1 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Need Assessment Survey ReportPlastic Cluster, Aurangabad
Survey byNIFT Mumbai
Supported byMCED Aurangabad,
NID Ahmedabad, & Design Clinic Scheme
by Ministry of MSMEs Govt. of India
2014www.designclinicsmsme.org
2 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Design Clinic Scheme is a tested strategic model of design intervention, where a solution to an existing design problem is diagnosed and remedial steps suggested by a multi-disciplinary team of design experts. In this scheme, the value additions to an idea or a concept are imparted through interaction at a lesser cost to a specific industry/sector. It applies to a sector that requires intervention, like manufacturing etc. as the existing conventional models of design consultancy and training are not viable. These models bring design exposure to the door-step of industry clusters for design improvement, evaluation, analysis and adopting even long-term consultancy/design related intervention
The main objective of the Design Clinic is to bring the MSME sector and design expertise into a common platform, to provide expert advice and solutions on real time design problems, resulting in continuous improvement and value addition for existing products. It also aims at value added cost effective solutions. These Design Clinics in clusters of the country are to usher in a continuous competitive advantage to the MSMEs.
The broad activities planned under the scheme include creation of Design Clinics Centre along with four regional centres for intervention on the design needs of the MSME Sector. Further these centres will have linkages with engineering, management, design institutes of the country.
The scheme is under operation in a Public Private Partnership (PPP) Mode.
http://www.dcmsme.gov.in/schemes/DesignClinic.htm
FRONT COVERInjection Moulding at Darshan PlasticsMIDC, Waluj, Aurangabad
BACK COVERFinal Packing of finished products at Darshan Plastics MIDC, Waluj, Aurangabad
3 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Contents
Synopsis 04Acknowledgement 05Need Assessment Survey 06
Introduction 07About DCS MSME 08 About MCED Aurangabad 10About NID Ahmedabad 11About NIFT Mumbai 12The PESTEl Analysis-Aurangabad 13SWOT analysis–Aurangabad 21Industry Attractiveness & Govt. Initiatives 22About the Plastic Cluster 24Intervention Pathway 25
Survey 26list of Participants 27
Annu Industries 29APM Plast 40Blue Star Engineers 60Concept Auto Packaging 72
SWOT analysis - Cluster 380Finding 383Recommendations 386
5 Day Workshop 390About the Workshop 391Schedule of the Workshop 392Day 1 394Day 2 395Day 3 396Day 4 397Day 5 398Design Briefs 399
References 401
Notes 402
Cool Engineering 81Darshan Plastic 91Electro Plast Industry 102Jayshree Enterprises 121Jyoti Industries 136Mitali Industries 146Moraz Plastic 163Mould Technology 166Plast Tech 180Rupesh Enterprises 189 Sejal Plastic 200Siddhi Polymers 214Snehal Plastic Industries 228Sunrise Auto Pack 241Sushma Industries 252Suyog Plastic 260Swagat Polymers 280Tirumala Industries 295Trimurti Polymers 311Ulka Plastic Industries 325V. P. Pet Polymer 336Varroc Polymer Pvt. ltd. (Tech.) 351Yogesh Plastic Industries 365
roble
4 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Design Awareness Programme (DAP) is part of the Design Clinic Scheme, an initiative of the Ministry of Micro, Small & Medium Enterprises (MSME), Government of India (GOI) & National Institute of Design (NID).
The National Institute of Design, Ahmedabad, acts as the nodal agency for the Design Clinic Scheme. The Maharashtra Centre for Entrepreneurship Development (MCED) associated with National Institute of Fashion Tech-nology (NIFT), Mumbai; set up by Ministry of Textiles, Govt. Of India; to leverage the expertise of the institute in the arena of design education and its commitment to contribute to society.
The main objective of the Design Clinic Scheme is to provide a common platform for the MS&ME sector and Design experts for mutual sharing of ideas and form symbiotic relationship for creating sustainable growth envi-ronment for the MSME sector.
DAP initiative aims to evaluate real life issues and provide practical solutions for value addition in the current context while not ignoring the long term survival and growth potential.
Synopsis
Finished Products being packed at Snehal Plastic Industries, MIDC, Waluj, Aurangabad
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We would like to express our sincere gratitude to Ministry of Micro, Small and Medium Enterprises (MSME), Government of India and National Insti-tute of Design (NID) Ahmedabad, for giving us the opportunity to be a part of the Design Clinic Scheme.
We would also like to extend our special thanks to The Maharashtra Centre for Entrepreneurship Development (MCED) to select us to do the project.
Our gratitude is also due to Mrs. Nilima R. Singh, Director-National Insti-tute of Fashion Technology, Mumbai for providing us guidance and support to successfully complete the report.
Our heartfelt thanks to all the Owners and workers of the units surveyed who took time out of their busy schedule and spent time in explaining the modus operandi of their business to us.
Acknowledgement
PET jar being manufactured at V. P. Pet Polymer, MIDC, Waluj, Aurangabad
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The Plastic cluster at Aurangabad was contacted through MCED. An interview schedule was planned with all the unit owners who agreed to be a part of the survey.
Team:Mr. Saurabh KumarMr. Tanmay KandekarMs. lipi Choudhary
Objective: The primary objective of need assessment survey is to collate detailed cluster information in order to understand the business and supply chain issues like:
• Existing product design and packaging and scope of intervention or R&D for re-designing/ packaging changes or diversifying into different product categories.
• Current state of technology and scope of modernization• Visual identity and branding and other collaterals• Forward and Backward linkages for Marketing and Raw materials• Competitive structure and rivalry in the Industry• Infrastructure, ergonomics and environment factors• Manpower recruitment, availability of skilled labour, training and skill up‐
gradation opportunities.
Methodology:• Interview with unit owners (27 units).• Discussion with unit owner and workers.• Business Process observation.• Questionnaire survey of manufacturing units.• Self observation and analysis.
Need Assessment Survey
NEED ASSESSMENT PROCESS AND TOOlS
Expected outcome:This research aims to provide qualitative and detailed data of the plastic cluster to develop an understanding and generate insights into the business dynamics of the cluster. This would help identify the existing problems and future scope in the area for design intervention and business development.
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Agricultural Sheet net being manufactured at Yogesh Plastic Industries, MIDC, Shendra, Aurangabad
IntroductionDCS for MSMEsMCEDNIDNIFTPESTEl AnalysisSWOT AnalysisIntervention Pathwaylist of ClustersInd. Attractiveness & Govt. Initiatives About the Plastic ClusterIntervention Pathway
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PurposeTo increase awareness about the value of design and establish design learn-ing in MSMEs. To increase competitiveness of MSME products and services through design.
Objectives• To create a sustainable design ecosystem for the MSME sector through
continuous learning and skill development.• To promote use of design by MSMEs for developing products and services
that are market led.• To focus on building the design capability of MSMEs to enable them to
improve business performance as well as compete in the global market.
Key principles• Adopting a rigorous, yet applicant friendly, process.• Promoting and disseminating design concepts in regional or local languag-
es understood by the MSMEs. Establishing benefits without overwhelming the MSMEs.
• learning from other successful design-support programmes.• Establishing systematic processes for R&D in MSMEs.
Scheme descriptionFor easy percolation of design thinking and philosophy and maximum benefit for MSME units the Design Clinic Scheme is divided at 3 broader levels. These activities are helpful in smooth transition in to several levels of design inter-vention in industrial and business activities of MSMEs.
Design Awareness SeminarThe design sensitisation seminar is aimed to create a platform for MSME units
to improve the manufacturing competitiveness. The seminar will help MSME participants to interact with design experts/speakers to understand design methodology and benefits of design to MSME in their business, product, process, service and operations. To take design to a higher level of manufactur-ing functions, it is very important to develop an understanding of the design scenario and environment at an early stage of conception.
Design Awareness ProgrammeThe design awareness programme is focused on exploring industrial functions and activities to develop a holistic map of MSME clusters and units. The design expert/s will generate design information about products, market scenario, technology, communication, research and development, and various industrial functions along with human factor study for ergonomics, safety, convenience, learning and skill up gradation through design research. The programme will also provide design remedies for identified opportunities through the design clinic workshop.
The design awareness programme is conducted in two stages:• Need Assessment Survey• Design Clinic Workshop
Design ProjectsDesign projects are identified during the need assessment survey and discussed during the design clinic workshop. Project which require intensive design observation and interventions can be taken up as design projects with the help of design experts. The project can be related to design intervention in area of product/process /strategic areas where design can help in generating solutions and value for individual or group of MSMEs.
About DCS for MSMEs
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Role of Design in Improving CompetitivenessDesign is an approach, process and methodology. Design is indented, purpose-ful, contextual, which is aimed to create advantage, distinction and futuristic outcome as a result. Design is systemic and holistic in nature, there fore helps in generating more creative, impactful and sustainable solutions. In manufac-turing, design is commonly associated with industrial product design – specif-ically the ‘aesthetics and appearance’ of a product at a surface level interaction. However, the application of design is much broader, for example designing for functional appeal, ease of manufacture, consumption and sustainability. De-signing may also be done for reliability or quality or business processes. Service designs are primarily to cater to customers experience of the delivered product and service.
The larger purpose of design is to do things in a better manner, to improve a situation and to make a positive difference. The role of design in business is to create value. A company can use the design process to add value to products, services, and the organisation. A well-designed product, service, or organisa-tion is always more valuable.
Design, innovation and growth are linked. Innovation and design are not simply about new products or technology. They are also about how to improve products for everyday use, leading to reduced costs, increased usability and new business opportunities. Design is recognised as an innovative discipline that can help MSMEs to sustain and grow in an increasingly competitive mar-ket.
About DCS for MSMEs
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MCED has been a pioneer in espousing social and economic entrepreneurship since 1988. It is one of the foremost institute working in the areas of Entrepreneurship development.
MCED conducts special training programs, Seminars and skill development courses for young and budding entrepreneurs and encourages them to solve their problems in respective start-ups.MCED benefits the self employed people greatly by sharing the knowledge and success of the industry experts.
MCED has its offices all over Maharashtra. Beyond Maharashtra, MCED has offices in Delhi, Assam and Goa.
Need Assessments Survey Approach Process:Steps below are followed to meet the objective of Need Assessment Survey
• Questionnaire survey of Units.• Process Observation of the Unit.• Interaction with Unit management.• Opportunity areas finding.
About MCED Aurangabad
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On April 7, 1958, Charles and Ray Eames presented the India Report to the Government of India. The India Report defined the underlying spirit that would lead to the founding of NID and beginning of design education in India. The Report recommended a problem-solving design consciousness that linked learning with actual experience and suggested that the designer could be a bridge between tradition and modernity. The Report called upon future de-signers to re-examine the alternatives of growth available to the country at that time.
Based on the recommendations made in the India Report, the Government of India with the assistance of the Ford Foundation and the Sarabhai family estab-lished the National Institute of Industrial Design, as it was originally called as an autonomous all-India body in September 1961 at Ahmedabad. This unique curriculum and revolutionary educational philosophy remain part of NID to the present day.Today the National Institute of Design is internationally acclaimed as one of the finest educational and research institutions for Industrial, Communication, Textile and IT Integrated (Experiential) Design. It is an autonomous institution under the aegis of the Ministry of Commerce and Industry, Government of In-dia and is recognised by the Department of Scientific and Industrial Research, Government of India as a Scientific and Industrial Research Organisation.The aim is to provide design intervention for craft, handloom, rural technol-ogy, small, medium and large scale enterprises, and outreach programmes for capability and institution building and sustainable livelihood, employment opportunities and economic growth.
NID has been a pioneer in industrial design education after Bauhaus and Ulm in Germany and is known for its pursuit of design excellence to make Designed in India, Made for the World a reality. NID’s graduates have made a mark in key sectors of commerce, industry and social development by taking role of catalysts and through thought leadership.
About NID Ahmedabad
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National Institute of Fashion Technology (NIFT) is an institution of Design, Management and Technology. It was set up in 1986 under the aegis of the Min-istry of Textiles, Government of India and NIFT has been granted statutory status under the act of Parliament of India in 2006, empowering the Institute to award degrees and other academic distinctions.
In 2006, the Parliament passed the National Institute of Fashion Technology (NIFT) Bill, 2006, thereby receiving a statutory status and empowering the in-stitute to grant its own degrees and other academic distinctions. It also counts among the coveted list of an Institute of National Importance by the Parliament of India.
With its head office in New Delhi, NIFT has centers at Mumbai, Kolkata, Kan-gra, Gandhinagar, Hyderabad, Chennai, Bangalore, Raebareli, Patna, Shillong, Bhopal, Kannur, Bhubaneswar and Jodhpur where it offers four-year bachelor and two-year master programmes in the areas of Design, Management and Technology.
NIFT’s graduates have made a mark in key sectors of entrepreneurship, com-merce, industry and social development by taking the leading responsibilities as design and business leaders.
About NIFT Mumbai
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A PESTEl analysis is a framework or tool used by marketers to analyse and monitor the macro-environmental (external marketing environment) factors that have an impact on an Industry/Organization.
Social Forces
LegislativeForces
Environmental Forces
TechnologicalForces
Organization
PoliticalForces
EconomicForces
PESTEL stands for:• P – Political• E – Economic• S – Social• T – Technological• E – Environmental• l – legal
As the Plastic Cluster in Aurangabad is similar in its dynamics to an indus-try barring its size, the PESTEl analysis of Aurangabad becomes pertinent to identify the key variables that drive the Plastic Cluster.
The PESTEl Analysis - Aurangabad
POLITICAL
Social Forces
LegislativeForces
Environmental Forces
TechnologicalForces
Organization
PoliticalForces
EconomicForces
History:A prime minister of the Muslim Kingdom of Ahmednagar, Malik Ambar established a town at a village called Khirki. later, his son Fateh Khan named the town as Fatehpur in 1626. Mohammad Bin Tughlaq tried to switch over the capital of his Delhi sultanate to Fatehpur in 14th century keeping in mind the strategic location of the town. The town was at the centre of India, and the region was considered the safest from the marauding armies of the Afghan and Central Asian raiders.
When Aurangazeb took over the Deccan kingdoms, he changed the name of the town to Aurangabad in 1653. Aurangazeb used the town as the strategic point to suppress the rising power of Shivaji. Aurangabad was taken over by the Nizam of Hyderabad after the death of Aurangazeb in 1707 that retained control till it was merged with Maharashtra in 1956.
Source: http://www.maharashtratourism.net
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* Aurangazeb * Shuja, Aurangzeb, and Murad Bakhsh
Current Scenario: The BJP-Shiv Sena alliance is ruling the Aurangabad Municipal Corporation (AMC). Aurangabad comprises of 9 talukas and 1344 villages, covers an area of 10,107 sq km out of which 141.1 Sq. Km is urban area and 99,587 sq. Km is rural area. The population of around 36.95 lacs. There are no minerals availa-ble in Aurangabad. In Aurangabad district total forest area is 135.75 Sq.Km.
ECONOMIC
Social Forces
LegislativeForces
Environmental Forces
TechnologicalForces
Organization
PoliticalForces
EconomicForces
Maharashtra Industrial Development Corporation established a number of industrial estates at various locations in and around Aurangabad, which con-tributed immensely to the economic growth and development of the area.
Key Economic Drivers: AurangabadIndustry Established Industries: Automobiles, Auto components, Pharmaceuticals,
Breweries, Food Products, Plastic, Rubber, Paper & Paper ProductsTourism World heritage sites of Ajanta, Ellora and other tourist destinations of
Daulatabad, Bibi-ka-Makbara attract large number of touristAgriculture Cotton, Sugar-cane, Maize, Bajra, Jowar, Soyabin, Sunflower, etc.Education Engineering, Management, Medical and vocational fieldsHealth Availability of ample medical facility with hospitals viz. Govt. Hospital, MGM
Hospital, Nandlal Dhoot Hospital, Dr. Hegdewar Hospital, Kamalnayan Bajaj Hospitals, Etc.
Present Industrial Status of Aurangabad:
Prominent Industries:•AutomobilesAssembly•AutoComponents•Beverages•Pharmaceuticals•WhiteGoods
The major industrial houses present are as follows:
• Videocon, Garware, Ajanta Pharma, Glenmark, lupin, Wipro, Orcid Pharma, Endurance Systems, Rucha Engg., Indo German Tool Room, Ceekay Daikin ltd., Cosmo Films, NRB bearing, Hindalco, Almex Aerospace, Can-pack India, Varroc, Dagerforst, FriogoriFico, Allana, Nath Seeds among others.
• Speciality in Automotive, Auto components, Pharmaceuticals, Breweries, Con-sumer durables, Plastic processing, Agriculture and Biotech. Among these Re-combinant Insulin Manufacturing Plant of Wockhardts (Wockhardt Biotech Park) is the largest Bio-pharmaceutical plant in India.
• The Shendra, Chikalthana and Waluj MIDC are prominent industrial zones on the outskirts of the city, with various major multinational groups having set up manufacturing or processing plant in and around the city.
