-operation and

also would like to thank to all the respondents of the survey, members of the faculty & all my

other fellow summer trainees for their co-operation & co-ordination in the project along with me.

Place-Pune

Mrinal Khajuria

6

EXECUTIVE SUMMARY

Objectives: -

1) To know the total polymer consumption in the automobile sector

2) How many injection moulding companies are using polymers for automobile industry in Pune

Region?

3) What are the prices at which injection moulding companies are buying raw materials from

other manufacturers

4) To know the availability of substitutes and grade of polymers in Pune region

5) To find out the awareness of the product in the market

6) To know the strengths and weaknesses of the companies

7) To know various parameters whatever the business rivals of APPl. are following:

o Marketing strategy

o Pricing policy

o Credit policiesvQS

Findings: -

Polypropylene is used readily in automobile sector because we can enhance its properties by

adding filler for example: glass, mica, talc, etc. as per the requirement of the product. Appl

produces PP + Filler as per the customer requirements. Polypropylene is used in bumpers,

dashboards, fuel tanks etc. Polypropylene is used frequently because:

1) There is no problem in the availability.

2) Its trends do not vary.

3) It is cheaper then metal.

4) Properties are more or less same as of metals.

5) The weight is lesser then metals which helps in increasing average of the vehicle.

7

Recommendations: -

The company should increase sales

The company should try to reduce the cost of production

Growth opportunities in public transport and commercial sectors

Material handling

Sourcing of materials

Proper inputs from customer

Trend analysis

Limitation of the study: -

Sometimes consumers are not aware of the new product

Due to limited sample representation population may not be that much accurate

I, here by declare that this project report entitle “Total polymer Consumption In Automobile

Sector” with special reference to APPL Industries Limited Pune, Which is the outcome of the

summer training undergone by me from 15th June 2005 to 30th July 2005. The empirical finding

of the study is entirely based on the data collected by myself.

8

INTRODUCTION

9

INTRODUCTION

History and significance of polymers

Plastics are polymers. What is a polymer? The simplest definition of a polymer is something

made of many units. Think of a polymer as a chain. Each link of the chain is the "mer" or basic

unit that is made of carbon, hydrogen, oxygen, and/or silicon. To make the chain, many links or

"mers" are hooked or polymerized together. Polymerization can be demonstrated by linking strips

of construction paper together to make paper garlands or hooking together hundreds of paper clips

to form chains.

Polymers have been with us since the beginning of time. Natural polymers include such things as

tar and shellac, tortoise shell and horns, as well as tree saps that produce amber and latex. These

polymers were processed with heat and pressure into useful articles like hair ornaments and

jewelry. Natural polymers began to be chemically modified during the 1800s to produce many

materials. The most famous of these were vulcanized rubber, gun cotton, and celluloid. The first

synthetic polymer produced was Bakelite in 1909 and was soon followed by the first semi-

synthetic fiber, rayon, which was developed in 1911

Even with these developments, it was not until World War II that significant changes took place

in the polymer industry. Prior to World War II, natural substances were generally available;

therefore, synthetics that were being developed were not a necessity. Once the world went to war,

our natural sources of latex, wool, silk, and other materials were cut off, making the use of

synthetics critical. During this time period, we saw the use of nylon, acrylic, neoprene, SBR,

polyethylene, and many more polymers take the place of natural materials that were no longer

available. Since then, the polymer industry has continued to grow and has evolved into one of the

fastest growing industries in the U.S. and in the world.

Characteristics of Polymers

The two major groups of polymers are thermoplastics and thermosets. Thermoplastic and

thermosetting nature is based on the heat response of polymers. The light transmittance of

polymers includes the description of materials as being transparent, translucent, or opaque.

Transparent polymers are those that you can see through, translucent are those that you cannot see

through but allow light to pass through, and opaque polymers are those that you can neither see

10

through nor allow light to pass through. Light penetration qualities are dependent on the degree of

crystallization of the polymer and the presence of additives.

Every polymer has very distinct characteristics but most polymers have the following general

attributes.

1. Polymers can be very resistant to chemicals

2. Polymers can be both thermal and electrical insulators

3. Generally, polymers are very light in mass with varying degrees of strength

4. Polymers can be processed in various ways to produce thin fibers or very intricate parts

As a leading manufacturer of engineered thermoplastic compounds having largest capacity in

India with multilocational compounding base, thus providing the complete solutions for

Automotive and Appliances Industries.

Research and Development

Manufacturing is fully supported by a team of dedicated Research and Development officers. A

laboratory scale Extruder very similar to the production machines has been installed in our R & D

department. This ensures that the scale up is smooth from R&D to production. In house R&D also

helps us to develop new materials in the shortest time period to meet our customer's new and

exacting requirements. R & D department is well dedicated to upgrade our material time to time

as per customer's requirements.

11

COMPANYPROFILE

12

Company Profile

About APPL

APPL Industries Limited, which has been formed by the merger of three groups of companies –

Aalekh Polymers (P) Limited, Aalekh Industries (P) Ltd., and Prateek Enterprises, is one of the

leading compounder of engineered thermoplastics in India. We have been providing material

solutions to our customer for over 15 years. Today, we offer precoloured compounds based on

Polyolefin’s and engineering plastics modified with minerals, glass fiber/beads, wood flour, flame

retardants etc. We also offer blends and alloys of various plastics, colour concentrates and

additive master batches.

Article I. APPL Facilities

Production units at multiple sites - strategically located to meet customer's requirements.

Latest fully Computer controlled state-of-the-art compounding systems from Germany, Japan

offer Advanced Materials Technologies.

International standard Quality Control Laboratory.

APPL has established highly sophisticated Polymer Compounding units at IMT Manesar near

Delhi and at Pune in Maharashtra with a total installed capacity of 30,000 MTA, and by the end of

2006, APPL will set up its third compounding unit at Hosur, Tamil Nadu with additional 10,000

MTA capacities.

APPL PROCESS

Twin Screw Super Compounders – Co-rotating and counter-rotating type

Gravimetric Loss-in-Weight feeders from Brabender Technologies, K-Tron

Automation of material handling

Our production equipment and its variety allow us to match each product to the right process,

highest and consistent product quality in shortest lead-time.

VISION

To be a multilocation company engaged in production of Engineered Thermoplastic Compounds

based on Polyolefin’s and Engineering Plastics, thereby attaining a top-performing compounding

industry dealing in multiple products and developing new applications close to customers.

13

MISSION

To provide materials based on advanced technology to our esteemed customers, which meet

challenging demands.

To respect the strength and capability of all our employees, customers and associates. To

honour all commitments we undertake.

ACHIEVEMENTS

1990: - The Company was established at New Delhi to manufacture Color Concentrate.

1995: -Manufacturing Plant dedicated for Black Masterbatch was set up at Rajasthan.

1998: - Two compounding line from Japan were installed at Delhi for PPAM compounds.

2001: - Two state-of-the-art compounding line from Theysohn Maschinenbau, Germany were

installed at pune.

2002: - Commissioned IMT - Manesar plant with two lines from Japan and two more

Compounding Lines from Theysohn, Germany.

2003: - Obtained ISO - 9001:2000 accreditation.

2003: - Automated Feeding system was installed at IMT – Manesar Plant.

2004: - Appointed as consignment agent of Ciba Speciality chemicals for plastics additives for

Eastern India.

2005: - Accelerated Weather meter instrument was set up at Pune plant.

2005: - Two state-of-the-art compounding lines from Coperion were installed at Pune and IMT

Manesar plant.

2005: - Two Research & Development purpose compounding lines from Coperion were installed

at Pune and IMT Manesar plant.

2006: - One Counter Rotating Twin screw extruder from Japan was installed at Pune

14

PRODUCT

PROFILE

15

SEGMENT DESCRIPTION TRADE NAME

Engineered Plastics based on Commodity Resins

Advanced Polypropylene Compounds

APPCOM

Advanced Styrenic Compounds

APPSTRON

Advanced Colour Masterbatches

APPCOL

Speciality Additive Masterbatches

APPLENE

Engineered Plastics based on Advanced Plastic Resins

Polycarbonate Compounds APPNATE

Alloys APPLOY

PBT Compounds APPET

Nylon Compounds APPLON

16

Engineered Plastics based on Commodity Resins

A product may start with homopolymer, copolymer, TPO (rubber-modified alloys). The

application may require UL recognition, special stabilizers for improved weatherability, and extra

heat stabilizers for under the hood applications. The type, particle size and amount of filler can be

adjusted as per requirement for their aesthetics and mechanicals. For improved impact, impact

modifier can be incorporated. We can provide pre-colored materials as well as natural colour

materials. A complete product listing, incorporating all would be too long to list.

Our ABS and HIPS compounds have been developed specifically to meet the requirements of

major customers. These grades are the cost-effective answer for purchasers. These grades are

available as per customer-specific colours. Our ABS compounds offer excellent processability,

good heat resistance and show good balance between impact resistance and rigidity.

APPL also offer SAN compounds, which have high heat resistance and chemical resistance. It

has a wide range of applications in electrical/electronic parts, automotive parts, office

consumables and so on.

17

An engineered plastic based on commodity resins includes: -

ADVANCED POLYPROPYLENE COMPOUNDS: These compounds are used in

manufacturing “bumpers, instrumental panel, door trims, speedometer housing,

speedometer body cover, seat side balance, household items, case heater of air conditioner,

automotive filters, refrigerator body parts, foot rest paddles” etc.

ADVANCED COLOUR MASTERBATCH GRADES: These resins are used in

manufacturing “Cover Inner of Two Wheeler Sector, Washing Machine Body Part, Tray

for Washing Machines, Hood Meter Cluster.

ADVANCED ADDITIVE MASTERBATCH GRADES: These resins are used in

manufacturing “Blown Film.

ADVANCED STYRENIC COMPOUNDS: These resins are used in manufacturing

“Washing Machine Body Parts, Hood Meter Cluster, UPS Body Parts, Blower for Air-

Conditioner, Two Wheeler Front Cover, Seat and Door Handle, UPS Housing.

18

Engineered Plastics based on Advanced Plastic Resins

We at APPL are offering various grades of mineral filled, glass reinforced, fire retardant

polycarbonate compounds, and their alloys, compounds of PBT and nylon. Our R & D

department is constantly working in this wide spread Engineering Plastics field.