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Micro Small and Medium Enterprises (MSMEs):
Aurangabad has 3,405 medium and small scale units generating about 36,871 jobs with an investment of Rs. 404.86 Cr. It is estimated that by year 2020 these units will grow to 9000 nos, generating about 95,000 jobs with an investment of Rs. 1050 Cr.
Large Scale Enterprises in the District:
• Aurangabad has around over 195 units of large scale enterprises or Indus-trial Enterprises Memorandum (IEM) which has generated 80,500 jobs with total investments of Rs. 7,384 Cr.
23% 30%
7%29%
11%
21% 30%
8%29%
12%
Sector wise Units Contribution -2010 Sector wise Units Contribution -2020
Engineering
Manufacturing Machinery
Beverages & Food Products
Pharmaceuticals
Rubber & Plastic
Engineering
Manufacturing Machinery
Beverages & Food Products
Pharmaceuticals
Rubber & Plastic
• It is estimated that by year 2020 these units will grow to 343 units generat-ing over 1,95,000 jobs with total investment of Rs. 1,79, 590 Cr.
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Currently has 5 MIDCs and 2 Growth Centres.•PlasticandRubberProducts
Comparative Analysis of Industrial Districts:
SOCIO-CUlTURAl
Social Forces
LegislativeForces
Environmental Forces
TechnologicalForces
Organization
PoliticalForces
EconomicForces
The rule of the “ Satavahanas” witnessed the era of peace and prosperity and hence the district of Aurangabad then centered around Pratishthan the capi-tal of the Satvahanas for centuries together, became the hub of socio-cultural activities of the Deccan.
The Satvahanas gave incentive to trade and commerce and monopolised the Greeco-Roman markets as far textile goods namely Paithani the high-class silk-en sarees of Paithan is concerned.
The current day Aurangabad offers a wonderful opportunity to step back to past history. Ajanta and Ellora caves and Bibi-Ka-Makbara bring back the visi-tors to the past history of the town.
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Aurangabad Caves Bibi-Ka-Makbara
Key Festivals and Fairs in Aurangabad:Ajanta and Ellora Festivals: It is the festival of classical dance and music under the backdrops of the Ellora Caves. The festival usually falls in March. The festi-val showcases best talents from across India. Maharashtra government organiz-es the festival.
Aurangabad Festival: Aurangabad Festival promotes the rich local culture, tal-ent, art and heritage of the city. The festival is organized to explore the hidden talents and to increase the vibrancy of this historic city. The festival generally falls in December. The Aurangabad Festival Committee organizes it.Buddha Jayanti: Buddha Jayanti is organized in the city as an important fes-tival. Community halls and public places are remained crowded for mass prayers. Religious processions are also taken out on this day.
Dussehra: Dussehra is celebrated for ten days. On the tenth day, a fair is held when people greet each other with offerings of ‘Apta’ leaves that symbolize good luck. Source: http://www.maharashtratourism.net
Current social scenario:Population: According to the census of 2011 the Male Vs Female population of Aurangabad is 1,928,156 Vs 1,767,772 respectively.Traffic is minimal, the roads are barely motorable and the errant traffic sense of
its residents is no different than in any other Tier II town.
However, the southern side is the face of new wealth: A stretch of sprawling bungalows dotting the streets. Jalna Road, an arterial road that connects the city, is the nerve centre. Practically everything is located in and around this stretch.
The evidence of prosperity and change are clearly visible; from the four-month-old 800,000 sq ft Prozone mall, which is the largest and only mall in the city, to dealerships of automobile brands like Skoda, Nissan and Maruti Suzuki and eateries and hotels like the Taj and lemon Tree.
In the last five years, the city has morphed well beyond its status as Maharash-tra’s tourism capital into a hotbed of industrial activity, primarily led by the automobile and engineering cluster. In more recent times, the growth has been spurred by agriculture and real estate development. Cotton farming has grown in the surrounding villages.
Farmers have thrived thanks to cotton prices hovering at an all time high of around Rs. 4,500 per quintal. Residential real estate prices have zoomed. Prop-erties were valued at around Rs. 20 lakh an acre in areas like Nashik Road, Old Bombay Road and Beed Road in 2006. Prices have risen five times in the last four years.
Source: http://forbesindia.com/article/on-assignment/the-value-hunters-of-au-rangabad
Emerging Socio Economic Trends•ItisemergingasaregionalhubonthelinesofPuneandNagpur•Attractinglargeinvestmentsinindustrial,Services&Tourismsectors•Thecityhasovertenlakhpopulationwithalarminggrowthprojections•Itisemergingasacentreforhighereducationandhealthfacilities•Rapidurbanizationandencouragingdevelopment•Enhancedsocialinfrastructure•Worldclasstouristdestinations,promotionstoindustrialsector
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TECHNOlOGICAl
Social Forces
LegislativeForces
Environmental Forces
TechnologicalForces
Organization
PoliticalForces
EconomicForces
The IT sector promotion was initiated in Aurangabad since year 2003 along with the formation of HTPI office and IT park in Chikalthana in vicinity to Pune and Mumbai.
Good educational base, existence of local IT units and industrial maturity of the city due to manufacturing segment, low cost of operation are plus point of the city for the future IT sector growth.
i) Currently, around 22 IT units are operational employee 2500 professionals. The city has 6 registered HTPI, 100% EOUs exporting services worth Rs, 7 crores per year to USA, Germany, Neatherland, among others.
ii) In past two years, BPOs have been established which are providing services in various languages to local customers and also to few international clients. Aditya Birla group, Vodaphone are extending services to their clients, through BPOs at Aurangabad.
The key machines used by the plastic cluster are:• Injection• Extrusion• Compressor
• Grinder
The key software used in the plastic cluster:• Tally(foraccounting)• MicrosoftExcelandWord
ENVIRONMENTAl
Social Forces
LegislativeForces
Environmental Forces
TechnologicalForces
Organization
PoliticalForces
EconomicForces
The total area of Marathwada region is of 64,813 km. and is bounded by the Vidharbha region on the North, by Andhra Pradesh on the East and South-east, by Karnataka on the South and by Western Maharashtra on the West. The entire region is situated at an average height of about 300-650 m. above Mean Sea level gradually sloping from West to East, and is traversed by hill ranges origination from the Sahyadris in the West and the Satpudas in the North.The weather is generally dry and moderately extreme. The average day tem-perature ranges from 27.70 C to 38.00 C while it falls from 26.90 to 20.00C during night. Similarly summer and winter temperature also varies greatly. The highest during summer day being about 43.30C while the lowest during winter nights about 6.00C. Relative humidity is extremely low for major part of the year (between 35 to 50%) while it is highest (85%) during monsoon.
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The rainy season is considered from middle of June to the end of September which is followed by a sultry period from about the end of September to the middle of November. The winter season commences from the middle of No-vember and ends by the end of the January followed by a dry hot summer from February to middle of June. Summers are in general full of gusty winds. The normal average rainfall is about 90 cm but is rather variable form year to year.
Aurangabad and Nanded districts covers more forest area than the others. There are Teak, Sandalwood, Anjan, Moh, Tembhurni, Ain and other kinds of trees in these forests. In Aurangabad district, Gautala is a well known sanctu-ary, Jayakwadi is also famous for bird sanctuary. Thorny scrub forests are hav-ing major trees like Bor, Babul, Aloe-voera etc. The major agricultural crops of the Marathwada region are Cotton, Oil seeds, Bajra, Jowar, Groundnut, Wheat, Safflower and irrigated crops like Sugarcane which is one of the important irrigated crop.
lEGAl
Social Forces
LegislativeForces
Environmental Forces
TechnologicalForces
Organization
PoliticalForces
EconomicForces
MICRO, SMAll & MEDIUM ENTERPRISES DEVElOPMENT (MSMED) ACT, 2006
Definition of Micro, Small and Medium Enterprises :(a) Enterprises engaged in the manufacture or production, processing or pres-ervation of goods as specified below:
i. A micro enterprise is an enterprise where investment in plant and machin-ery does not exceed Rs. 25 lakh;
ii. A small enterprise is an enterprise where the investment in plant and ma-chinery is more than Rs. 25 lakh but does not exceed Rs. 5 crore; and iii. A medium enterprise is an enterprise where the investment in plant and machinery is more than Rs.5 crore but does not exceed Rs.10 crore.
Key initiatives by the Government:a) As per announcement made by the Governor in the Annual Policy Statement 2005‐06, a scheme for strategic alliance between branches of banks and SIDBI located in clusters, named as “Small Enterprises Financial Centres” has been formulated in consultation with the Ministry of SSI and Banking Division, Ministry of Finance, Government of India, SIDBI, IBA and select banks and circulated to all scheduled commercial banks on May 20, 2005 for implementation. SIDBI has so far executed MoU with 15 banks (Bank of India, UCO Bank, YES Bank, Bank of Baroda, Oriental Bank of Commerce, Punjab National Bank, Dena Bank, Andhra Bank, Indian Bank, Corporation Bank, IDBI Bank, Indian Overseas Bank, Union Bank of India, State Bank of India and Federal Bank).
b) Targets for lending to Micro and Small enterprises (MSE) sector by Domestic Commercial Banks and Foreign Banks operating in India.
c) Issue of Acknowledgement of loan Applications to MSME borrowers.
d) Banks are mandated not to accept collateral security in the case of loans upto Rs.10 lakh extended to units in the MSE sector. Banks are also ad-vised to extend collateral‐free loans upto Rs. 10 lakh to all units financed under the Prime Minister Employment Generation Programme of KVIC.
e) A composite loan limit of Rs.1 crore can be sanctioned by banks
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to enable the MSE entrepreneurs to avail of their working capital and term loan requirement through Single Window.
f) Public sector banks have been advised to open at least one specialised branch in each district. As per the policy package announced by the Govern-ment of India for stepping up credit to MSME sector, the public sector banks will ensure specialized MSME branches in identified cluster/centres with preponderance of small enterprises to enable the entrepreneurs to have easy access to the bank credit and to equip bank personnel to develop requisite expertise.
g) UDYOG SETU:Objective: To establish new industries, give information & guidance regarding: •Variousrules®ulationsofGovt.•Variousincentiveschemes.•PermissionrequiredfromGovt./SemiGovt.Institutes•Clearancecertificates.•Variousservicesasperneedofapplicant.•Allaboveservicesatonecounter&withinpredeterminedtimelimit
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Strength:1. Historical background of the District useful for Foreign Investor.2. Tremendous scope for ancillarisation of industries Especially in Engineering units3. Central location of India.4. Good communication system available.5. Good Transportation Connectivity available i.e. Road, Rail & Air, with all over India.6. A strong young first Generation Entrepreneurs in Aurangabad.7. Skilled & unskilled man power Available at very low cost.8. Good dealer network & logistic facility is Available.9. Educational Intuition like ITI/Engg. College/IGTR/ CIPET/MCED to facilitate and support to industries.10. Due to major financial institute running in Aurangabad, finance is made easily available to the Industries.
Weakensses:1. Poor Water Supply System.2. Improper maintenance of available Infrastructure3. lack of coordination with different Govt.. Depts.4. Inadequate Working Capital from F.I. & higher rate of interest.5. R & D / Technology up gradation Facilities are not available.6. low level of Business exports7. Awareness Camps/seminars are not organized so frequently.8. High level of skilled man power is not available
Opportunities:1. MIDC has plan to develop Additional MIDC’s in the region which creates good opportunities for industries. (MIDC - Maharashtra Industrial Development Corporation )2. Cluster development programme of Central Govt.. boost for creation of jobs
SWOT Analysis of District Aurangabad
/ skilled & unskilled man power.3. Expansion project of CIPET is playing vital roll for plastics mfg in the region.4. DMIC (Delhi Mumbai Industrial Corridor) Project develops the Region.5. Scope for tourism due to Historical background.6. Major Investment & Job creation due to State Govt.. Mega Project policy.7. Wide Scope for retail sector.
Threats:1. Shortage of Power.2. labour policy to be reviewed.3. Pollution (17th rank district)4. Non availability of Agriculture labour5. Dependency on large scale Industries for ancillary Industries.6. High costing of Industrial land.7. labour union problems. Experts from DIC (District Industries Centre ) document published online.
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Industry Attractiveness & Government Initiatives - Aurangabad
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DMIC Corridor
24 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The cluster comprises of small and medium industries manufacturing product parts for various industries like Bajaj Auto, Crompton Greaves, Verroc group, Videocon, Tata Motors, Piaggio.
The cluster makes sub-components for the OEM’s (Original Equipment manu-factures ) and Tier 1 & Tier 2 suppliers. The products from the MSME units to their customers are tail lamp, foot rest cover, poly-wraps, pet jar, PVC irriga-tion pipes, automotive plastic components, water tank, case for mirror
The key machines used by the plastic cluster are: Injection, Extrusion, Com-pressor, Grinder etc.
The key software used in the plastic cluster are: Tally (for accounting), Micro-soft Excel and Word.
Institutions at Aurangabad•DistrictIndustriesCentre,Aurangabad•MaharashtraIndustrialDevelopmentCorporation(MIDC)•Micro,Small&MediumEnterprises–DevelopmentInstt.Aurangabad–Abranch office of MSME-DI, Mumbai.•MSME-ToolRoom,Aurangabad(IGTR)•NationalSmallIndustriesCorporation(NSIC)•MSME–TestingCentre,Mumbai.•BureauofIndianStandards(BIS)•EngineeringExportPromotionCouncil(EEPC)•SmallIndustriesDevelopmentBankofIndia(SIDBI)•IndianInstituteofTechnology,Mumbai(IIT)•MITCON•MaharashtraCentreforEntrepreneurshipDevelopment(MCED)•Govt.Engineeringcollege,Aurangabad
About the Plastic Cluster at Aurangabad
Associations & Firms•TheTinyIndustriesCo-operativeIndustrialEstateLtd•MarathwadaAssociationofSmallScaleIndustries&Agriculture(MASSIA)•ChamberofMarathwadaIndustriesandAgriculture(CMIA)
Category of companies in AurangabadCategory – 1 Suppliers of raw materialsCategory – 2 Plastic Component manufacturers (Tier 1, 2 or 3 suppliers)Category – 3 Part Assembly unitsCategory – 4 Precision Plastic product mfrs.Category – 5 Testing & Analysis unitsCategory – 6 Plastic products small manufacturers & retailers Category – 7 lead Firms (such as Bajal Auto ltd., Crompton Grieves ltd., Videocon, Varroc)Category – 8 Plastic Equipment SuppliersCategory – 9 Outsourcing Companies, Merchant & Traders, Market AgentsCategory – 10 Clearing Agents, CA firms, etc.
Salient features of cluster1. Good infrastructure with RCC buildings and-roads2. Frequent Job orders from customers3. Availability of Business education through MCED.4. Financial assistance from banks for Machines & Infrastructure.5. Sustained growth over the years6. Cluster association looks into welfare of all units.
25 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
ElICIT
EXPlORE
EXPAND
EVAlUATE
EMPOWER
Survey to arrive at SWOT for each unit and understand their future goals and aspirations
Workshops to identify their training needs and competencies to chalk out a customised growth plan by mutual consent
• Evaluation of success
• Consolidation of learning
• Modifying systems and processes wherever possible
Intervention on:• New Product development• Market linkages• Branding• Display• Sign-ages• Website development and
online marketing• Awareness about Govt. Rules,
Regulations and schemes• Common Facility Centres
• Forming associa-tions or groups to disseminate learning
• Documenting the success stories for reference by others as Best Practices
• To ensure that the cluster becomes sustainable
The 5-E process of Solution- Focused Intervention
Step 1: Eliciting - Obtaining a clear understanding of the Client’s goals at the outset of intervention.Step 2: Exploring – Delving deeper into issues to arrive at possible alternatives.Step 3: Expanding – Enabling the client to expand his success and resources to other areas and encouraged to “do the exception” more frequently.Step 4: Evaluating – Clients’ judgement is yardstick to evaluate the success of intervention.Step 5: Empowering – When desired results are achieved, the focus shifts towards empowering these people to maintain the changes on an ongoing basis by rou-tinely employing maintenance strategies on an ongoing basis.
Intervention Pathway
26 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Turning Process at Mould Technology, MIDC, Waluj, Aurangabad
Survey - Plastic ClusterA total of 27 companies were surveyed
Colour Coding:The following pages have different coloured circles over the photographs to indicate the effectiveness of the process. These are colour coded and also vary in size to indicate relevancy.
Good process/product feature/practice
Decent process/product feature/practice, can be improved further
Needs immediate intervention
27 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Need Assessment Survey - Plastic Cluster, AurangabadSr. no. Name of Unit Name of Proprietor/
OwnerProducts Unit Address Mail ID Contact No.
1 Annu Industries Vishal Panjabi Automotive Parts. F- 60, MIDC, Waluj, Aurangabad. [email protected] 92253646332 APM Plast Ajinkya Nandkumar
KawathekarEngineering Plastic Products Pl. no. ,A-42, B/2, Railway Sta-
tion,MIDC, [email protected] 9689737899,
98226832963 Blue Star Engineers Rajesh K. Sanghavi Plastics M. V. & Home Appli-
ances Parts.Plot NO. 96/13, Arihant, Pannal al Nagar,Osmanpura, A'bad.
[email protected] 9371135475, 9371135486
4 Concept Auto Pack-aging
Rahul S. Neele fully Auto on line Care Pack-ers.
F-16/4, MIDC Chikalthana, Auran-agabad
9405963499, 8888864242
5 Cool Engineering S. P. Kale Water Chillers, Industrial Re-frigerators
Plot No.23,MIDC,Station Road,Au-rangabad
9822019718
6 Darshan Plastic Ashok B. Thorat Plastic Injection mowded Com-ponents.
W-71, MIDC, Waluj, Aurangabad. [email protected]
8007800122, 8007800112
7 Electro Plast Industry Syed Shaukat Abdul Rauf
Inter Strage Tank Electro Plast Industries , K-49, MIDC, Waluj, A'bad.
[email protected] 9595463964, 9890217103, 7620077735
8 Jayshree Enterprises Shailendra Prataprao Baviskar
Plastic Injection Products Plot No.19, MIDE, Waluj, A'bad. [email protected]
8888805868
9 Jyoti Industries Atmajyoti Bapu Na-gare
Drip Irigation. D-107, Shendra MIDC,Aurangab-ad.
8928187703
10 Mitali Industries Pramila Kanha Kashide
Auto Components. Pl.no. 5-1, Opp. Good year tyre Midc, Waluj, A'bad.
9421683397, 9767100466
11 Moraz Plastic Vilas More In Process Yeshwant Nagar, Navle, Paithan [email protected]
9028173531
12 Mould Technology Bhalchandra Dhond-pant Bhandrao
Plastic Moulds & moulding Products.
Plot No. M-92/1, MIDC, Waluj, A'bad.
9370656737
13 Plast Tech laxman Irana Man-dkar
Appliances spare parts Plot no. C-252/6-A-4, MIDC, Waluj, A'bad.
9326206512
list of Participants
28 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
14 Rupesh Enterprises Godavari Dattrao Narwade
Plastic Mould & Dies Plot No. D-51/10, MIDC, Waluj, A'bad.
9881243938
15 Sejal Plastics Santosh Vajantrao Joshi
P. P. Mats Plot No. D-81, MIDC, Shendra, A'bad.
9370150700
16 Siddhi Polyweave Shashikant Nagnath-rao Ernale
P. P. Mats Plot no. l-18/1, MIDC, Waluj, A'bad.
9970053151
17 Snehal Plastic Indus-tries.
Bharat Hariba Shindi-kumate
Caster Wheel M-127, MIDC, Waluj, Aurangabad. [email protected]
8888837991
18 Sunrise Auto Pack Raju Suresh Neele Flyash Bricks. F-16/4, MIDC, near Gautamn Dalmill, Naregaon road Chikaltha-na, Auranagabad
8888864242
19 Sushma Industries Parvati Mahadeo Phunde
PVC Pipe Shendra MIDC, B-95, Aurangabad. [email protected]
9404012247
20 Suyog Plastic. Vinay Walandikar Agriculture , Electrical, Auto-mobile.
E-70/27, Waluj, Auranagabad. [email protected]
9923143839
21 Swagat Polymers Ashok R. Joshi Packaging Products Plot NO. 210, Saileela, Ulka nagari, Waluj, A,bad.
9822037318
22 Tirumala Industries Ajay Annasaheb Patharikar
Plastic Water Tank Plot no.H-5/41, MIDC, Chikaltha-na, Aubad.
9850963136
23 Trimurty Polythenes Misal Bhaskar Hariha-ranrao
Poly Bags & Sheets For India. Gut No. 48, Plot No. 12, Near MIDC, Waluj, A'bad.
[email protected] 9372005542
24 Ulka Plastic Industries Sachin S. Thete Krishi Pipe, polymers Sheets B-10, Add. Midc Jalna, A'bad. [email protected] 997565619325 V. P. Pet polymer. Jayshree N. Somase pet jars , pet bottels E-97, MIDC, Waluj, Aurangabad. info@vppetpolymers.
com9370146402
26 Varroc Polymer Pvt. ltd. Tech. Centre
Ritesh Solanke Seat Assembly, Air Forse, Body Parts & Mirrors.
M-138/139, MIDC, Waluj, Aurangabad
9673001597, 9673001490
27 Yogesh Plastic Indus-tries
Yogesh Vrajlal Parmar Plastic Shed net. Plot No. A-114/3, Five star MIDC, Shendra, Aurangabad
9403759542
29 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
01Ann
uIn
dustr
ies
30 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Annu IndustriesAddress of the Company: F – 60, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9225364633 (Vishal Panjabi, Plant head)Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: 2010
Type of Company: Proprietorship
Company’s Specialization/Product/Services: Nylon automotive parts like chain cover, foot rest cover
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Mr Niraj Goel
55 yrs Owner Graduate
Company’s Initial Investment: 30 lacs
Loan/Financial Assistance taken since the start of the company: Not taken
Annu IndustriesMIDC, Waluj, Aurangabad
Vendor Code Details: It is available for Kumar elastomer Pvt ltd., Tata motors and PIAGGIO for products such as Tail lamps, chain cover and foot rest cover.
Types of Customer:Type Total number of
CustomersNames/List of Customers Products
ManufacturedAutomotive 2 Kumar Elastomer and Tata
Motors
Total number of Employees at the company: 45
Types of Business: As a Tier 2 Supplier to OEM for products such as Chain cover, foot rest cover, tool lamp
Area of the Unit: Plot area is 7000 sq. ft.
Certifications: TPM
Audit Reports: Yes
Types of Machines: 12 injection moulding, grinder, Mixer, etc.
Raw materials: Nylon
Warehouse/Storage of Raw material (Inventory Control Techniques)Order Quantity: As per customer requirementOrder Process: Direct from SupplierQuality Control: Yes as per requirement
31 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Quality Control PlanProject Documentation Yes
Quality Control Procedure: (In house/ External agency)
Yes In-house• Visual Inspection• Finishing & Deflashing• Dimension Checking & other defects
Testing of Raw Materials (Incoming - Quality Control Techniques)
Yes• Weight measurement• Strength and moisture checking
Name of Testing Labs for Raw Materials (tie-ups for Raw Materials)
N. A.
Name of Testing Labs (tie-ups for Finished Products)
N. A.
Testing of Finished Products Yes• Visual Inspection• Dimension & Weight measurement• De-flashing & Finishing
Marketing and BrandingEffectiveness of the company logo Medium
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
N. A.
Exhibition/trade shows visits: Plexpo and PlastIndia as visitors
Online services Yes
Human Resource ManagementEmployment recruitment rules On The Basis of
• Education• Work Experience in which company• Asking questions• Practical test
Male & Female Employees: 43 Males & 2 Female
Covered under ESI/EPF/Gratuity: Yes
Contract Worker Policy: N. A.
Assistance required from Government in the following areas:• Expansion• Up-gradation• Subsidies on raw material, new product development and business devel-
opment Assistance by CIPET, IGTR, ITI, MCED Aurangabad: N. A.
32 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Company’s main entrance and is very well maintained.
The exit gate for the finished products.
33 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Company’s raw material area clean and well maintained. The raw materials are very well segregated as per their specification.
34 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Raw material HDPE bags stacked neatly
The wooden panels used to stack the raw material bags
35 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Good management practices to maintain display boards
Area for continuous inspection of sample products manufactured on a daily basis
Bags of finished goods ready to be transported to clients
36 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The injection moulded parts
The injection moulded parts
Annealing process adds value to the injection moulded parts w.r.t. its strength
The posture of the workers for long hours will make them suffer from work-related diseases.
37 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Different moulds ready for maintenance
Annealing process in case of bulk items
Table for maintenance needs maintenance
Scrap stored is ready to be transported for recycling
38 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Spanner and Allen-key board needs regular checks
Moulds are maintained in place neatly
39 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement Space arrangement is a concernNew Product Development No in-house product development process
followedPackaging Need to improveMarketing Market awareness is a problem. No marketing
for business growthHuman Resource Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Need to developWebsite Need to develop better one
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-
gency situations.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: Company is supplying 90% of its production to single company. To reduce the business risk Company need to diversify into other products instead of focus-ing on single company.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• A company website needs to be developed on an urgent basis so that the
customer reach can be extended.• As the company need to venture into other products, it requires more pub-
licity on retail level. A proper branding strategy should be formalised to get maximum visibility in the market.
• The brand identity (logo) needs to be more creative, to make a place in the customers perception.
• A proper career growth plan should be formalised, so that the attrition rate is reduced.
• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers.
• Company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the develop-ment process.
40 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
02APM
Plas
t
41 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: APM PlastAddress of the Company: Plot No. A-42 – B/2, B/3 & B/4 Aurangabad Co. Op. Industrial Estate, Railway Station, MIDC, Aurangabad. landline number: 0240 - 2331312Mobile Number: 9822683296, 9822683294, 9922920338, 9689737899Company e-mail id: [email protected] Website: N. A. Company started in: 1990
Type of Company: Partnership
Affiliated units/sister concern/subsidiary:Sr. No. Unit Name Product/Service Address Contacts1 A. R. Polymers P. U. Casting,
Epoxy castingC-252, V- 16, MIDC Waluj
N. M. Kawathekar & R. S. Deshpande
Details of the Owners / Partners:
Sr. N
o.
Nam
e of
O
wne
r /
Prop
riet
or
/ Par
tner
s /
Dir
ecto
r
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 N. M. Kawathekar 58 Partner BSC 15 yrs [email protected]
9822683296
2 S. Y. Despande 60 Partner B. Com. With BAl N. A. 9822683296
Company’s Specialization/Product/Services:• Injection moulding of Eng. Plastics • Epoxy casting• P. U. casting
Details of the Owner/Director Family members:
Sr. N
o.
Fam
ily M
embe
r
Rel
atio
n to
the
Ow
ner o
f th
e C
ompa
ny
Age
(in
Year
s)
Educ
atio
nal Q
ualifi
catio
n
Wor
k Ex
peri
ence
pri
or to
jo
inin
g th
e C
ompa
ny
Invo
lved
in C
ompa
ny’s
busi
ness
act
iviti
es (Y
es/N
o)
Rol
e in
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 A. N. Kawathekar
Son of N. M. Kawathekar
23 B. E. - Yes Produc-tion
9689737899
2 R. S. Deshpande
Son of S. Y. Despande
28 B.E. M.B.A.
Yes Market-ing
9922920338
Company’s Initial Investment: N. A.
loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name / Govt.
AssistanceYear Purpose Amount (Rs.) Status (Active/
Closed)1 Deogiti Nagari Co. Op. 94-97 Ind. Shade Rs. 400000 Nil
C. C. Rs. 800000
APM PlastMIDC, Railway Station, Aurangabad
42 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Vendor Code Details:Vendor Code
Customer Issued in
Products Supplied Last Audit by Customer
1 Crompton Greaves ltd. 1990 Guide bush for VI 19.01.20142 Easun Refolled ltd. Electric Component
3 Vijai Electric ltd. Guide bush
Production capacity of the Unit:Year Production capacity2013-2014 28050210 (20 M.T.)2013-2012 35529827 (23.787 M.T.)2012-2011 39389982 (24.171 M.T.)2011-2010 31405620 (20.741 M.T.)2010-2009 29553356 (18.476 M.T.)
Types of Customer:Type Total number
of CustomersNames/List of Customers Products
ManufacturedAutomotive 7 Kumar elastomers Pvt.
ltd., SM Auto, Vedant etc.Waher, bush, spacer, Plung, fender clamp
Household Appliances 1 Texas furniture BushOthers Electrical 4 CGl, BMC, Tushiba group Bush, coller, Cap,
indicator, clip, cover
Total number and list of Vendors or Suppliers:• Hitesh polymer• G.K. Sales Corporation• OM Engineering• Shree ram Polymos• Shriram Enterprises
Total number of Employees at the company: 16
Organization Chart:
Director & M. R.(Mr. N. M. Kawathekar)
Purchase & Store I/C
Molding Machine Operator
Finishing Operator
Marketing Manager Quality In-charge ProductionShift In-charge
Director(Mr. S. Y. Deshpande)
Production & Dispatch I/C
APM PLAST
Types of Business:Business Type Products Products supplied toAs a Tier 1 Supplier to OEM Guide bush, switchgear
unit componentsCGl, Toshiba, ERl, BMC, S. M. Auto, Badve Eng.
As a Tier 2 Supplier to OEM Washer and auto parts Kumar elestomer Pvt. ltd.
Area of the Unit:Plot Area 1300 Sq. FeetTotal Built-up Area 1300 Sq. Feet
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2009-2010 6820629 1387497 6475492010-2011 7325062 2224451 13526632011-2012 9444973 2815519 19332112012-2013 10024783 2412054 1395007
43 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
2013-2014 (expected) 1,12,00000 2700000 1550000
Certifications:Certification Description of the Certification Year taken in local AgentISO 9001 : 2008 Main Certificate No.
18355-2008-AQ-IND ; R. A. Rev. 02ISO 9001 : 2008
Sept. 2004 Diwan
Audit Reports:• ISO• CGl Audit report
Company Plant and Process FlowCompany’s Plant layout:
Types of Machines:
Sr. N
o.
Nam
e of
M
achi
ne
Qua
ntity
Mak
e of
m
achi
ne
Spec
ifica
-tio
n
Pric
e of
the
Mac
hine
Year
of
Purc
hase
Loan
/ by
Self
1. Semi Automatic injection moulding
1 Ramco 200 grams
N. A. 1990 N. A.
2. Semi automatic Plenger type toggle lock machin
1 WASPAN 60 grams
N. A. 1992 N. A.
3. Semi automatic injuction moulding machine
2 WASPAN 40 grams
N. A. 1994 N. A.
4. Semi Automatic moulding machine
1 Self Made 200 grams
N. A. 2010 N. A.
5. Semi automatic moulding machine
1 Self Made 70 grams
N. A. 2011 N. A.
6. Bench Grinder 1 N. A. N. A. N. A. 2000 N. A.7. Drill machine 1 N. A. N. A. N. A. 2000 N. A.8. Electrical oven 1 N. A. 3500
wattsN. A. 2000 N. A.
9. Electrical oven 1 N. A. 3000 watts
N. A. 2011 N. A.
Types of Hand Tools:Sr. No. Name of Hand Tool Quantity1 Screwdrivers 10 - 152 Pilers 3 - 43 Magnifier 14 Hammers 2 - 35 Driling Machine 2
Raw materials
44 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Sr. N
o.
Raw
Mat
eria
l
Cur
rent
Rat
e (R
s. Pe
r Kg)
Spec
ifica
tion
Supp
lier’s
Nam
e
Min
imum
qua
ntity
mai
n-ta
ined
in th
e co
mpa
ny p
er
mon
th
Prod
uct M
anuf
actu
red
with
th
e m
ater
ial
Prod
uct S
uppl
ied
to (O
EM/
Tier
1 su
pplie
r/Ti
er2
Supp
li-er
/Tie
r 3 S
uppl
ier)
1 Nylon 205 N. A. Windsor 300-400 kg
Guide spring washer
2
2 Glass field B 145 N. A. Shriram Polymers
400-500 kg
Bush coller indicator
1
3 Nylon B 150 N. A. Hitech Polymers
300-400 kg
N. A. 2
4 PPCP 126 N. A. Shriram Polymers
250-300 kg
N. A. 1
Information of Workers, Supervisors, Managers and Staff for clean-ing:
Shift Timings: 8 A.M. to 8 P.M.
Number of Shifts per day: 2
Sr. N
o.
Nam
e of
wor
ker
Age
(yrs
)
Gen
der (
M/F
)
Wor
kers
/Sup
ervi
sor/
Man
ager
/Sta
ff fo
r cl
eani
ng
Qua
lifica
tion
Ope
ratio
n/ F
unct
ion
Year
s of e
xper
ienc
e in
In
dust
ry
Wor
king
hou
rs/d
ay
1 N M Kawathekar 58 M Director B SC 24 yrs2 S V Deshpande 60 M Director B Com 24 yrs
3 A N Kawathekar 23 M Production Manager
BE 6 months
4 R S Deshpande 28 M Marketing BE MBA
2 yrs
5 Nitin M Supervisor 10th 19 yrs6 Baban Jadhav M Supervisor 10th 16 yrs7 Abhijit
DeshmukhM Worker 10th 2 yrs
8 Rohit Batelu M Worker 10th 2 yrs9 Bhimrao Kolte M Worker 10th 3 yrs10 Devendra Kolte M Worker 10th 3yrs11 Karan Mahske M Worker 10th 14 yrs12 Rahul Kumawat M Worker 10th 2 yrs13 Dnyaneshwar
JadhavM Worker 10th 11 yrs
14 Jankiram Ram-dari
M Worker 10th 12 yrs
15 Chaya Tapre F Worker 7th 24 yrs16 Mina Kolte F Worker 7th 17 yrs
Functions/Operations in the company:Function / Operation Required
Qualifi-cation of workers
Required number of workers
Shortfall of workers
Number of hours /shift
Number of shifts/day
Plastic Moulding 10th 8 hrs 1
Machine operations:Sr. No.