Polycarbonate and its alloys e.g. PC/ABS, PC/PBT, PS/ASA characterized by their unique

balance of impact strength, heat resistance and high mechanical properties are the right choice

for a multitude of applications including automobile, medical equipment, optical, electrical

and electronics, home appliances and various other sectors.

Polybutylene Terephthalate (PBT) resin with its combination of heat, chemical resistance,

and outstanding electrical properties deliver unique design advantages with exceptionally

good processability & surface appearance. PBT compounds find application in

electrical/electronic connectors, automotive components, telecommunication enclosures & so

on.

Nylon is the most versatile plastics-easy to process; easy to modify to meet specific needs,

environmentally responsible in production. Due to their outstanding properties these materials

have become indispensable in almost all fields of engineering for the wide variety of

components and machine parts, as high-quality electrical insulating materials and for many

special applications.

Nylon grades are exceptional for their high mechanical strength, rigidity & thermal stability.

19

Engineered Plastics based on Advanced Plastic Resins includes: -

POLYCARBONATE COMPOUNDS: These resins are used in manufacturing “Head

Lamp Reflector, Door Handle, Electrical/Electronic Body Parts.

ALLOYS: These resins are used in manufacturing “Wheel Cover, Inverter Housing, Cub

Panel & Exterior Automotive Body Parts, Exterior Automotive Body Parts, Tail Light

Housing.

PBT COMPOUNDS: These resins are used in manufacturing “Garnish, Louvers, CFL

Housing

NYLON COMPOUNDS: These resins are used in manufacturing “Chain Cover, Heater

Cover, Handle Window Regulator, Roof Clip, Radiator Fan, Handle, Ash Tray

20

OBJECTIVES

OF

THE STUDY

21

OBJECTIVES OF THE STUDY

1. To know the total polymer consumption in the automobile sector

2. How many injection moulding companies are using polymers for automobile industry in Pune

Region?

3. What are the prices at which injection moulding companies are buying raw materials from

other manufacturers

4. To know the availability of substitutes and grade of polymers in Pune region

5. To find out the awareness of the product in the market

6. To know the strengths and weaknesses of the companies

One more important aspect is transportation related issues: - incidents like chemicals get

contaminated during transportation process due to: -

o Delays in transporting

o Exposure to air

o Leakages in tanks

To know various parameters whatever the business rivals of APPl. are following:

o Marketing strategy

o Pricing policy

o Credit policies

22

RESEARCH

METHODOLOGY

23

Research Methodology

RESEARCH APPROACH

1) Observation and survey

a) In this research report survey method is used. Survey is the method of gathering of

primary data by asking the questions to the customers about their usage and requirements.

2) Contact method

a) Telephone

b) Personal interviews

c) E-mails

3) Target respondents

Here personal interviews of all the respondents are taken; Proprietors of all injection moulding

companies are interviewed personally at their specific place where they are standing

RESEARCH DESIGN

The research has been done for the market of polymer consumption in automobile sector so the

research design for this survey is exploratory research

For the presentation and preparation of this report I have covered following things: -

1) Study of theory

2) Market research

3) Sample questionnaire

4) Graphical presentation

5) Analysis of data

6) Company visit

7) Internet information, books, magazines

24

25

OBSERVATIONS

AND

FINDINGS

26

NAME: Yuvraj Sadashiv Marath

DESIGNATION: Owner

ORGANISATION: PLAST O MECH

PRODUCT NAME: Exide Container Caps, Bajaj Pulsar Lights, Wireless handsets for

Bharat Electronics

OEM: Tata Johnson, Exide, Bharat Electronics, Bajaj Auto

ADDRESS: 55-77/1, MIDC Bhosari

TEL NO: 020-27120618

EMAIL: plastomech@bsnl.net

MOBILE: 9850062653

ABS+

FILLER

NYLON6 NYLON66

+ FILLER

POLYC

ARBON

ATE

P

B

T

PP +

FILLER

HI

PS

PC

AB

S

PC

PB

T

GP

PS

NY+

30%

GF

AC

RY

LIC

HD

PE

8 1.5 1.5 1 - 25 - - - - - 8 -

From the above information we come to know that the plastomech company use 56% of

polypropylene + filler as compare to other polymers the company use the polymer in

manufacturing wireless handsets and Bajaj Pulsar lights

27

NAME: Muley A.S.

DESIGNATION: G.M. (Operations)

ORGANISATION: SPS Plastics Pvt. Ltd.

PRODUCT NAME: Pulsar mud guard, Caliber mud guard

OEM: Bajaj Auto

ADDRESS: Sector C, 7/10&11, Ranjangaon, MIDC

TEL NO:

EMAIL:

MOBILE: 9890600382

ABS+

FILLER

NYLON6 NYLON66

+ FILLER

POLYC

ARBON

ATE

P

B

T

PP +

FILLER

HI

PS

PC

AB

S

PC

PB

T

GP

PS

NY+

30%

GF

AC

RY

LIC

HD

PE

- - - 2 - 10 0.5 - - - - - -

From the above information we come to know that SPS plastics use 80% of polypropylene + filler

as compare to other polymers. The company is using the polymers in manufacturing the products

like mudguards for two wheelers.

28

NAME: Ashok G. Chavan

DESIGNATION: Asst. Engg.

ORGANISATION: Sermo PM (I) Ltd.

PRODUCT NAME: White Goods

OEM: Bajaj Auto, Honda

ADDRESS: 5/4, Nagar Road, Pune - 14

TEL NO: 020-27013840

EMAIL:

MOBILE: 9822647158

ABS+

FILLER

NYLON6 NYLON66

+ FILLER

POLYC

ARBON

ATE

P

B

T

PP +

FILLER

HI

PS

PC

AB

S

PC

PB

T

GP

PS

NY+

30%

GF

AC

RY

LIC

HD

PE

- - - - - - 20 - - 10 - - -

From the above information we come to know that sermo pm uses 67% high impact polystyrene

as compare to other polymers. It is engaged in manufacturing white goods.

29

NAME: Sandesh Kumar

DESIGNATION: Proprietor

ORGANISATION: Vinayak Polymer Industries

PRODUCT NAME: Fuel Tank, Brake Fluid Container

OEM: Kinetic Motors

ADDRESS: 2, Vighnahar Chambers, Erandawane, Karve Road, Pune - 4

TEL NO: 020-25459218

EMAIL: sandk@rediffmail.com

MOBILE: 9822192885

ABS+

FILLER

NYLON6 NYLON66

+ FILLER

POLYC

ARBON

ATE

P

B

T

PP +

FILLER

HI

PS

PC

AB

S

PC

PB

T

GP

PS

NY+

30%

GF

AC

RY

LIC

HD

PE

2 - - - - 2 - - - - - - 11

From the above information we come to know that vinayak polymers uses 74% of HDPE as

compare to other polymers. The company is engaged in manufacturing fuel tanks

30

NAME: Nitin Mulay

DESIGNATION: Partner

ORGANISATION: Niky Engineers

PRODUCT NAME: Intricate Shape Precision Components

OEM: Bajaj Auto, Piaggio, Mahindra & Mahindra

ADDRESS: B26&27, Satyam Estate, Erandwane, Pune - 38

TEL NO: 020-25467976

EMAIL: nikyengg@vsnl.net

MOBILE: 9822063868

ABS+

FILLER

NYLON6 NYLON66

+ FILLER

POLYC

ARBON

ATE

P

B

T

PP +

FILLER

HI

PS

PC

AB

S

PC

PB

T

GP

PS

NY+

30%

GF

AC

RY

LIC

HD

PE

- 1.5 0.5 - - 10 - - - - 2 - -

From the above information we come to know that niky engineers uses 71% of polypropylene +

filler as compare to other polymers. It is engaged in manufacturing intricate shape precision

components.

31

NAME: Rathi Lalit

DESIGNATION: Director

ORGANISATION: Nitiraj Plastics & Engineering

PRODUCT NAME: Car Tanks, Reservoir Tanks

OEM: Maruti Udyog Ltd., Tata Motors

ADDRESS: Plot No. 41, Sinhgad Road, Manik Baug, Pune

TEL NO: 020-243654040

EMAIL: nitiplast@vsnl.net

MOBILE: 9371003914

ABS+

FILLER

NYLON6 NYLON66

+ FILLER

POLYC

ARBON

ATE

PB

T

PP +

FILLE

R

HI

PS

PC

AB

S

PC

PB

T

GP

PS

NY+

30%

GF

AC

RY

LIC

HD

PE

1 2.5 - - - 7.5 - - - - 0.5 - 29

From the above information we come to know that the company uses 72% of HDPE and is

engaged in manufacturing car reservoir tanks

32

NAME: M.S.R.CH. Murty

DESIGNATION: Proprietor

ORGANISATION: Apex Engineers

PRODUCT NAME: Electical Items for two wheelrs

OEM: Bajaj Auto

ADDRESS: S. No. 27, Wadgaon Bk., Sinhgad Road, Pune - 51

TEL NO: 020-24353307

EMAIL: murtymsp@vsnl.com

MOBILE: 9850954087

ABS+

FILLER

NYLON6 NYLON66

+ FILLER

POLYC

ARBON

ATE

P

B

T

PP +

FILLE

R

HI

PS

PC

AB

S

PC

PB

T

GP

PS

NY+

30%

GF

LD

PE

HDPE

- - 0.5 - - - - - - - - 0.3 0.65

From the above information we come to know that Apex engineers uses 45% of HDPE, 21% of

LDPE, 34% nylon 66 + filler. It is manufacturing electrical items for two wheelers.

33

NAME: Hemant R. Lasaris

DESIGNATION: Partner

ORGANISATION: Shrimani Industries

PRODUCT NAME: Tool Box, Fender, Cowling, Fan Cover, Battery containers

OEM: Bajaj Auto, Exide

ADDRESS: D-3, Plot No. 59, MIDC, Chinchwad, Pune – 19

TEL NO: 020-27472449

EMAIL: shrimanii@eth.net

MOBILE: 9422324936

ABS+

FILLER

NYLON6 NYLON66

+ FILLER

POLYC

ARBON

ATE

P

B

T

PP +

FILLER

HI

PS

PC

AB

S

PC

PB

T

GP

PS

NY+

30%

GF

AC

RY

LIC

HD

PE

3 3.5 - - - 35 - - - - - - 18

From the above information we come to know that shrimani industries uses 59% of

polypropylene, 30% of HDPE, 5% of abs + filler and 6% of nylon 6. it is engaged in

manufacturing tool box etc.