Machine name No. of labors required per machine
Time required for process
Idle time per shift of 8 hrs
Wastage %
1 Serni automatic Plastic injection moulding machine
1 As per compo-nent
0.25%
45 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Flow chart of Business Process:
46 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Flow chart of Manufacturing Process:
47 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Products manufactured at the Company:Sr. No.
Product Name Cost to Company
Price to Customers
Repeat Order
Supplied to
1 Washer 0.12824 0.1603 Yes Aurangabad, Pune, Delhi2 Plug 0.58072 0.7259 Yes Aurangabad3 Guide Spring 3.216 4.02 Yes Aurangabad, Pune4 Guide bush 11.4 14.25 Yes Aurangabad, Hyderabad5 Former 14 17.5 Yes Hyderabad6 Epoxy Bushing 640 800 Yes Aurangabad7 Bobbin 20 25 Yes Aurangabad8 Nylon insulator 124.8 156 Yes Aurangabad9 Cable Clip 84 105 Yes Banglore10 Flamge indicator 12.8 16 Yes Banglore
Quality Control PlanProject Documentation: Does the company maintain Documents for every Project?
Yes
Quality Control Procedure: (In house/ External agency)
In house
Testing of Raw Materials (Incoming - Quality Control Techniques)
Raw material quality control done by the suppliers. Using test certificates at the MSME’s end
Name of Testing labs for Raw Mate-rials (tie-ups for Raw Materials)
S. N. Metallurgical
Name of Testing labs (tie-ups for Finished Products)
S. N. Metallurgical
Testing of Finished Products It is done in house by manually
Quality Standard for Product:Sr. No. Product name Specification Strictly followed (Yes/No)1 V4 – 3 1079 All dimensions Yes2 K 39217924 All dimensions Yes
3 CAP – 12kv - 005 All dimensions Yes
Quality Manual: Sequence of Interaction of Process
Design & DevelopmentWhat is Design? “Design is the creation of a plan or
convention for the construction of an object or a system. It is a strategic approach for someone to achieve a unique expectation”
Design Process of existing products (choose any top one product that is being manufactured at the company for a OEM or a Customer)
Design Process/Plan for a new Product innovation: APM Plast has decided plan for near future to acquire Horizontal injection moulding machine to produce plastic articals which are more than 250 gms by weight. M/S Easun Reyrolle ltd Bangalore has given concept to produce such items for them.
Secondaly as our current business is vendor base, we propose to produce households items such as plastic buckets, Mugs, jugs and Glass.
To work out this plan we needs assistance in acquiring machine of appropriate capacity additional land for machine and running capital to run the business.
We had already started one project of key holder for entering in to retail mar-ket prototype of this is being made. Final touches will be given by the 2nd week of Feb 2014
48 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Budget allocated for Research & Development (Annually in Rs.)
Rs. 1.5 lacks for last year (2012-13)
IT/CAD/Softwares/CAM used in the Company
N. A.
Exhibition/trade shows visits:
Sr. N
o.
Exhi
bitio
n /
Show
Part
icip
ant /
V
isito
r
Last
atte
nded
(Y
ear)
Fees
(in
case
th
e co
mpa
ny
part
icip
ated
)
Bene
fits
1 Engg. Expo Participant 2011-12 26,000 Yes2 Plast Vision Visitor 2012-13 600 Yes3 Elecarama Visitor 2013-14 - Yes
Safety standards in the Company:Manufacturing Op-erations
Possible accidents / hazards
Safety measures in the company
Remedies / Medica-tion
Plastic Injection Moulding
Splash of overheated material
Preheating of materi-al, glows, shoes
First Aid Box, Medi-cal Checkup
Marketing and Branding:logo of company:
Effectiveness of the company logo Medium
Describe the Company’s Target Market: Automobile industry, switchgear industries
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
N. A.
Online services No
Company label:Sr. No.
Labeling type Label specification
Material used
Vendor name/ In house
Machine details if pro-duced In house
1 Printed Stickers N. A. Paper Address Advertisor N. A.
Company Packaging:Sr. No.
Packaging type Packaging specifications
Material used
Vendor name / In house
Machine details if produced In house
1 PP Bags PP - -2 Corrugated Box Paper Akansha Packs -
Finance & AccountsCostingCost Sheet: Washer NylonDESCRIPTION
49 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
ITEM CODE lDA00010DESCRIPTION Washer NylonVENDOR CODEVENDOR NAME APM PlASTPlACE AURANGABADMOD NO 0RM SPECIFICATIONS NylonCOlOUR NaturalRM RATE-BASIC Rs/Kg 205.00 RM RATE-lANDED Rs/Kg 215.65 UV STABIlISER %ge Rs/Kg 0 0.0000 UVS CHARGES Rs 0.0000 NET WEIGHT Grms 0.1400 RUNNER WEIGHT Grms 0.0900 MElTING lOSS %ge 2.5 0.0058 less UVS WEIGHT Grms 0.0000 GROSS WEIGHT Grms 0.2358 RM COST Rs 0.0508 CONVERSION COST DE-TAIlSMACHINE TONNAGE SEMI AUTOMATMACHINE SHIFT RATE Rs 650.0000 NO OF CAVITY 10.0000 CYClE TIME Sec 40.0000 EFFICIENCY - IN %ge 95.0000 PROD PER SHIFT 6840.0000 MOUlDING COST Rs/each 0.0950 FINISHING COST (Rs) Rs 0.0200 OTHERS
CONVERSION COST Rs 0.1150 0.0000 0.0000 0.0000
BOUGHT OUT ITEM COST Rs 0.0000 PROFIT (%ge) : RM 10 0.0051 PROFIT (%ge) :lABOUR 10 0.0115 I C C (%ge) 0 0.0000 SAlES TAX IMPACT (%ge) - 0.0000 REJECTION (%ge) 0 0.0000 PACKING 0.0200 TRANSPORT 0.0200 TOTAl COST --> 0.2225
-->--> 0.22
Raw material break upBASIC 205.0000 EXCISE 12 25.3380 TOTAl 230.3380 SAlES TAX 5 11.5169 TOTAl 241.8549 TURN OVER TAX 0 0.0000 SURCHARGE ON ST 0 0.0000 TOTAl 241.8549 OCTROI 2.75 6.6510 COlOURING (RS/KG) 0 0.0000 TRANSPORT AND HANDlING 4.0000 TOTAl 252.5059
lESS ST SET OFF 5 11.5169 lESS EXCISE CREDIT 100 25.3380
RM lANDED (RS/KG) 215.6510
Explain the Distribution Process. Backward Linkages and Forward Linkages (Supply Chain): Direct sale to customer. No distributor chain
50 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Human Resource ManagementEmployment recruitment rules There are no special rules for recruit-
ment but for operator education is at least 10th pass.
Money charged (in Rupees) by contractors for each worker/staff in case the workers/staff are recruited through Contractors
Rs. 10,000
Training Policy for the new recruits and already employed with the company:For New Recruits For Already Employed
Machine Operator Competence review attached
And training needs
SupervisorManagerHelper/Cleaning Staff
leave Policies: N. A.
Overtime Policy: N. A.
Insurance/Medi-claim Policy: Covered under EsIC / Covered under WCT
Wage Rate Policy:Staff Wage Rate PolicyMachine Operator 150 – 250 Rs. Per day basicSupervisor 300 Rs. Per day basicManager 35000 Rs. Per MonthHelper/Cleaning Staff 150 – 200 Rs. per day
Salary Structure::Staff For Fresher (in
Rupees)With experi-ence of 3 years (in Rupees)
Training required, if yes then please mention the training
Machine details if produced In house
Machine Oper-ator
250 275 N. A. N. A.
Supervisor 400 600 N. A. N. A.Manager 3500 40000 N. A. N. A.Helper/Cleaning Staff
N. A. N. A. N. A. N. A.
Male & Female Employees:Staff Number
of staffProfile (Machine Operator / Su-pervisor / Man-ager / Helper / Cleaning Staff)
Hometown (Aurang-abad/Outside Au-rangabad but within Maharashtra/Outside Maharashtra)
Years of experience in the Com-pany
Machine details if produced In house
Male 10 Machine Opera-tor, Supervisor
Aurangabad N. A. N. A.
Female 2 N. A. N. A. N. A. N. A.
Covered under ESIC/EPF/Gratuity: Yes covered under ESIC
Contract Worker Policy: N. A.
Compensation Plan for workers in case of injury or accidents: The company has taken policy from New India assurance co. for all workers
Views on Government Initiatives taken so far: The company is satisfied with the government support w.r.t. the subsidies, trainings, etc.
Assistance required from Government in the following areas:• For enhancement of sales / production the company needs
51 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
• One horizontal injection moulding machine of 200 T
Assistance by MCED, Aurangabad:• Entrepreneurship Development Programme is beneficial for our Managers• MCED always helps us by giving information about plastic clusters and
other surveys
SWOT Analysis of the CompanySTRENGTHS• Technical expertise and core
knowledge in plastic moulding polyurethane and epoxy mould-ing with more than 25 years of experience.
• Tailor made products as per cus-tomer demands.
• Supplying products to different types of industries which includes Automobiles, Electrical, Switch-gear, Packaging, Pharmaceutical, Furniture
WEAKNESSES• Horizontal moulding machine
and appropriate land is not avail-able.
• Plastic products weighting more than 200gms cannot be manufac-tured with current machinery
THREATS• Almost 70% of the business
comes from one customer.• lack of advanced technology and
production.
OPPORTUNITIES• To create ever growing demand of
heavy plastic products (more than 200gms) in nearby waluj, Paithan and shendra MIDC
• To supply epoxy and polyure thane parts weighting more than 5kg to switchgear industries.
Future Plan of the CompanyTime-lines
Plan Assistance required by the Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months To manufacture components weighting more than 250gms for industrial as well as domestic market
Finance, land and Machinery
With increase in production ca-pacity sales will increase there by employment will be generated.
1 year N. A. N. A. N. A.3 years N. A. N. A. N. A.5 years N. A. N. A. N. A.
Product Design BriefDesign Brief
Design & development of new plastic products and estimated cost for the same up to 10 lacs to 30 lacs
Plan of the Design ProjectProduct Design Brief specifications Plastic injection moulded compo-
nents weighting 250 gms and aboveProposed Design Process N. A.Timeline 6 months June, 2014Budget Rs. 30 lacsTeam members & Skills Required N. M. Kawathekar / S. Y. Deshpande /
A. N. KawathekarBenefits for the Company Increase in product capacity will lead
to increase in sales
52 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Proper management of raw material stock
Needs better arrangement as per the specification of the tools
Proper segregation of raw material stock
Proper display of sample material
53 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The worker is trapped from all sides aswell as the sitting posture is notergonomically conducive
The space is very less around the worker and the machine parts are open which may cause injury to the worker
The wires are exposed to the heater which may case melting or short circuit
The size of the hopper funnel is small which requires multiple filling which
increases the total process time
54 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Proper storage for moulds
Proper use of tool for finishing the moulded pieces
Proper display of the safety procedures and company’s progress reports
The cutting tool used for finishing is too small and can be unsafe for the worker
55 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The place is unclean and disorganized to be accessed. The wiring is exposed.
The place is unclean
56 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Proper safety measures adopted while handeling the product
The waste magement has to followed properly
The fire extinguisher is not easily accessible in case of emergency
57 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The material stock in the store is not properly organised
The machine is not properly maintained w.r.t. the parts of the machine. The files are kept to close to the meter box and the heater.
The fire extinguisher is not placed properly. The store room is not easily accessible.
58 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The water dispenser is unhy-gienic and there is no proper mechanism to dispose off the
wasted/accumulated water
The wash room is unclean and not properly maintained
The external facade is poorly managed as it reduces the visi-
bility of the company signage
59 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Need to improveWorkplace & Ergo. Need to improvePlant layout Im-provement
• Space arrangement is a concern as the plant area is congested
• No use of Natural light• No Workstation or work arrangement for labours
NPD No in-house product development process followedPackaging Need to improveMarketing • Market awareness is a problem. No marketing for business
growth• Good branding material available• Sample swatches are available
Human Resource Focus on manpower training by chalking out customized train-ing programs and evaluation of the workers after undergoing the programs.
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid
pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: Three major categories where the company focuses on are:i) Automobile, ii) Electrical and iii) luggage. In order to provide regular fund-ing, the company may be linked to the respective corporate houses as dedicat-ed vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to get into household products, it can also explore product diversification in the home decor and kitchen products.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• Branding exercise needs to be conducted on priority basis as the company
aspires to get into the household product segments. Trademark registration should be taken to protect equity and prevent litigation in future.
• There is a huge dependence on one customer which might harm the busi-ness in the long run. Increasing the customer base is mandatory for long term sustenance and growth.
• Assistance should be provided to the company to set up their stall in exhi-bitions to highlight their products to the retail and manufacturing partners.
• Re-structuring of the website to increase vendor accessibility.• As the company plans to get into retail consumer segments like plastic
buckets, jugs, mugs etc. it should develop its distribution channel to reach out to the right target market.
60 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
31
2
03Bl
ue St
arEn
ginee
rs
61 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Rajesh K. SanghaviAddress of the Company: B-72, M.I.D.C., Waluj, Aurangabad, Pin: 431136, Maharashtra, Indialandline number: 0240 - 2556612, 2555855Fax : 0240 - 2555902Mobile Number: 9371135475, 9371135480Company e-mail id: [email protected]: www.sanghavigroup.co.in Company started in: 1998
Type of Company: Proprietorship
Company’s Specialization/Product/Services:Engineering Plastic Products
Affiliated units/sister concern/subsidiary: N. A.
Details of the Owners / Partners:
Sr. N
o.
Nam
e of
O
wne
r /
Prop
riet
or
/ Par
tner
s /
Dir
ecto
r
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Rajesh K. Sanghavi
40 Propri-etor
Me-chan-ical engi-neering
N. A. [email protected]
9371135475
Details of the Owner/Director Family members: Wife takes care of HR is-sues, 1 son in 10th, other in 6th
Blue Star EngineersOsmanpura, Aurangabad
Company’s Initial Investment: 6 lacs
Loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name / Govt.
AssistanceYear Purpose Amount (Rs.) Status (Active/
Closed)1 MFSC - Machines 6,00,000 -2 SBI - Machines 2,00,00,000 -
Customer Details: Bajaj Automobiles, Niranjan Plastic, Videocon
Types of Customer: Automotive
Total number and List of Vendors or Suppliers:• Reliance• SRF• DCM
Total number of Employees at the company: 16
Types of Business: OEM
Area of the Unit: 8000 sq ft
Turnover of the Unit (in Rupees): Rs 10 crore/annum. The gross Profit is 18%-20% and the net profit is 3% - 4%
Certifications: ISO 9001:2008 Certified company and CRISIl
62 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Company Manufacturing Process FlowRaw material
passed through Hopper
Injected through Screw
Barrel
Injected in Mould
Cooling
Types of Machines: Injection Moulding, Hopper, Mould Temperature & Mix-ers
Raw materials: Average cost of Raw materials is Rs. 100 to Rs. 250/kg• Poly-propylene• lDPE• HDPE• Nylon 6• Polycarbonate• ABS• Dupont
No. of Shifts/day: 2 (7am – 7pm and 7pm – 7am)
Quality Control Plan• No quality check done for Raw Material. Brand name is an indicator of
quality.• Plating is outsourced.• 80% - 90% importance given to Aesthetic look, Dimensions and Branding
are also checked.• 100% of the products are checked visually.
Design & DevelopmentR&D:• All the moulds are developed in-house. No outsourcing.
• After receiving the order, they study the drawings and check
Inquiry received from
Clients
Drawings are studied
Tolerance issues are
checked with Clients
Clearance taken from
Clients
Moulds are prepared
E.g. Metallic washers converted into Plastic washers, Exploration in market items like Industrial bobbin or spool. No specific budget allocated for R&D. Visited Switzerland for developing a mould.
Softwares used:Deven Infotech, softwares for TPM
Trade shows:Only attended but not participated.• Plastovision• Amtex• Chinaplast• PlastoIndia
Visited China to attend Trade Show.
Safety standards in the Company:All machines are safe and as per the specifications of safety norms.
Marketing and Branding:Logo of company:
63 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Effectiveness of the company logo Medium. No need to focus on Brand-ing and Marketing as it is a B2B business and Brand awareness of the company is high in its target market.
Online services No
Company Label: Tags and labels are put on every part. Supplies are made in bins which have replaced corrugated boxes.
Human Resource Management• Total employee strength: 110• Hiring through references or HR contractor.• No qualification required for workers but compulsory for staff.• Weekly off on Friday.• No paid leave for workers.• 5-6 days leave for workers in Diwali, May 1st-labour Day and 2 more days
of leave during other festivals during the year. • All employees are covered under ESIC and yearly health check-up conduct-
ed on campus.• Training is imparted at regular intervals. 4 days of training per month. 12%
- 15% increment per annum. Career path for employees is being worked out and assessment will be made through software.
Views on Government Initiatives taken so far:• Govt. Is not bothered if the company has received payment from vendor or
not. There is no relaxation on interest rates or Sales tax or concessions in Excise Duty.