34

NAME: Borate Sadashiv Rambhau

DESIGNATION: MD (Proprietor)

ORGANISATION: Elite Plastic Industries

PRODUCT NAME: Battery Containers, Electrical Items

OEM: Exide, Bharat Electricals

ADDRESS: Sector 65, MIDC, Bhosari, Pune - 26

TEL NO: 020-27120619/24113772

EMAIL: elite_plastic@vsnl.net

MOBILE: 9822015531

ABS+

FILLER

NYLON6 NYLON66

+ FILLER

POLYC

ARBON

ATE

P

B

T

PP +

FILLER

HI

PS

PC

AB

S

PC

PB

T

LD

PE

NY+

30%

GF

AC

RY

LIC

HD

PE

2 3 - - - 12 - - - - - 6 5

From the above information we come to know that ELITE plastic industry uses almost all kind of

polymers but it uses more of PP + filler about 42% and rest are all other polymers. It is

manufacturing electrical items and battery containers.

35

NAME: Nilesh S. Sawant

DESIGNATION: Production Incharge

ORGANISATION: Rantnadeep Enterprises

PRODUCT NAME: Fuel Filter, Backup Rings

OEM: Bajaj Auto

ADDRESS: Talawadi Road, Sahayognagar, Pune - 1

TEL NO: 020-251305000000000

EMAIL: plasticprd@vsnl.net

MOBILE:

ABS+

FILLER

NYLON6 NYLON66

+ FILLER

POLYC

ARBON

ATE

P

B

T

PP +

FILLER

HI

PS

PC

AB

S

PC

PB

T

LD

PE

NY+

30%

GF

AC

RY

LIC

HD

PE

- - 0.7 - - 1 - - - 0.3 - - 1

From the above information we come to know that Ratnadeep enterprises uses 34 % of EP +

filler, 33& HDPE, 23 % of nylon 66 + filler and 10 % of LDPE. It manufactures fuel tanks and

backup rings.

36

NAME: R.M. Agrawal

DESIGNATION: CEO

ORGANISATION: Shree Plastics

PRODUCT NAME: Brake Oil Container

OEM: Maruti Udyog Ltd., Tata Motors, Mahindra & Mahindra, Kalyani

Brakes

ADDRESS: 29/9, D-2 Block, MIDC, Chinchwad, Pune

TEL NO: 020-27477285, 56111870

EMAIL:

MOBILE: 9822294440

ABS+

FILLER

NYLON6 NYLON

66+

FILLER

POLYC

ARBON

ATE

PB

T

PP +

FILLER

HI

PS

PC

AB

S

PC

PB

T

GP

PS

NY+

30%

GF

AC

RY

LIC

HD

PE

- 1.5 1 - 0.5 9 - - - - - - -

From the above information we come to know that Shree plastics are using 75 % of PP + filler, 13

% of Nylon 6, 8 % of nylon 66 + filler + 4 % of PBT. It is manufacturing brake oil containers

37

NAME: Nadeem S. Kazi

DESIGNATION: Commercial Manager

ORGANISATION: Trimurti Plastics Industries

PRODUCT NAME: Dash Board, Facia for Speedometer, Battery lids and Containers

OEM: Exide, Minda Instruments

ADDRESS: 20, D III Block, MIDC, Chinchwad, Pune – 19

TEL NO: 020-27470805

EMAIL: trimurtiplastics@rediffmail.com

MOBILE: 9422317847

ABS+

FILLER

NYLON6 NYLON66

+ FILLER

POLYC

ARBON

ATE

P

B

T

PP +

FILLER

HI

PS

PC

AB

S

PC

PB

T

GP

PS

NY+

30%

GF

AC

RY

LIC

HD

PE

1 - 2.5 - 10 - - - - 2.5 - 6

From the above information we come to know that TRIMURTI plastics uses 46 & of pp + filler,

27 % of HDPE, 11% of nylon 66 + filler and 11 % of nylon + 30 % glass fields. It is

manufacturing Dashboards etc.

38

NAME: Pankaj Kumar

DESIGNATION: Incharge (Quality Control)

ORGANISATION: Prima Paper & Engineering Pvt. Ltd.

PRODUCT NAME: Cowling, Dash Board Fender

OEM: Force Motors, TATA Motors, Mahindra & Mahindra, Piaggio

ADDRESS: T-73, MIDC Bhosari, Pune - 26

TEL NO: 020-27129353

EMAIL:

MOBILE: 9822086496

ABS+

FILLER

NYLON6 NYLON66

+ FILLER

POLYC

ARBON

ATE

P

B

T

PP +

FILLER

HI

PS

PC

AB

S

PC

PB

T

LD

PE

NY+

30%

GF

AC

RY

LIC

HD

PE

- 20 5 - 1 55 10 - - 3 - 20 10

From the above information we come to know that Prima paper is using 45 % of EP + filler, 16%

of nylon 6 and 16 % of polycarbonate, 8 % HIPS & HDPE, 4 % of nylon 66 + filler, 2% of LDPE

& 1 % PBT. It uses in manufacturing in cowling & dashboard.

39

NAME: B.V. Poptani

DESIGNATION: Incharge (Moulding Shop)

ORGANISATION: Tek Component Pvt. Ltd.