• Grants are enough. • All India Plastic Manufacturers Association is also working efficiently.• MASSIA cluster and CEPAT are working for their benefit.
SWOT Analysis of the CompanySTRENGTHS• Their Brand Awareness in the
B2B market as their capacity is always full.
WEAKNESSES• No new product development
mechanism• Marketing not in place
THREATS• Chinese products other than mo-
torcycles where the Japan based products sell better.
• Support from OE as there is com-plete dependence on OE market.
OPPORTUNITIES• New customers need to be ac-
quired.• New products need to be devel-
oped with existing machinery
Future Plan of the Company• Entryintothemarketforallelectricalmachines.• 2-3CopyrightedproductsforstrengtheningBrandIdentity.• DonotwanttogetintoRetailbusinessasitisacashbasedbusinessandrequires huge investment in marketing.
64 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Mould for ice trays loaded on machine
Injection moulded ice-trays ready for finishing
Rejected and scrap Injection moulded ice-trays ready for reprocessing
Moulds neatly arranged on shelves
65 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Finishing of injection moulded parts in progress
Safety precautions taken while de-flashing the parts
Packages of injection moulded parts are being stacked in carton boxes.
Finished parts are being packed in plastic sheets
66 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Master samples on display
Marking on finished parts with screen printing technique
Screen printed parts drying under fan
Alternate and efficient method can be used for marking
67 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Overhead cranes to lift the moulds
There are chances of slippages of the moulds. Need a better method to lift the moulds and shift.
68 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Improper approach for feeding plastic granules in the hopper
Spoilage of raw material which changing the mould
liquid colour master-batch stored properly
Carton being readied for packing the finished parts
69 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Fire extinguisher placed in the working area
Customer complaint board maintained on a daily basis
Finished goods packed and ready for transportation to the clients
70 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Tiffin rack
Drinking water storage
71 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology High investment in technologyAesthetics As per the product requirementsQuality As per the product requirementsOperations As per the product requirementsWorkplace & Ergonomics Need to improvePlant layout Improvement Well PlannedNew Product Development No dedicated Product Development wingPackaging As per requirementMarketing Brand awareness is high in the B2B marketHuman Resource Satisfactory
Business DesignMarketing Satisfactorylogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Very well managed as per the cluster standards. However, since the company has the potential for becoming a national player, latest machinery and technol-ogy needs to be employed to be in sync with global standards.
Supply Chain & Operations: The company is efficiently handling it’s supply chain and operations but further streamlining might help since the company plans to diversify into different product categories in future.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: The company needs to set up a dedicated product development wing and even collaborate with Govt. bodies to take up consultancy projects for new product development. It can also look at producing cheaper variants of internationally successful products.
Human Resource: Although the company takes substantial initiatives to train its people, more investment in hiring experts might help in new product development process.
Marketing:The company is banking heavily on its brand awareness in the current target market. However, it should not become complacent as new competitors with greater marketing efforts might erode its equity in future.
Participation in trade shows and more online marketing might be effective solutions to tackle the issue.
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2
04Co
ncep
t Aut
o Pa
ckag
ing
73 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Concept Auto Packaging (Sister concern of Sunrise Autopack)Address of the Company: F – 16/4, MIDC, Chikalthana, Aurangabad, Pin: 431 210, Maharashtra, IndiaLandline number: 0 240 - 2482097Mobile Number: 8888864242, 95951 74242, 94222 94242Company e-mail id: [email protected]
Website: www.sunriseautopack.com Company started in: 2013
Type of Company: Proprietorship
Company’s Specialization/Product/Services• PET Packaging machinery manufacturer & Bottling machine
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Rahul Owner Grad-uate
4 -- 9405963499
Company’s Initial Investment: N. A.
Loan/Financial Assistance taken since the start of the company: Not takenProduction capacity of the Unit: 150 bottles per minutes
Types of Customer: B2B
Total number of Employees at the company: 15 Males (14) and Female (1)
Area of the Unit:Plot Area 8000 Sq. ft.Total Built-up Area 3600 Sq. ft.
Turnover of the Unit (in Rupees): N. ACertifications: No
Types of Machines: Buffing m/c, Milling m/c, Drilling M/c and lathe m/c, Welding machine
Raw materials: Stainless Steel, Mild Steel, High Density polymer
Quality Control PlanDocumentation of every Project
No
Quality Control Procedure: (In house/ External agency)
No
Concept Auto PackagingMIDC, Chikalthana, Aurangabad
74 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Mineral Water Bottling Plants in production
Cardboard box is used as support
75 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The worker climbs on the machine while assembly
Grinding
Power board is broken and is dangerous while in use
76 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
No safety gears used
Drilling process
Scrap material is not maintained properly.
77 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Scrap material is not maintained properly.
loose wires hang around the machine. Needs maintenance.
Welding of machine is not even and smooth
No safety gears used
78 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Raw material room is not lit properly. No facility for natural light.
There is not labelling on the racks for different items.
79 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Magnet is used to separate the metal scrap material
Scrap material is not collected and packed very loose
Halogen light system is very loose and hangs in the working area.
Advertisement of different company is painted on the wall of the company
80 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology As per standardAesthetics Good Quality SatisfactoryOperations Safety kits are not provided to the operatorsWorkplace & Ergonomics NeededPlant layout Improvement • Space arrangement is a concern as there is
lot of congestion of machine.• No use of Natural light.
New Product Development Yes, R & D in process for bottling machineryPackaging Yes, goodMarketing Good market presence in bottling automationHuman Resource 1 year training is provided to new recruit
Business DesignMarketing Yes, need to improvelogo Design NoVisiting Card NoBrochures & leaflets NoWebsite Yes
Recommendations• As company has plan for huge expansion, company logo has to more
creative and need to be protected. it has good visibility in market, need to capitalise on that.
• Production layout is not so good. Sufficient space has to be kept between machinery so the better working condition.
• Very less safety precautions are taken by workers, this need to be improved
by providing gloves and other safety gears to workers.• The work area need to be cleaned regularly and scraps and used tools re-
moval process has to be planned. • Need to focus on regular maintenance and servicing of machines to avoid
pre-mature wear and tear.• There is an urgent need for the certification of the company as this will
improve the image of the company in the market. For this proper record keeping in all departments is needed.
• No testing is done on the product during production, so proper quality control procedures need to be formed.
81 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
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82 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Cool EngineeringAddress of the Company: Plot no 23, MIDC, station Road, Aurangabad, Maharashtra, IndiaLandline number: 0240-2321065Mobile Number: 9822019718Company e-mail id: [email protected] No.: 0240-2335968Website: www.coolengineering.co.in Company started in: 1990
Type of Company: Partnership
Company’s Specialization/Product/Services• Custom made machinery, fabrication of refrigerators, chillers
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 S. P. Kale 54 Partner BCom 0 - 9822019718
2 Ajay Sathe - Partner 0 - -
Company’s Initial Investment: 3 lacs
Cool EngineeringMIDC, Station Road, Aurangabad
loan/Financial Assistance taken since the start of the company:Sr. No.
Bank Name / Govt. Assistance
Year Purpose Amount (Rs.) Status (Ac-tive/Closed)
1 Bank of Maharashtra 2013 Machineries 60 lacs Cash credit
Total number and List of Vendors or Suppliers: Two
Total number of Employees at the company: 7 (All males)
Types of Business: OEM
Area of the Unit: 3000 sq ft
Certifications: ISO9001
Competitors: Bluestar and Voltas
Machines & raw materialsTypes of Machines: Compressor, Bending m/c, spot welding, drilling, grinder
Raw materials: Stainless steel sheets, copper tube and pipes
Quality Control PlanProject Documentation: yes
83 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Does the company maintain Documents for every Project?
Yes
Quality Control Procedure: (In house/ External agency)
Yes
Testing of Raw Materials (Incoming - Quality Control Techniques)
Yes
Name of Testing Labs for Raw Materials (tie-ups for Raw Materials)
No
Name of Testing Labs (tie-ups for Finished Products)
N. A.
Testing of Finished Products Yes
Exhibition/trade shows visits
Sr. N
o.
Exhi
bitio
n /
Show
Part
icip
ant /
V
isito
r
Last
atte
nded
(Y
ear)
Fees
(in
case
th
e co
mpa
ny
part
icip
ated
)
Bene
fits
1 Canton, China Visitor 1993 N. A. N. A.2 Singapore Visitor N. A. N. A.
Marketing and Brandinglogo of company:
Effectiveness of the company logo Medium
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
N. A.
Online services Yes
Human Resource ManagementEmployment recruitment rules On The Basis of
• Education• Work Experience in which company• Asking questions• Practical test
Male & Female Employees: 7 Males & 0 Female
Shift timing: 9 AM to 6 PM (One shift)
Salary Structure: Machine Operator (4000-5000), Supervisor (7000-8000) and Manager (10000)
Covered under ESI/EPF/Gratuity: Yes
Contract Worker Policy: N. A.
Assistance required from Government in the following areas:• Expansion• Up-gradation• Subsidies on raw material, new product development and business devel-
opment
84 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Assistance by CIPET, IGTR, ITI, MCED Aurangabad: N. A.
SWOT Analysis of the CompanySTRENGTHS• Service quality is very good• Quick and personalized service
WEAKNESSES• No skilled worker• Marketing not in place
THREATS• Chinese manufacturers are
providing the similar products at lower prices and better quality and eventually winning the cus-tomer base
OPPORTUNITIES• New product development in the
household category • Focusing the new customer base
by developing new product
Future Plan of the CompanyTime-lines
Plan Assistance required by the Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months Improve the aesthetics of productImprove marketing efforts
N. A. N. A.
1 year Venturing into new product categoriesNew machineries like ultra low temperature and cold chain ma-chines
N. A. N. A.
Product Design Brief: N. A.
85 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The entrance of the main unit area.
The main work area of the unit.
The gas cylinders are lying in the middle of the walk way in the work area.
86 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The posture of the workers for long hours will make them suffer from work-related diseases.
The posture of the worker for long hours will make them suffer from work-related diseases.
The open work area at the entrance of the unit.
The open work area at the entrance of the unit.
87 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The tools rack is cluttered. Needs proper arrangement procedures.
Sheet metal work done manually.
88 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The tools are seen unattended in the working area.
Clutter and scrap is seen around the machine area
The gas cylinders are lying in the middle of the walk way in the work area.
First-aid box
89 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The work area needs maintenance. Tools lying unattended.
Raw material area
lot of waste and scrap is seen around the unit area.
90 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement Space arrangement is a concern as the plant
area is congestedNew Product Development In-house product development process fol-
lowedPackaging Need to improveMarketing Market awareness is a problem. No marketing
for business growthHuman Resource Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Need to developWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space
allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to get into household products, it can also explore product diversification in the home appliances.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• A website need to be up-graded on urgent basis so that the customer reach
can be extended.• As the company is venturing into other products, it requires more public-
ity on retail level. A proper branding strategy should be formalised to get maximum visibility in the market.
• A logo needs to be more creative, to make a place in the customers percep-tion.
• A proper career growth plan should be formalised, so that the attrition rate is reduced.
• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers.
• A company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the de-velopment process.
91 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
31
2
06Dar
shan
Plas
tics
92 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Darshan PlasticsAddress of the Company: W – 71, Near Kamgar Chowk, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 8007800122Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: 2002
Type of Company: Partnership
Company’s Specialization/Product/Services• Automobile lighting parts• Indicator parts
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Mr. Ashok Thorat - Partner B. E. Mech.
- - -
2 Mrs. Thorat - Partner BSC - - -
Darshan PlasticMIDC, Waluj, Aurangabad
Loan/Financial Assistance taken since the start of the company: Not taken
Vendor Code Details: For Varroc and Videocon
Production capacity of the Unit: 2.5 tons per day in 2013-14
Types of Customer:Type Total number of
CustomersNames/List of Cus-tomers
Products Manufactured
Automotive 1 Varroc Automotive partsConsumer Products 1 Videocon
Total number of Employees at the company: 66
Types of Business: As a Tier 2 supplier to Automotive parts to Varroc
Area of the Unit:Plot Area 8000 Sq. ft.Total Built-up Area 6000 Sq. ft.
Turnover of the Unit (in Rupees): Rs. 25 crores in 2012-13 and the expected amount is Rs. 27.5 crores in 2013-14
Certifications: KMS TS16949 and Total Productive Maintenance (TPM)
Audit Reports: Yes from its customers
Types of Machines: Injection moulding, pad printing, ultrasonic welding
93 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Raw materials: Polycarbonate, acrylic, ABS, Nylon, PP
Business Process FlowProcurement of raw material
Preparatory process- Preheating
Ultrasonic welding
De-flashing
Packing
Inspection of raw material
Production
Final Inspection
Pad Printing
Dispatch
Quality Control PlanDocumentation of every Project
Yes
Quality Control Procedure: (In house/ External agency)
Yes
Testing of Raw Materials (Incoming - Quality Control Techniques)
Yes
Name of Testing Labs for Raw Materials (tie-ups for Raw Materials)
N. A.
Name of Testing Labs (tie-ups for Finished Products)
N. A.
Testing of Finished Products • Visual Inspection• Dimension & Weight measurement• Deflashing & Finishing
Design & DevelopmentDesign Process/Plan for a new Product innovation
No
Budget allocated for Research & Development (Annually in Rs.)
N. A.
IT/CAD/Softwares/CAM used in the Company
No
Marketing and Branding:logo of company:
94 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Effectiveness of the company logo Medium
Describe the Company’s Target Market: Targeting Irrigation components & Automobile Industry
Exhibition/trade shows visits: No
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
No
Online services No
Packaging materials: Polybags, PP boxes, Plastic bins
Human Resource ManagementShift Timings: 9 AM to 5:30 PM
Number of Shifts per day: 2 two for operators (12 hours), three for engineers (8 hours) and general shift ( 9 am to 6:30 pm) for other staff
Overtime Policy: Payment according to overtime hours
Insurance/Medi-claim Policy: Yes
Covered under ESI/EPF/Gratuity: Yes
Contract Worker Policy: No
Career Graph Plan for Employees: Growth & continues development under motivation & guidance
Retention Policies and Welfare Schemes: Insurance Policies
Assistance required from Government in the following areas:• Guidance about new product development • Awareness about the new schemes and training programs organized by
various agencies
SWOT Analysis of the CompanySTRENGTHS• Composite moulding• Manufacturing of complex prod-
ucts
WEAKNESSES• 80 % business depend on only
one customer• No new product development
mechanism
THREATS• No threat as such as the product
is more complex and need huge investment for the new entrant
OPPORTUNITIES• New customers need to be ac-
quired.• New products need to be devel-
oped with existing machinery• Enter into mould manufacturing
Future Plan of the CompanyTimelines Plan Assistance required by the
Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months New plant of size 10000 Sq ft under construction
N. A. N. A.
1 year New product develop-ment
N. A. N. A.
Product Design Brief: N. A.
95 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Company’s work area is clean and well maintained
Company’s work area is clean and well maintained
Company’s raw material area clean and well maintained. The raw materials are very well segregated as per their specification.
Company’s main entrance and is very well maintained.
96 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The worker climbs the machines to pour the plastic granules in the hopper. Need to improve the this practice.
Injection moulded parts
97 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The injection moulded parts are getting finished.
The injection moulded tail light covers.
The injection moulded tail light covers are nice packed and stacked.
98 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Separate and well defined Inspection table. The area needs to better lit.
The pieces are inspected, packed and later arranged separately in boxes.
The pieces are inspected and finished at the site of its production.
99 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Separate and well defined area for keeping boxes of finished goods.
The mould under maintenance.
Whenever needed the mould is shifted in the work area on a trolley.
100 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The moulds are kept at its specified location. The tool-board is not in use.
The moulds are kept at its specified location.
The finished products are ready to be transported.
101 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations SatisfactoryWorkplace & Ergonomics Satisfactory Plant layout Improvement Satisfactory New Product Development No in-house product development process
followedPackaging Need to improveMarketing Market awareness is a problem. No marketing
for business growthHuman Resource Good training initiatives for the workers
Business DesignMarketing No marketing initiative logo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Need to develop
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-
gency situations.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: No new product development process is carried out. Company should look out for the new products that can be manufactured with the existing facilities to increase the customer base rather than depending on single customer.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:Company is supplying products to only single company Verroc. The company should increase its customer base to reduce the risk on the business.
As there is no marketing activity by company, it should start its branding in the market. A website should be formed as early as possible and advertisement should be given to various web portals like indiamart.com and alibaba.com to get more visibility in the market.
As company has plan for huge expansion, company logo has to more creative and need to be protected.
102 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
2
31
07El
ectro
Plas
t In
dustr
ies
103 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Electro Plast IndustriesAddress of the Company: K-49, MIDC, Waluj, Aurangabad, Pin: 431136, Maharashtra, Indialandline number: 0240-2040186Mobile Number: 919890217103Company e-mail id: [email protected] No.: 0240-2040186 Company started in: 1992
Type of Company: Proprietorship
Company’s Specialization/Product/Services:• llDPE Water Tanks ranging from 300 l to 5000 l
Affiliated units/sister concern/subsidiary: N. A.
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Shaukat Syed 48 Owner Graduate 25 yrs [email protected]
9890217103
Details of the Owner/Director Family members:
Sr. N
o.Fa
mily
Mem
ber
Rel
atio
n to
the
Ow
ner o
f th
e C
ompa
ny
Age
(in
Year
s)
Educ
atio
nal Q
ualifi
catio
n
Wor
k Ex
peri
ence
pri
or to
jo
inin
g th
e C
ompa
ny
Invo
lved
in C
ompa
ny’s
busi
ness
act
iviti
es (Y
es/N
o)
Rol
e in
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Shaffiqunissa Ansari
Wife 47 Grad-uation
N. A. No N. A. N. A. 9890217103
2 Ramsha Daughter 21 Grad-uation
N. A. No N. A. N. A. 9762718333
3 Altamash Son 22 BBA N. A. No N. A. [email protected]
9762718333
Company’s Initial Investment: 60 lacs
loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name / Govt. Assistance Year Purpose Amount (Rs.) Status
(Active/Closed)
1 MSFC 1995 Term-loan 3 lacks Closed
Vendor Code Details: N. A.
Electro Plast IndustriesMIDC, Waluj, Aurangabad
104 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Production capacity of the Unit:Year Production capacity2013-2014 1445000 lTR2013-2012 1150000 lTR2012-2011 1050000 lTR2011-2010 850000 lTR2010-2009 700000 lTR
Types of Customer:Type Total number
of CustomersNames/List of Customers Products
ManufacturedConsumer Products 16 Girdhar Tiles, laxmi Hard-
ware, Gurukripa Sanitary, etc.
Water Tanks
Total number and list of Vendors or Suppliers:• Rotoflow Polymer• Parshwanath Plastigrind• Alkemy India• Pooja Polymer
Total number of Employees at the company: 18
Types of Business:Business Type Products Products supplied toAs Supplier to Retailers Water Tanks Sanitary & hardware Distributors
Area of the Unit (in Square feet):Plot Area 510 Sq. mtr.Total Built-up Area 230 Sq. mtr.
Organization Chart:
Sales & Marketing Manager (Mr. Rajeev Kumar)
Operator 1
Operator 2
Casuallabour
Casuallabour
Casuallabour
Casuallabour
Casuallabour
Casuallabour
Sales Exe. 2Sales Exe. 1 Accountant Production Supervisor
(Shift 1)
Production Supervisor
(Shift 2)
Security Staff
Driver
Production Manager(Mr. Gajanand Ganjre)
Proprietor - Shaukat Syed
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2009-2010 2000000 100000 550002010-2011 2400000 128000 640002011-2012 2900000 180000 920002012-2013 3400000 225000 1100002013-2014 (expected) 3800000 350000 128000
Certifications: N. A.
Audit Reports: N. A.
105 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Business Competitors:Sr. No.
Competitor’s name
Competitor’s Prod-uct Specialization
Type of Business (Exporter/OEM/Tier 1 Supplier/Tier 2 Supplier / Tier 3 Supplier
1 Ram Polymers Water Tanks N. A.2 Sarita Tank Water Tanks N. A.3 Spintex Group Water Tanks N. A.4 Saraswati Water
TankWater Tanks, PVC Pipes
N. A.
5 Harsh Industries Water Tanks N. A.
Company Plant and Process FlowCompany’s Plant layout:
Extrusion
Section
Raw Material
Storage
Storage for
Finished Goods
Rotomoulding
Machine
Parking
Tank
Wastage
Storage
Toilet
Office
Chiller
Pulverizer
Powder
Storage
Types of Machines
Sr. N
o.
Nam
e of
M
achi
ne
Qua
ntity
Mak
e of
m
achi
ne
Spec
ifica
tion
Pric
e of
the
Mac
hine
Year
of
Purc
hase
Loan
/ by
Self
1. Extrusion 1 Raj Engineering, India
110 Mm 7 lakh 2003 By Self
2. Cutter 2 Raj Engineering, India
Cc-1541 50 Thousand 2003 By Self
3. Mixer 1 Raj Engineering, India
35 Hp Motor Qm-F9
1.5 lakh 2003 By Self
4. Grinder 1 Khalil, India 20 Hp Motor Pd-1100m
50 Thousand 1992 By Self
5. Pulveriser 1 Naroto, India 300 Mm Disc 5 lakh 2011 By Self6. Pulveriser 1 Plasmec, India 600 Mm Disc 20 lakh 2012 By Self7. Box- Type 1 Naroto, India 4 Hp Motor
With A/C Drive
8 lakh 2003 By Self
Types of Tools
Sr. N
o.
Nam
e of
M
achi
ne
Qua
ntity
Mak
e of
m
achi
ne
Spec
ifica
tion
Pric
e of
the
Mac
hine
Year
of
Purc
hase
Loan
/ by
Self
1. Hand Grinder
2 Hitachi, India PD 100M 27000 2012 By Self
2. Hand Drill 1 Hitachi, India CC 40 8200 2010 By Self
3. Welding Machine
1 Delt-Ton, India PQ-190 36500 2011 By Self
4. Buffing Tools
1 Idea, China Em-300 17500 2012 By Self
Raw materials
106 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Sr. N
o.
Raw
Mat
eria
l
Cur
rent
Rat
e (R
s. Pe
r Kg)
Spec
ifica
tion
Supp
lier’s
Nam
e
Min
imum
qua
ntity
mai
n-ta
ined
in th
e co
mpa
ny p
er
mon
th
Prod
uct M
anuf
actu
red
with
th
e m
ater
ial
Prod
uct S
uppl
ied
to (O
EM/
Tier
1 su
pplie
r/Ti
er2
Supp
li-er
/Tie
r 3 S
uppl
ier)
1 llDPE Granule
Rs. 130/KG
4.2 MFI, 0.939G /CC
GAIl 5MT Water Tank Hard-ware retailers
2 Master Batch Rs. 300 /KG
UV Polyone 200 KG Water Tank N. A.
3 Diesel Rs. 62/ lTR
Indian Oil
IOCl 250 lTR Water Tank
Information of Workers, Supervisors, Managers and Staff for cleaning:
Shift Timings: 8AM to 8PM and 8PM to 8AM
Number of Shifts per day: 2
Sr. N
o.
Nam
e of
wor
ker
Age
(yrs
)
Gen
der (
M/F
)
Wor
kers
/ Su
perv
isor
/M
anag
er /
Staff
for
clea
ning
Qua
lifica
tion
Ope
ratio
n / F
unct
ion
Year
s of e
xper
ienc
e in
In
dust
ry
Wor
king
hou
rs /
day
1 Wagmare 38 M Operator 12th Pass 12 Years 12 Hour2 Dhani Ram 32 M Helper Matric 5 Years 12 Hour3 Ram Babu 37 M Operator Matric 10 Years 12 Hour4 Shankar 44 M Operator 12th Pass 17 Years 12 Hour5 Mukesh 38 M Operator 12th Pass 7 Years 12 Hour
6 Suresh 28 M Helper Matric 8 Years 12 Hour7 laxmi Devi 32 F Helper Matric 4 Years 8 Hour8 Babu Ram 35 M Helper Matric 5 Years 12 Hour9 Shobha Rani 28 F Helper Matric 5 Years 8 Hour10 Gajanan 29 M Supervisor Graduate 8 Years 12 Hour11 Mobin 25 M Accountant Matric 4 Years 12 Hour12 Mujfar 28 M Sales Graduate 8 Years 12 Hour13 Kavri Devi 34 F Causal 10th Pass 3 Years 8 Hour14 Gouri Shankar 52 M Causal 10th Pass 12 Years 8 Hour15 Rajiv 43 M Sales Graduate 19 Years 12 Hour16 Mera Rani 38 F Causal 10th Pass 4 Years 8 Hour17 Maane 27 M Driver 12th Pass 7 Years 12 Hour18 Patil 35 M Security 12th Pass 4 Years 12 Hour
Functions/Operations in the company:Function / Operation
Required Qualification of workers
Required number of workers
Shortfall of workers
Number of hours /shift
Number of shifts/day
Marketing & Sales MBA, Graduate 3 1 1Accounting Graduate, Relevant
Experience1 1 1
Production Graduate, Diploma, Unskilled
12 2 2
Machine operations:Sr. No.
Machine name No. of labors required per machine
Time required for process
Idle time per shift of 8 hrs
Wastage %
1 Extruder 2+2 Continuous 30 Min 1%
2 Pulverizer 2+1 Continuous 40 Min 1%3 Rotomoulding
Machine2+2 Continuous 120min 5%
107 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Products manufactured at the Company:Sr. No.
Product Name Cost to Company
Price to Customers
Repeat Order
Supplied to
1 lDPE Water Tank
Rs 3.00/litre
Rs 3.60/litre
Yes Aurangabad, Pune, Delhi
Quality Control PlanProject Documentation: Does the company maintain Documents for every Project?
No
Quality Control Procedure: (In house/ External agency)
• Standardized Manufacturing Process• Inspection At Pelletizing Stage For
Colour • Inspection Of Powder After Pulveri-
zation For Correct Mesh Size• Inspection Of Final Product Tank For
Aesthetics, Pinholes, leakages.• Inspection For Patches And Delami-
nationTesting of Raw Materials (In-coming - Quality Control Tech-niques)
Product Purchased From Reputed Su-pliers like Gail. Certificate Of Quality Received With Consignments. Occasional Testing at CIPET
Name of Testing labs for Raw Materials (tie-ups for Raw Mate-rials)
CIPET Aurangabad
Name of Testing labs (tie-ups for Finished Products)
In-house testing
Testing of Finished Products Inspection of Final Product Tank For Aesthetics, Pinholes, leakages.Inspection For Patches And Delamina-tion
Quality Standard for Product:Sr. No. Product name Specification Strictly followed (Yes/No)1 Water T-anks Non ISI product
manufactured
Design & DevelopmentWhat is Design? “Design as per dictionary definition
is a plan or drawing produced to show the look and function of a product to be manufactured.”
Design Process of existing products: When the company entered market there were existing established players who had already standardized product design. But at that most tank manufac-turers were using Mild steel moulds in which surface finish of resultant prod-uct was not good.
Electro Plast was one of the few companies who started making tanks in Stain-less steel moulds in which inner surface is very smooth and tanks were also with good surface finish.
The process followed for existing product is studying the accepted norms/de-sign in the industry. Then finding out advantages and disadvantages and then working for improvements required.
Design Process/Plan for a new Product innovation: For any new design the process followed is studying the accepted norms/de-sign in the industry. Then finding out advantages and disadvantages and then working for improvements required in association with machinery manufac-turers and mould manufacturers.
108 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Budget allocated for Research & Development (Annually in Rs.)
No specific budget allocated. Mini-mum Rs. 25000 per year
IT/CAD/Softwares/CAM used in the Company
Help of outside agencies taken. In house designing facilities not availa-ble
Exhibition/trade shows visits: N. A.
Safety standards in the Company:Manufacturing Op-erations
Possible accidents / hazards
Safety measures in the company
Remedies / Medica-tion
Electrical operations Fire Fire extinguishers
Marketing and BrandingBrand of the Company: POlO
logo of company:
POlO Tank is a brand by Electro Plast Industries
Effectiveness of the company logo Medium
Describe the Company’s Target Market: Hardware and Sanitary equipment Retailers
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
N. A.
Online services No
Company label: N. A.
Company Packaging: N. A.
Finance & AccountsCosting: Raw MaterialRaw Material Quantity
(Kgs)Rate (Rs.) Amount (Rs.)
GAIl (Plastic Granules) 100 125 12500Masterbatch 2180 360Processing Charges 102 8 816Total Amount 13676Per Kg cost of making llDPE Powder 134This is per Kg powder cost which is used in water tank 134 per kg
Costing: Water Tank making Cost (1000lts)Items Quantity (Lts) Rate AmountDiesel 2 64 128Powder 21 134 2814Processing Charges 50 50Total Amount 2992This is 1000 lts of water tank cost Rs. 3 per ltr
109 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Human Resource ManagementEmployment recruitment rules Educational qualifications should
be as per job requirement. Previous experience considered. Background check through references given by employee and previous employer
Money charged (in Rupees) by contractors for each worker/staff in case the workers/staff are recruited through Contractors
No involvement of contractor. Direct hiring.
Training Policy for the new recruits and already employed with the company:For New Recruits For Already Employed
Machine Operator Give 10 Days Training in Plant N. A.Supervisor Give 10 Days Training in Plant N. A.Manager Give 10 Days Training in Plant N. A.Helper/Cleaning Staff Give 10 Days Training in Plant N. A.
leave Policies:For New Recruits For Already Employed
Machine Operator Every Friday, local holidays Every Friday, local holidaysSupervisor Every Friday, local holidays Every Friday, local holidaysManager Every Friday, local holidays Every Friday, local holidaysHelper/Cleaning Staff Every Friday, local holidays Every Friday, local holidays
Overtime Policy: Not Required
Insurance/Medi-claim Policy: NIl
Wage Rate Policy:
Staff Wage Rate PolicyMachine Operator Rs. 300/shiftSupervisor Rs. 10000/monthManager Rs. 15000/monthHelper/Cleaning Staff Rs. 280/shift
Salary Structure::Staff For Fresher
(in Rupees)With experience of 3 years (in Rupees)
Training required, if yes then please mention the training
Machine details if produced In house
Machine Operator 280/shift 300/shift On job training N. A.Supervisor Never
employed10000/month
N. A. N. A.
Manager NA 15000/month
N. A. N. A.
Helper/Cleaning Staff 260/shift 280/shift N. A. N. A.
Male & Female Employees:Staff Number of
staffProfile (Ma-chine Operator / Supervisor / Manager / Helper / Clean-ing Staff)
Hometown (Aurangab-ad/Outside Aurangabad but within Maharash-tra/Outside Maharash-tra)
Years of experience in the Com-pany
Machine details if produced In house
Male 14 18 including all Aurangabad Min 3 years N. A.Female 4 N. A. N. A. N. A. N. A.
Covered under ESI/EPF/Gratuity: No
Compensation Plan for workers in case of injury or accidents: Company takes responsibility for any medical assistance required in case of injury or accidents
110 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Career Graph Plan for Employees: Solely on education background and expe-rience merit
Retention Policies and Welfare Schemes: Bonus once in a year
Views on Government Initiatives taken so far: Although there are various schemes implementation is very poor. The paper work is very cumbersome. Moreover there is a lot of red tape and corruption involved.
Assistance by CIPET, Aurangabad: low testing rates for SSI
Assistance by IGTR, Aurangabad: Not Aware
Assistance by ITI, Aurangabad: Not Aware
Assistance by MCED, Aurangabad: Not Aware
SWOT Analysis of the CompanySTRENGTHS• Good product & market
knowledge• low operating cost• Good market credibility• Inhouse powder production
facility
WEAKNESSES• Non-availability of funding at
attractive interest rates hampering expansion activities
• Unorganized sector in rotomoulding industry
• Supply radius limited to only 300km
THREATS• Newer technologies like blow
moulded tanks having higher output rates affecting in short term
• Excessive credit offered by bigger companies due slump in demand
OPPORTUNITIES• Knowledge regarding machinery
and experimentation with newer manufacturing processes has opened machinery manufacturing as a new avenue
Future Plan of the CompanyTimelines Plan Assistance required
by the Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months Planning to launch tanks with new attractive design
N. A. N. A.
1 year Rotomoulding Machin-ery manufacturing
• Susbisdy for new ma-chinery
• lower electricity rates
Higher profits for asset creation and employee welfare
3 years • Pulverizer manufac-turing
• Conversion to Pvt ltd company
• Susbisdy for new ma-chinery
• lower electricity rates
Higher profits for asset creation and employee welfare
5 years PET jar manufacturing plant
• Susbisdy for new ma-chinery
• lower electricity rates
Higher profits for asset creation and employee welfare
Product Design BriefDesign Brief 1
New machinery manufacturing plan proposed. New energy efficient design which will save upto 10% of energy heating costs conversion of certain parts of machine to stainless steel from mild steel and introduction of pilot burners.
Design Brief 2
New pulverize manufacturing unit planned with segmented discs which will reduce machine disc cost drastically. Special segments to be made of hardened steel and chrome plated which shall reduce wear and tear.
Plan of the Design ProjectProduct Design Brief specifications
Change of material for certain parts, introduction of pilot burners
111 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Proposed Design Process Design already developedTimeline Upto 31st Dec’14Budget Rs. 8 lac per machineTeam members & Skills Required
Proprietor Shaukat Syed has good contacts with machine shop operators, as he has been always interested in new developments in machinery.
Benefits for the Company lateral marketing concept. We will get into products already associated with our current product market. Net profit Margins are better in machinery, which help create new assets for future expansion and provide funds for employee welfare.
112 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Improper and strenuous way of lifting plastic granules
heavy bags. This is also ergonomically inappropriate.
Children in the working area should be avoided at any time.
Gas cylinders are kept in the open and in the working area.
113 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Open wires all around the heaters. These may cause fire and if not attended properly this may give electricity shocks to the workers if these wires come in contact with the workers.