PRODUCT NAME: Automobile connetors

OEM: Tata Yazaki

ADDRESS: EL 32/15 J Block, MIDC Bhosari, Pune

TEL NO: 020-30680300/19

EMAIL: bhupendra_poptani@tekcomponents.com

MOBILE: 9850880352

ABS+

FILLER

NYLON6 NYLON

66+

FILLER

POLYC

ARBON

ATE

PB

T

PP +

FILLER

HI

PS

PC

AB

S

PC

PB

T

GP

PS

NY+

30%

GF

AC

RY

LIC

HD

PE

- 2 4 1 0.5 3 - 0.5 - - - - -

From the above information we come to know that Tek is using 36 % of nylon 66 + filler, 27 % of

PP + filler, 18 % of Nylon 6,9 % of PC, 5 % of HDPE & ABS + filler. It is manufacturing

automobile connectors

40

NAME: T.S. Virdi

DESIGNATION: Partner

ORGANISATION: Tej Plastics

PRODUCT NAME: Autoswitches

OEM: Minda Industries

ADDRESS: J 362, MIDC, Bhosari, Pune - 26

TEL NO: 020-27120976

EMAIL: tej@pm3.vsnl.net.in

MOBILE: 9890006928

ABS+

FILLER

NYLON6 NYLON66

+ FILLER

POLYC

ARBON

ATE

P

B

T

PP +

FILLER

HI

PS

PC

AB

S

PC

PB

T

LD

PE

NY+

30%

GF

AC

RY

LIC

HD

PE

- 2.5 - - - - - - - 0.5 - - 2

From the above information we come to know that TEJ plastics is using 50 % of nylon 6, 40 % 0f

HDPE and 10 % of LDPE. It is manufacturing auto switches for two wheelers.

41

NAME: Hemant Joshi

DESIGNATION: Purchase Incharge

ORGANISATION: Emdet Engineers Pvt. Ltd.

PRODUCT NAME: Steering, Bumpers, Shrouds

OEM: Tata Motors, Mahindra & Mahindra, Larson & Tubro

ADDRESS: J-146, MIDC, Bhosari, Pune - 26

TEL NO: 020-27122004/1528

EMAIL: emdet@p2.vsnl.net.in

MOBILE: 9823070075

ABS+

FILLER

NYLON6 NYLON66

+ FILLER

POLYC

ARBON

ATE

P

B

T

PP +

FILLER

HI

PS

PC

AB

S

PC

PB

T

GP

PS

NY+

30%

GF

AC

RY

LIC

HD

PE

4 - - - - 41 - - - - 15 - -

From the above information we come to know that Emdet is using 68 % of PP + filler, 25 % of

nylon + 30 % glass fields and 7 % ABS + filler. It is manufacturing bumpers + fillers

42

NAME: Ashwin Garg

DESIGNATION: MD

ORGANISATION: Argee Plastics Pvt. Ltd.

PRODUCT NAME: Battery Handle, Radiator Fan, Radiator Housing

OEM: Piaggio, Exide

ADDRESS: MIDC Bhosari, Pune

TEL NO:

EMAIL:

MOBILE:

ABS+

FILLER

NYLON6 NYLON66

+ FILLER

POLYC

ARBON

ATE

P

B

T

PP +

FILLER

HI

PS

PC

AB

S

PC

PB

T

LD

PE

NY+

30%

GF

AC

RY

LIC

HD

PE

5 6.5 5 1 1 16 - - - - - - 15

From the above information we come to know that Argee plastics is using 31 % of PP + filler, 30

% of HDPE & 13 % nylon 6 and 10 % of ABS + filler & 6% of other polymers. It is

manufacturing battery handles.

43

NAME: V. Sugathan

DESIGNATION: Proprietor

ORGANISATION: Jaihind Enterprises

PRODUCT NAME: Inner and Outer Handles

OEM: Tata Motors

ADDRESS: J – 132, Opp. Quality Ice Cream, MIDC, Bhosari, Pune - 26

TEL NO: 020-27122044

EMAIL: jaihindent@vsnl.com

MOBILE:

ABS+

FILLER

NYLON6 NYLON66

+ FILLER

POLYC

ARBON

ATE

P

B

T

PP +

FILLER

HI

PS

PC

AB

S

PC

PB

T

GP

PS

NY+

30%

GF

AC

RY

LIC

HD

PE

1 1 0.5 - - 7.5 - - - - - - -

From the above information we come to know that Jaihind industries is using 75 % of PP + filler,

10 % of ABS + filler, 10 % nylon 6 and 5 % nylon 66 + filler. It is manufacturing inner and outer

handles for four wheelers and other automobile components

44

NAME: Ravindra Bhorpe

DESIGNATION: GM (Operations)

ORGANISATION: Renata Plastics

PRODUCT NAME: Automotive components

OEM: Tata Motors

ADDRESS: J – 526, MIDC, Bhosari, Pune - 26

TEL NO: 020-27121285

EMAIL: renata@vsnl.com

MOBILE:

ABS+

FILLER

NYLON6 NYLON66

+ FILLER

POLYC

ARBON

ATE

P

B

T

PP +

FILLER

HI

PS

PC

AB

S

PC

PB

T

GP

PS

NY+

30%

GF

AC

RY

LIC

HD

PE

1 1 0.5 0.5 1 - - - - - - - -

From the above information we come to know that Renata plastics is using 25 % of nylon 6 & PBT, 24 % of ABS + filler and 13 % polycarbonate and nylon 66 + filler.