114 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The gap between the wall and the rotomoulding machines is very less to walk through.
115 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The Cooling plant has been made in-house using the water tank produced at the unit.
Mr. Syed Shaukat posing with his design of a new rotomoulding machine. The machine is being designed and developed completely in-house.
116 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The clutter of pipes seen around the cooling plant.
The window is being used as storage space for the heater cover panels leaving not enough space for the fresh air and light to come in the working area.
117 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The plastic lids are kept outside and in open on their arrival from it’s suppliers. This may soil the lid or damage before it is sent to the retailers.
No proper placement for the fire extinguisher unit.
118 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Need urgent attention for the proper wiring to avoid fire or any kind of accident.
The items out of use is kept in the regular working area. Need proper arrangement.
Area for storing drinking water. The area should be dry and clean.
119 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The items out of use is placed in the working area. Need proper arrangement.
The company’s logo is seen incomplete. Need proper maintenance.
The company’s logo needs to be printed more accurately.
The company’s entrance gate needs maintenance.
120 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement Space arrangement is a concern as the plant
area is congestedNew Product Development No in-house product development process
followedPackaging Need to improveMarketing Market awareness is a problem. No marketing
for business growthHuman Resource Training initiatives for the workers need to
improve
Business DesignMarketing Needs to improvelogo Design Needs to developVisiting Card Needs to developBrochures & leaflets Need to developWebsite Need to develop
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear and thus the productivity of machines can be im-proved. More amount to be spent on research and development work to devel-op new products which are smaller in size and can cater to larger market.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: n order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: Company currently producing only one type of product, it should venture into other categories to reduce the business risk. Product testing should be done at various levels and report can be prepared to increase customer confidence.
Human Resource: To reduce Employee attrition rate, the salary levels need to be revised to attract better skilled manpower.Proper training should be formalised to improve the skill of the workers.
Marketing:• A website need to be developed on urgent basis so that the customer reach
can be extended.• It requires more publicity on retail level. It urgently requires a modifica-
tion in a logo so that customers identity the product with the company. A proper branding strategy should be formalised to get maximum visibility in the market.
• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers.
• A company should participate in trade fairs and exhibition related to plas-tics to attract new customers
• A company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the de-velopment process.
121 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
31
2
08Jay
shre
eEn
terpr
ises
122 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Jayshree EnterprisesAddress of the Company: Plot No. M-19, MIDC, Waluj, Aurangabad Maharashtra, IndiaLandline number: N. A.Mobile Number: 8888805868
Company e-mail id: [email protected]
Website: NA Company started in: 2011
Type of Company: Proprietorship
Company’s Specialization/Product/Services• Auto Component • Furniture & House hold products
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Shailendra Prataprao Baviskar
27 Proprietor MMM (Finance)
4 Years [email protected]
8888805868
Jayshree EnterprisesMIDC, Waluj, Aurangabad
loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name /
Govt. AssistanceYear Purpose Amount (Rs.) Status (Ac-
tive/Closed)1 State Bank of
India2011 C. C. 1000000 Active
Vendor Code Details:Sr. No. Customer Issued
inCriteria/Guidelines to become the Vendor
Products Supplied
1 Badve Engineering ltd. 2011 ISO Certification Plastic Moulded2 Rohit Exhaust Systems
Pvt ltd2011 ISO Certification Plastic Moulded
3 Darshan Plastic 2011 ISO Certification Plastic Moulded
Production capacity of the Unit:Year Production capacity2013-2014 60%2013-2012 90%2012-2011 70%2011-2010 30%
Types of Customer:Type Total number of
CustomersNames/List of Customers Products
ManufacturedAutomotive 2 Badve Engineering ltd.,
Darshan PlasticsPlastic Moulded Prod-uct
123 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Household Products
1 Rohit Exhaust Systems Pvt ltd
Plastic Moulded Prod-uct
Organization Chart:
Proprietor(Shailendra Baviskar)
Quality Head (Babasahbh Tupe)
Operator: 1. Sanjay Dushing2. Gajanan Nikas
ladies (Deflashing)1. Sharada Nikas2. Sangita Rajput
Production Head (Sanjay Kumbhar)
Accountant(Jiven Kadam)
Types of Business:Business Type Products Products supplied toAs a Tier 1 Supplier to OEM Platina Tail Cap, D-105
Tail CapBottom Cap
Badve Engineering ltd. -VRubber
Rohit Exhaust Systems Pvt ltdAs a Tier 2 Supplier to OEM K G Cover Darshan Plastic
Area of the Unit:Plot Area 6000 Sq. feet.Total Built-up Area 2700 Sq. feet.
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2010-2011 4,70,580/- 1,86,692/- 1,86,692/-2011-2012 23,15,471/- 8,64,420/- 2,29,404/-
2012-2013 70,53,916/- 12,82,738/- 5,09,712/-
2013-2014 (expected) 60,00,000/- 10,00,000/- 4,00,000/-
Certifications:Certification Description of the Certification Year taken inISO 9001:2008 The Quality Management System 22 April 2013
Business Competitors:Sr. No.
Competitor’s name
Competitor’s Product Spe-cialization
Type of Business (Exporter/OEM/Tier 1 Supplier/Tier 2 Supplier / Tier 3 Supplier
1 Mitali Enterprises Plastic InjectionMoulding Products
Tier 1 supplier
2 Tulja Enterprises Plastic Moulding & painting Shop
Tier 1 supplier
Company Plant and Process FlowCompany’s Plant layout:
SemiFinishedGoods area
FinishedGood area
RawMaterialRoom
Office
Injection Moulding M/c 2
Working table 1
Working table 2
Injection Moulding M/c 1
Main Gate
Hea
ting
M/c
Coolingtower
Room for workers
Garden area
124 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Types of MachinesSr
. No.
Nam
e of
M
achi
ne
Qua
ntity
Mak
e of
m
achi
ne
Spec
ifica
-tio
n
Pric
e of
M
achi
ne
(Rs.)
Year
of
Purc
hase
Loan
/ by
Self
1 Injection Moulding M/c 01 Jet Master, Taiwan 180 Ton 12,00,000 2011 Self
2 Injection Moulding M/c 01 Hy-Plast, India 150 Ton 8,00,000 2011 Self
3 Vertical Injection Moulding M/c
01 Niranjan, India 60 Ton 3,50,000 2012 Self
4 Heater 01 S. V. Enterprises, India
- - - -
One Crane is available which has a capacity of 3 tons.
Raw materials
Sr. N
o.
Raw
Mat
eria
l
Cur
rent
Rat
e (R
s. Pe
r Kg)
Spec
ifica
tion
Supp
lier’s
N
ame
Min
. qua
ntity
m
aint
aine
d in
th
e co
mpa
ny/
mon
th
Prod
uct M
an-
ufac
ture
d w
ith
the
mat
eria
l
Prod
uct
Supp
lied
to
(OEM
/Tie
r 1
supp
lier/
Tier
2 Su
pplie
r/Ti
er
3 Su
pplie
r)
1 Polypropylene Copolymer (PPCP)
113 Plastic Gran-ules
Poly Gran India Pvt ltd
3 Ton House hold
Tier 1
2 Acrylonitrile Butadiene Styrene (ABS)
130 Plastic Gran-ules
Badve En-gineering
4 Ton Auto Comp
Tier 1
Sr. N
o.
Wor
kers
/ S
uper
-vi
sor/
Man
ager
/ S
taff
for
clea
ning
Qua
lifica
-tio
n
Ope
ratio
n / F
unct
ion
Year
s of
expe
rien
ce
in In
dus-
try
Wor
king
ho
urs /
da
y
1 Supervisor 12th 3 Yrs 8 hrs2 Accountant B. Com. 1 Yr 8 hrs3 Operator 12th 2 yrs 8 hrs4 Operator 10th 2 Yrs 8 hrs5 ladies 10th 2 Yrs 8 hrs
6 ladies 10th 2 Yrs 8 hrs
Business Process Flow chartReceive
Order from Customer
Generate Inter-nal Order
Check raw Material & Pig-ment Availability
Allocate job into Pro-duction Schedule
Allocate Machine
Issue Production Order to Factory
Set Mould into allocated Ma-chine and do Sample Run
Check Acceptability of First-run Samples
Check Availability of Packaging
Quality Check Sample
Commence Production Run against Internal Order Sheet
No
A
Yes
125 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Manufacturing Process Flow
Start
Receiving of Raw Material
Pre drying of Raw Material
De-flashing
Despatches
Packing
Inspection
Final Inspection
Injection moulding
Machine operations:Sr. No.
Machine name No. of labors required per machine
Time required for process
Idle time per shift of 8 hrs
Wastage %
1 Injection Mould-ing Machine
02 45-60 min 30 min 1%
Products manufactured at the Company:Sr. No.
Product Name Cost to Company Repeat Order
Supplied to
1 Platina Tail Cap 4.92 Yes Badve Engineering ltd2 D-105 Tail Cap 5.99 Yes Badve Engineering ltd3 K G Cover 1.6 Yes Darshan Plastics4 Bottom Cap 1.24 Yes Roht Exhust Systems Pvt ltd5 Angle Nut 2.19 Yes Roht Exhust Systems Pvt ltd6 Washer 0.23 Yes Roht Exhust Systems Pvt ltd
Quality Control PlanProject DocumentationDoes the company maintain Documents for every Project?
Yes
Quality Control Procedure: (In house/ External agency)
• Inward inspection for raw material check sheet also available.
• After production of component initial-ly it is inspected by machine operator itself & forward it to packing area.
• For dispatch of product pre-dispatch inspection is done and PDIR is given with every invoice.
Name of Testing Labs for Raw Materials (tie-ups for Raw Materials)
CIPET
126 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of Testing Labs (tie-ups for Finished Products)
• Badve Engineering ltd.-V • Aurangabad Auto Cluster
Testing of Finished Products • Finish product checked dimensional as well as visually checking is carried out in house.
• We are having some of measuring instrument
Quality Standard for Product:Sr. No. Product name Specification Strictly followed1 Platina Tail Cap • NoFlash
• ShrinkageYes
2 Bottom Cap • Shrinkage• ColorVariation
Yes
Exhibitions/trade shows
Sr. N
o.
Exhi
bitio
n /
Show
Part
icip
ant /
V
isito
r
Last
atte
nded
(Y
ear)
Fees
(in
case
th
e co
mpa
ny
part
icip
ated
)
Bene
fits
1 Plast Expo (Pune) 2012 Free Market opportunity2 Plexpo (gujarat) 2013 100 Market opportunity3 Plast Vision 2014 300 Market opportunity
Safety standards in the CompanyManufacturing Op-erations
Possible accidents / hazards
Safety measures in the company
Remedies / Medication
Manufacturing Fire Fire Extinguisher First Aid
Marketing and Branding:logo of company:
Effectiveness of the company logo High
Brand Awareness in respective markets; whether B2B or B2C
Medium
Do you operate Online? No
Finance & AccountsPricing:Pricing of plastic product mainly depends upon its weight and type of machine requires to produce that part.
Component name: Motor CoverSr. no. Description Unit1 Name of moulder -- Jayshree Ent.2 Component Wt. Gms. 25.0003 Runner Wt. Gms. 2.0004 Shot Wt. Gms. 52.0005 Reco Wt. with 2% loss Gms. 25.5006 RM Rate Rs. 130 3.3157 M/C used Tons 150.00
127 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
8 M/C tarrif Rs./shift 1200.009 Cost of preheating Rs./shift 0.0010 Cycle time Sec. 30.0011 No. of shots/8 hrs shift due to lower volume Nos. 96012 No. of cavity Nos. 213 No. of pieces/shift Nos. 192014 Prod. by efficiency@90% % 172815 Moulding cost Rs. 0.69416 Finishing cost Rs. 0.00017 Prod. with 1% Rej Rs. 0.0118 Total cost of moulding comp. Rs. 0.6919 Total effective cost Rs. 4.00920 Profit 10% on effective cost Rs. 0.41021 Total cost of component Rs. 4.41022 ICC on RM - 3% 0.09923 Reprocess cost per piece Rs. 0.00024 Packing cost Rs. 0.05025 Transportation cost Rs. 0.04026 Final rate with RM per piece Rs. 4.60
Distribution Process:Finished product dispatched to customer by transport or customers directly purchased from our factory premises by their own vehicle.
Human Resource ManagementEmployment recruitment rules
• Minimum 3 yrs of work experience • Good manpower handling skill• Well knowledge of plastic injection Moulding Machine
Leave Policies:Staff Leave PolicyMachine Operator Inform before 10-15 days
Supervisor Inform before 10-15 daysManager Inform before 10-15 daysHelper/Cleaning Staff Inform before 10-15 days
Overtime Policy: Overtime is given as per their working hours
Insurance/Medi-claim Policy: United India Insurance company
Wage Rate Policy: As per their skill
Salary Structure:Staff For Fresher (in Rs.) With experience of 3 years (in Rupees)Machine Operator 150/shift 190/shiftSupervisor 200/shift 250/shift
Male & Female Employees:Staff Number
of staffProfile (Machine Operator / Super-visor / Manager / Helper / Cleaning Staff)
Hometown (Aurang-abad/Outside Au-rangabad but within Maharashtra/Out-side Maharashtra)
Years of experience in the Company
Machine details if produced In house
Male 5 1 Supervisor, 1 Accountant, 1 Production Head, 2 Operator
With-in Maharashtra 2
Female 2 De-flashing With-in Maharashtra 2
Views on Govt. Initiatives taken so farAssistance required from Government in the following areas:• Electricity Rate Very High Compare to other State• Government Scheme is not aware of new business men• Road Facility is not good for transport • Develop New Plastic industries
Assistance by CIPET, Aurangabad:
128 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
• CIPET regularly arrange training for labour also give knowledge about new technology in plastic industry
Assistance by IGTR, Aurangabad:• Manufacturing of Moulds
Assistance by ITI, Aurangabad:• Helping in recruitment of New Employees (Technical)
Assistance by MCED, Aurangabad:• Help in development and design in association with Design Consultants
SWOT Analysis of the CompanySTRENGTHS• Excellent product quality• Prompt service• Customer Satisfaction
WEEKNESSES• Insufficient Funds• Un-skilled labour
THREATS• Competitor sale product on lesser
amount• Credit sale recovery
OPPORTUNITIES• To achieve zero customer returns.• To achieve 100 % compliance of
deliveries on scheduled time • To improve machine up time.• Reduction in internal non-
conformities.• Maintain clean & tidy work place.
Future Plan of the CompanyTime-lines
Plan Assistance required by the Govt. (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months Design & development Finance Improvement in turnover
1 year Purchase new machine Finance Improvement in turnover
3 years Expansion of new unit Finance Improvement in turnover
5 years Increase more machine Finance Improvement in turnover
Product Design BriefDesign Brief It is an automobile part used in head light area of
two wheeler
Plan of the Design ProjectProduct Design Brief specifications
Plastic injection moulded component
Proposed Design Process N. A.Time-line 6 monthsBudget Rs. 15-20 lacksTeam members & Skills Required
Two skilled person
Benefits for the Company Growth in profit as we will supply directly to main customer
129 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The entrance needs maintenance
The gap between the wall and the machine is blocked because of the pipes hanging loosely
130 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The glass is damaged and the process is not visible.
The marking for the switches is not properly shown. It needs urgent attention and maintenance. Overall the machines needs maintenance
131 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The marking for the switches is not properly shown. It needs urgent attention and maintenance.
The gap between the wall and the machine is blocked because of the pipes hanging loosely
The floor needs maintenance
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133 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Security camera in the work area but not functioning
The raw material room is not lit properly
134 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The tool board is not well maintained
The packaging area of the unit is well maintained
The windows in the work area is not clean. Need to be maintained properly.
Temporary arrangement at the cooling plant.
135 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology As per standardAesthetics As per the product requirementsQuality As per the product requirements Operations Need to improveWorkplace & Ergonomics Workplace need to be properly managedPlant layout Improvement Need to be more efficiently managedNew Product Development No in-house product development process
followedPackaging Yes, satisfactoryMarketing Not much visibility in marketHuman Resource Training is provided to new recruit
Business DesignMarketing No marketing, need to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Need to create a website
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Very less safety precautions are taken by workers, this need to be improved by providing gloves and other safety gears to workers.
Financials: n order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to get into household products, it can also explore product diversification in the home decor and kitchen products.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:Company is supplying products to only single company Badwe Engineering. The company should increase its customer base to reduce the risk on the busi-ness. As there is no marketing activity by company, it should start its branding in the market. A website should be formed as early as possible and advertise-ment should be given to various web portals like indiamart.com and alibaba.com to get more visibility in the market. As company has plan for huge expan-sion, company logo has to more creative and need to be protected.
Quality Control:A quality control procedure has to be formed as there is no formal testing is done on products; products only checked visually for quality
136 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
31
2
09Jy
oti
Indu
stries
137 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Jyoti Industries (sister concern of Sushma Industries)Address of the Company: D – 107, MIDC, Shendra, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 8928187703, 9404012247, 9822193777Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: 2007
Type of Company: Proprietorship
Company’s Initial Investment: 35 lacs
Company’s Specialization/Product/Services: Drip Irrigation Pipes
Affiliated units/sister concern/subsidiary: Sushma Industries
Details of the Owners / Partners:
Sr. N
o.