45

Abs+(filler)

Nylon6

Nylon66

Polycarbonate

PBT PP+Filler

H.I.P.S

PCABS

PCPBT

GPPS

Nylon +30% GF

Acrylic

HDPE

Nylon66

Polycarbonate

26.9%

43.5%

21.2%

6% 6.7%

99.3%

10.5%

1.2%

1% 10%

21.5%

17%

72.65%

21.25%

6%

46

CONCLUSIONSAND

SUGGESTIONS

47

CONCLUSION

Actually the main function of the company was to find out the consumption of polymers in

automobile sector in pune region so as to find out the potential in the market. From the total

polymer consumption chart mentioned earlier we come to the conclusion that polypropylene is

used readily in automobile sector because we can enhance its properties by adding filler for

example: glass, mica, talc, etc. as per the requirement of the product. Appl produces PP + Filler as

per the customer requirements. Polypropylene is used in bumpers, dashboards, fuel tanks etc.

Polypropylene is used frequently because:

There is no problem in the availability.

Its trends do not vary.

It is cheaper then metal.

Properties are more or less same as of metals.

The weight is lesser then metals which helps in increasing average of the vehicle.

As a student I have got a wonderful opportunity to work with such a good company as from

this study I have learnt a lot, I have given the work of research throughout the whole Pune

region that what are the steps company should follow in regard with their competitors, that

was indeed to be the best phase of my project when the recommendations given by me were

accepted and the company is following some steps which they think the most important

among all of the suggestions given by me. As well as I am thankful to all my subordinates and

my project guide Mr. Arun Sharma, as without their support and ally it was difficult to work

or attain something.

48

SUGGESTIONS

After studying all the aspects of the company I have certain suggestions, which are as follows:

The company should increase sales in such areas where it is lacking in sales in other

words company have to first take care of its marketing strategy that whether the

company is meeting as per the demands of the customers or not because a customer

accepts what he expects.

The company should try to reduce the cost of production by way of automation, if this

would be taken in consideration then the supply of the company automatically meets

the ordered quantity and it saves time too which is very important as money spended

on idle time would be saved and cost of production must be low.

Growth opportunities in public transport and commercial sectors

o As being a polymer industry a company have a wide scope in public as well as

commercial sector because still these transport companies are using metals

other then polymer

Material handling

o Proper utilization of resources so that there should not be any wastage

o Take care of the rejected lot

o Transportation issue is the biggest or considered to be the most vital because of

the expectation of the consumer V/S the delivery of the product.

Sourcing of materials

o Analysis of the market trends as demand changes as per the trend therefore

company have to adopt a policy of trend analysis because with the help of this

a company can change its standardization of the product which plays a very big

or essential role to attract consumers towards their own product.

Proper inputs from customer

o A company have to produce as per the specifications lead by the customer what

are their actual wants and desires what are the things which they are looking in

their purchasing behaviour

49

Market study must be done time to time as to know the behaviourial aspect of the

customer and to become aware about their wants and desires

Meetings must be done separately with each and every customer to add some new

inputs to the product, this is considered to be the best way to retain a customer for a

long time, as customer has become a part of production in this process.

Dealing with customer on several aspects such as

o Credit policies

o Complaints and customer care issues

o Salesmanship (personal interaction with the customer)

Personal visit must be done by a marketing head by presenting seminars on monthly

basis and each and every customer must be given a sense of participation so that they

can raise their issues regarding anything

50

ANNEXURES

51

ANNEXURES

Our Original Equipment Manufacturers:

Our Major Customers:

MARUTI UDYOG LIMITEDTATA AUTO PLASTICS SYSTEMS

LIMITED

TATA MOTORS LIMITEDVARROC ENGINEERING PRIVATE

LIMITED

BAJAJ AUTO LIMITED VARROC LIGHTING PRIVATE LIMITED

HONDA MOTORCYCLES INDIA LIMITED BRIGHT BROTHERS LIMITED

HERO HONDA MOTORS LIMITEDPARADISE PLASTICS ENTERPRISES

LIMITED

GAS AUTHORITY INDIA LIMITED SUBROS LIMITED

PREMIERE INSTRUMENTS AND CONTROLS LIMITED

SUN VACUUM FORMERS LIMITED

SAMSUNG INDIA ELECTRONICS LIMITED

TATA FICOSA LIMITED

LG ELECTRONICS INDIA PRIVATE LIMITED

LUMAX GROUP OF COMPANIES

VDO INDIA LIMITED MOTHERSON GROUP OF COMPANIES

AMERICAL POWER CONSERVATION COMPANY INDIA LIMITED

THE SUPREME INDUSTRIES LIMITED

GODREJ LIMITED DYNAMIC INDUSTRIES

PHILIPS INDIA LIMITED DURALINE INDIA PRIVATE LIMITED

52

QUESTIONNAIRE

NAME:

DESIGNATION:

ORGANISATION:

ADDRESS:

TELEPHONE NO: ………………. FAX NO: ……………….

E-MAIL: ……………………………………………………………….

1. Nature of your business?

2. Which polymers you use?

3. What are the sources of purchasing raw material?

4. Are you using blends?

5. If you are willing to use it in future?

6. What is your approval base?

7. What is the time framing of testing?

8. Which part of the automobile you mould, for which company and for which model?

9. What is the weight of the part you mould?

10. What are the critical requirements?

11. What are the credit terms?

12. What is the price range?

13. What is your total requirement?

What are your suggestions or comments which u likes to make regarding the

service of the product

53

Total Polymer Consumption of Automobile Sector In Pune Region

CUSTOMER NAME

PRODUCT NAME

OTHER EQUIPMENT MANUFACTURER

LDPE

ABS + (FILLER)

NYLON 6

NYLON66

POLYCARBONATE

PBT

PP+ (FILLER)

H.I.P.S

PCABS

PCPBT

GPPS

NYLON+30%GF

ACRYLIC

HDPE

TOTAL IN (MT)

PLAST O

MECH

Exide Batter

y Caps,Bajaj Pulsor Lights,Wirel

ess Handset For Bhara

t Electronics

Tata Johns

on Exide Bhara

t Electronics Bajaj Auto

8 1.5 1.5 1 25 8 45

SPS Plasti

cs

Bajaj Auto

2 10 0.5 12.5

Sermo PM

White goods

Bajaj Auto, Hond

a

10 + (10)

10 30

Vinayak

Polymer

Industries

Fuel Tank Brake Fluid conainer

Kinetic

Motor1 0.3 0.2 2 1.5 10 15

Niky Engineers

Intricate

Shape Precis

ion Component

s

Bajaj Auto, Piaggi

o, Mahindra & Mahin

dra

1.5 0.5 (10) 2 14

54

CUSTOMER NAME

PRODUCT NAME

OTHER EQUIPMENT MANUFACTURER

LDPE

ABS + (FILLER)

NYLON 6

NYLON66

POLYCARBONATE

PBT

PP+ (FILLER)

H.I.P.S

PCABS

PCPBT

GPPS

NYLON+30%GF

ACRYLIC

HDPE

TOTAL IN (MT)

Nitiraj Plastics

and Engineeri

ng

Car Tank

s, Reservoir Tank

s

Telco, Maruti Udyog

0.8 2 0.2 7.3 0.20.5

29 40

Apex Enginee

rs

Electrical Items

for two Wheelers

Bajaj Auto Ltd.

0.30.05

0.65 1

Shrimani

industries

Tool Box, Fender,

Cowling,

Battery

Container

Bajaj Auto, Exide Batteri

es

3 3 0.5

18 +

(3.5)

28

ElitePlastics

Battery

Containers, Electi

cal Items

, Headlights Container

Exide

Batteries, Bhar

at Electronic

s, Varroc

Lighting, Hi-

Tech Plast

0.5 2 1.5 0.5 0.510 +

(2)5 28

RatnadeepEnterprises

Fuel Filter, Back

up Ring

Bajaj Auto

0.5 (0.5) 1 1 3

55

CUSTOMER

NAME

PRODUCT

NAME

OTHER

EQUIPMENT

MANUFACTURER

LDPE

ABS +

(FILLER

)

NYLON 6

NYLON66

POLYCARBO

NATE

PBT

PP+

(FILLER

)

H.I.P.S

PCABS

PCPBT

GPPS

NYLON+30%GF

ACRYLIC

HDPE

TOTAL IN

(MT)

                                   

Shree

Plastics

Brake Oil Container

Maruti

Udyog,

Tata Motor

s, Mahindra & Mahin

dra, Kalya

ni Brake

s

1.5 1 0.5 9 12

                                   

Trimurti

Plastic

Industries

Dash

Board,

Facia

For Speedometer,

Battery

Lids &

containers

Minda Instruments, Exide Batter

ies

1 2.2 0.310 +

(6)2.5 22

                                   

Prima

Paper &

Engg. (P) Ltd.

Cowling, Das

h Board, Fender

Force Motor

s, Tata

Motors,

Mahindra & Mahin

dra, Piaggi

o

3 20 5 1

25 +

(50)

10 10 124

                                   Tek Components (P) Ltd.

Autombile

Connectors

Tata Yazak

i2 4 0.5 3 0.5 10

Tej Plasti

cs

Auto

Switches

Minda Indust

ries0.5 2.5 2 5

56

57

CUSTO

MER NAME

PRODUC

T NAME

OTHER

EQUIPMEN

T MANUFACTURE

R

LDPE

ABS +

(FILLER

)

NYLON 6

NYLON66

POLYCARBONAT

E

PBT

PP+

(FILLER

)

H.I.P.S

PCABS

PCPBT

GPPS

NYLON+30%GF

ACRYLIC

HDPE

TOTAL IN

(MT)

                                   

Emdet

Engineers

Steering

Wheels,

Bumpers, Shrouds

Tata Motors

, Mahindra & Mahin

dra, Larson

& Tubro

4 30 15 49

                                   

Argee

Plastics

Battery

Handles,

Radiator

Housing, Radiator Fans

Exide Batteri

es

0.5

5.5 6 5 0.5 1 15 0.5 1 15 50

                                   

Jai Hind Enterprises

Inner and Oute

r Hand

les

Tata Motors

1 1 0.55 + (2.5)

10

Renata

Plastics

1 1 0.5 0.5 1 3 7

58