Nam
e of
O
wne
r /
Prop
riet
or
/ Par
tner
s /
Dir
ecto
r
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Atmajyoti Bapu Nagare
22 Owner B. A. [email protected]
8928187703
loan/Financial Assistance taken since the start of the company:
Jyoti IndustriesMIDC, Shendra, Aurangabad
Sr. No. Bank Name / Govt. Assistance
Year Purpose Amount (Rs.) Status (Ac-tive/Closed)
1 Khamgaon Urban Cooperative Bank ltd
2007 Building and Machinery
17.5 lacs Active, Current EMI approx. Rs22000/- per month
Types of Customer:Type Total number of
CustomersNames/List of Customers Products
ManufacturedAgricultural/Irrigation
1 Biggest customer Rajput from Naregaon, Custom-ers from Pachur, Paithan, Jalgaon, Nanded, Beed etc
DripperIrrigation pipes with Dripper
Total number and List of Vendors or Suppliers: Vendors from Jalgaon for Dripper
Total number of Employees at the company: 13
Area of the Unit: 800 sq. mt
Turnover of the Unit (in Rupees):Year Annual Turnover2009-2010 40 lacs2010-2011 45 lacs2011-2012 50 lacks
138 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
2012-2013 75 lacks2013-2014 (expected) 1 crore
Certifications: ISO
Types of Machines: Extrusion Machine, Coiling Machine, Grinder and Mixer
Types of Tools: Complete tool box
Business Process FlowSample is shown
Production begins
Quality Inspections & Finishing
Quality and rates are negotiated and finalize
Sorting and packaging
Dispatch
Quality Control PlanProject Documentation:Does the company maintain Documents for every Project?
Yes
Quality Control Procedure: (In house/ External agency)
• Visual Inspection• Finishing • Dimension Checking & other defects
Testing of Raw Materials (In-coming - Quality Control Tech-niques)
• Weight measurement• Strength and moisture checking• Brand name is an indicator of quality
Name of Testing Labs for Raw Materials (tie-ups for Raw Ma-terials)
N. A.
Name of Testing Labs (tie-ups for Finished Products)
N. A.
Testing of Finished Products • Visual Inspection• Dimension & Weight measurement
Safety standards: Fire extinguisher and First aid box is inside the factory premises and all medical expenses are reimbursed.
Marketing and Branding:logo of company:
Effectiveness of the company logo Medium
Company’s Target Market: Farmers
Brand Awareness in respective markets; whether B2B or B2C
High
Initiatives taken to promote the Brand and Respective expenses
Promotion through Direct Meetings, Branding on Key Chains, Calendar, Watches given as gifts
139 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Online services Not yet
Exhibition/trade shows visits:
Sr. N
o.
Exhi
bitio
n /
Show
Part
icip
ant /
V
isito
r
Bene
fits
1 Exhibition Participant Knowledge about new machines2 Training on new machines
handling organized by CIPETParticipant
Human Resource ManagementShift Timings 9 AM to 6 PM
Number of Shifts per day: 1
Employment recruitment rules Direct Interview and referrals
Leave Policies: • WeeklyoffonFriday• Holi-2Days• 26thJan• 1stMay• Dussehra• Diwali
Salary Structure: Rs. 5000 to 12000 for Machine operators
Assistance required from Government in the following areas:• More awareness for programmes and training workshop initiatives run by
the government• Discount the VAT charges
SWOT Analysis of the CompanySTRENGTHS• Quality of products• Brand awareness• Cheaper products as lesser no. of
people employed which results in cost cutting
WEAKNESSES• Competitors using better ma-
chines• Availability of trained manpower
THREATS• Increase in rates of electricity
OPPORTUNITIES• Support from government &
other initiatives for development of the firm
Future Plan of the CompanyTime-lines Plan6 months Manufacturing of Solution and Dripper1 year Insurance and Mediclaim for employees
Increase in no. of machines5 years Making all the products required for operations In-house. No procure-
ment from vendors.
Market expansion to target markets out of Maharashtra.
Product Design Brief: N. A.
140 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Raw material
Extrusion moulding for Irrigation pipes
Company board at the entrance
Raw material
141 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Online Drip extrusion line
Granules mixer
Grinder for the scrap material
Online Drip extrusion line
142 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Cooling tower
Compressor unit
Roll of Irrigation pipe.
Rolls of Irrigation pipe.
143 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Step to feed granules in the hopper
Automatic pipe rolling machine
Tool box
144 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Main entrance of the company
Mosquitoes breeding in the cooling tower (since the plant has stopped for maintenance)
Financial institution’s sticker on the machine
Rooms for the workers inside the campus.
145 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Need to improveWorkplace & Ergonomics Need to improvePlant layout Improvement Well plannedNew Product Development No in-house product development process
followedPackaging As per requirementMarketing Brand awareness is high. Kisan PVC Pipes is a
well known brandHuman Resource Needs improvement
Business DesignMarketing Satisfactorylogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Needs to make greater investment in machinery in future to keep pace with the market needs and for scaling up the business.
No software is being used currently. But technology will have to be adopted to manage the business efficiently.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: Three major sectors where the company’s products are used: i) Irrigation, ii) Drinking Water and iii) Electrical. In order to provide regular funding, the company may be linked to the respective corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to become self-sufficient in all the products re-quired for business, they need to undergo product training and even evaluate the feasibility of entering into all the categories vis-a-vis outsourcing the prod-ucts. The balance needs to be worked out.
Human Resource: Currently the number of employees is only 10. Three members of the family manage the business operations. The company perceives it to be a cost advan-tage. However, the outlook needs to change and more number of qualified people need to be hired to strengthen the business and enter into new markets.
Marketing:The company is banking heavily on its brand awareness in the current target market. However, it should not become complacent as new competitors with greater marketing efforts might erode its equity in future. Participation in trade shows and more online marketing might be effective solutions to tackle the issue.
146 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
2
31
10M
itali
Enter
prise
s
147 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Mitali EnterprisesAddress of the Company: Plot No. S-1, opp. Good year tyre, MIDC, Waluj, Aurangabad Maharashtra, IndiaLandline number: 0240-2554011Mobile Number: 9767100466Company e-mail id: [email protected] website: N. A. Company started in: September 2010
Type of Company: Partnership
Company’s Specialization/Product/Services: Plastic injection Moulding
Affiliated units/sister concern/subsidiary: N. A.
Company’s Initial Investment: 35 lacs
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Pramila Kanha Kashide 34 Partner BA 3 Years - 09421683397
2 Santosh Mukinda Sirsat 27 Partner BA 5 Years - 09767100466
Mitali EnterprisesMIDC, Waluj, Aurangabad
Details of the Owner/Director Family members:
Sr. N
o.Fa
mily
Mem
ber
Rel
atio
n to
the
Ow
ner o
f the
Com
-pa
ny
Age
(in
Year
s)
Wor
k Ex
peri
ence
pr
ior t
o jo
inin
g th
e C
ompa
nyIn
volv
ed in
Com
-pa
ny’s
busi
ness
ac
tiviti
es (Y
es/N
o)
Rol
e in
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Milind Kanha Kashide
Brother 27 5 years Yes CEO [email protected]
09767100466
loan/Financial Assistance taken since the start of the company:Sr. No.
Bank Name / Govt. Assistance
Year Purpose Amount (Rs.) Status (Ac-tive/Closed)
1 State Bank of Hyderabad 2011 Machine 20 lacs 12 lac2 State Bank of Hyderabad 2011 Cash Credit 18 lacs
3 State Bank of Hyderabad 2013 Machine 19.75 19.75
Vendor Code Details:Vendor Code
Customer Issued in
Criteria/Guidelines to become the Vendor
Products Supplied
1 Badve Engineering ltd.
2012 ISO Certified Plastic Moulded
2 Darshan Plastics 2012 ISO Certified Plastic Moulded
3 Tulja Enterprises 2013 ISO Certified Plastic Moulded
148 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Types of Customer:Type Total number of
CustomersNames/List of Customers Products
ManufacturedAutomotive 3 1. Badve Engineering ltd
2. Darshan Plastics3. Tulja Enterprises
Plastic Moulded Prod-ucts
Total number and List of Vendors or Suppliers:• Total Supplier - 04 nos• Badve Engineering ltd• Swagat Plymers• Shri Vyankatesh Plymer• Poly Gran India Pvt ltd.
Organization Chart:
Milind Kashide(CEO)
Shift I operators:-1. Ramesh Kapde
2. Anil Dhule
Shift II Operators:-1. Ramnath Dhage
2. Vishnu Kulte
Account Head(Narayan Bhagure)
Quality Head Raju Rudrakshwar
Production Head Sanjay Katolkar
Mrs. Pramila Kashide (MD)
Area of the Unit:Plot Area 3000 Sq. feetTotal Built-up Area 2000 Sq. feet
Types of Business:Business Type Products Products supplied toAs a Tier 1 Supplier to OEM Cowling BM 150 BOXER Plati-
na Side Cover Cap COWlING MIDDlE ASSlY
Badve Engineering ltd
As a Tier 2 Supplier to OEM K G CASEJ D CAPChain Cover
1. Tulja Enterprises2. Darshan Plastics
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2011-2012 36.15 10.22 0.232012-2013 102.90 15.76 1.442013-2014 (expected) 150 N. A. N. A.
Certifications:Certification Description of the
CertificationYear taken in
Local Agent
ISO 9001:2008 Quality Management Sys-tem
2013 Ajit Rajendra
Audit Reports: ISO 9001:2008
Business Competitors:Sr. No.
Competitor’s name
Competitor’s Product Spe-cialization
Type of Business (Exporter/OEM/Tier 1 Supplier/Tier 2 Supplier / Tier 3 Supplier
1 Sanjay Plastics Plastic Mould-ed Products
Tier 2
2 Vipra Plastics Plastic Mould-ed Products
Tier 2
3 Gajanan Indus-tries
Plastic Mould-ed Products
Tier 2
149 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Company’s Plant layout
Semi finish goods area
Finished goods area
Store Room
Open Space
Toilet
Machine No. 3 (300 Tons)
Machine No. 2 (250 Tons)
Machine No. 1 (180 Tons)
Electric Board
Shutter 1 Shutter 2
Semi finished Area
Office Space
Main Gate
Shut
ter 1
Types of Machines
Sr. N
o.
Nam
e of
M
achi
ne
Qua
ntity
Mak
e of
m
achi
ne
Spec
ifica
-tio
n
Pric
e of
th
e M
a-ch
ine (
Rs.)
Year
of
Purc
hase
Loan
/ by
Self
1. Plastic Injection Moulding
1 Electronic a/India
180 tons 10 lacs 2011 Self
2. Plastic Injection Moulding Machine
1 Jit / Philip-pines
300 tons 20 lacs 2012 loan
3. Plastic Injection Moulding Machine
1 Haitian / Vietnam
250 tons 27 lacs 2013 loan
Types of Tools
Sr. N
o.
Nam
e of
M
achi
ne
Qua
ntity
Mak
e of
m
achi
ne
Spec
ifica
-tio
n
Pric
e of
the
Mac
hine
(R
s.)
Year
of
Purc
hase
Loan
/ by
Self
1. Spanner Set 02 Engineering approach
All types Rs.8000/- 2013 Self
2. Other tools - local market All types Rs.10000/- 2013 Self
Raw materials
Sr. N
o.
Raw
Mat
eria
l
Cur
rent
Rat
e (R
s. Pe
r Kg)
Spec
ifica
tion
Supp
lier’s
Nam
e
Min
imum
qua
ntity
m
aint
aine
d in
the
com
pany
per
mon
th
Prod
uct M
anu-
fact
ured
with
the
mat
eria
l
Prod
uct S
uppl
ied
to
(OEM
/Tie
r 1 su
ppli-
er/T
ier2
Sup
plie
r/Ti
er 3
Sup
plie
r)
1 PPCP 115/kg
MI 3530 lokesh Plasto Chem
1.5 ton Plastic Mould-ed item
Tier 2
2 ABS 1.5 Tons
HI121U Badev En-gineering ltd.
2 tons Plastic Mould-ed item
150 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Shift Timings: 8am to 4pm, 4pm to 12am & 12am to 8am
Number of Shifts per day: 3
Sr. N
o.
Nam
e of
wor
ker
Age
(yrs
)
Gen
der (
M/F
)
Wor
kers
/ Su
-pe
rvis
or/M
an-
ager
/ St
aff fo
r cl
eani
ng
Qua
lifica
tion
Ope
ratio
n /
Func
tion
Year
s of e
xper
i-en
ce in
Indu
stry
Wor
king
hou
rs
/ day
1 Milind Kashide
27 M CEO B.E. All 5 yrs 8 hrs
2 - - - Accountant (staff)
MBA Account-ing
3 yrs 8 hrs
3 - - - Supervisor BA Shift incharge / supervi-sory
8 yrs 8 hrs
4 - - - Worker 9th Machine Operator
5 yrs 8 hrs
5 - - - Worker HSC Machine Operator
5 yrs 8 hrs
6 - - - Helper SSC Helper 3 yrs 8 hrs7 - - - Worker HSC Machine
Operator4 yrs 8 hrs
Functions/Operations in the company:Function / Operation
Required Qualification of workers
Required number of work-ers
Shortfall of workers
Number of hours /shift
Number of shifts/day
Design & development of plastic products
DME BE
02 0 8 hrs 1
Business Process FlowCustomer Enquiry
Decide rate based on machine capacity and cycle time of operation
Attend Meeting of negotiation
Take Input from Customer
Offer quotation
Receiver purchase order followed by mould
Start Production
Get the sample approved from customer
Submit sample piece
Manufacturing Process FlowMachine operations:
Sr. No.
Machine name No. of labors required per machine
Time required for process
Idle time per shift of 8 hrs
Wastage %
1 Injection Mould-ing Machine
02 55-60 min 30 min 1%
151 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Process Flow DiagramSr. No.
Operation Check Points Process Flow Dia-gram
Resp.
1 Receiving of Raw material
Raw material Grade as per Purchase order. Bags free from wet & torn Condition.
Store In-charge
2 Storage of Raw Material
Maintain FIFO Store In-charge
3 Pre drying of Raw material
Predrying Temp. & Time as per predrying chart
Material loading Op-erator
4 Injection Moulding
Visual & Dimensional parameters of compo-nent
Shift Super-visor & QA Inspector
5 Deflashing As per reference sample Operator
6 Final Inspec-tion
Free from visual, dimensional & printing defects.
Inspector
7 Packing as per standard packing chart
Operator
8 Despatches Free from transit dam-age
Despatch Supervisor
Products manufactured at the Company:Sr. No.
Product Name Cost to Company
Price to Customers
Repeat Order
Supplied to
1 Cowling boxer BM 150 38 44.08 Yes Badve Engineering ltdAurangabad
2 Platina Cap 3.30 3.87 Yes Badve Engineering ltdAurangabad
3 K G Case 4.20 4.75 Yes Darshan PlasticsAurangabad
4 J D Cap 1.2 1.45 Yes Darshan PlasticsAurangabad
5 Cowling Middle Assly 10.30 11.67 Yes Badve Engineering ltdAurangabad
Quality Control PlanProject Documentation Does the company maintain Documents for every Project?
No
Quality Control Proce-dure: (In house/ Exter-nal agency)
• Inward inspection is carried out for raw material as well as for insert and other check sheet also available.
• After production of component initial-ly it is inspected by machine operator itself & forward it to packing area.
• for dispatch of product pre-dispatch in-spected is done and PDIR is given with every invoice.
Testing of Raw Materi-als (Incoming - Quality Control Techniques)
• Mostly raw material is supplied by cus-tomer so visually inspection is done.
• If any problem occurs in raw material processing we immediately inform to customer so that they will report it to their respective supplier.
Name of Testing Labs for Raw Materials (tie-ups for Raw Materials)
CIPET
Name of Testing Labs (tie-ups for Finished Products)
Aurangabad Auto Cluster
Incoming Parts
Transporta-tion
StorageOpem. & in-spn. together
OperationPacking Delay
152 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Testing of Finished Products
• For finish product dimensional as well as visual checking is carried out in house
• We are having some of measuring in-strument such as a) Vernier Calliperb) Filler Gauagec) Thread Gauage
Quality Standard for Product:Sr. No. Product name Specification Strictly followed1 K G Case Air Filter No Shrinkage
No Warpage Scratches on insertYes
2 Cowling BM 150 No Scratches, No Weld lineNo shrinkageNo Warpage
Yes
Design & DevelopmentBudget allocated for Research & Development (Annually in Rs.)
15 - 20 lacs
IT/CAD/Softwares/CAM used in the Company
N. A.
Exhibition/trade shows visits:
Sr. N
o.
Exhi
bitio
n /
Show
Last
at
tend
ed
(Yea
r)
Fees
(in
case
th
e co
mpa
-ny
par
tici-
pate
d)
Bene
fits
1 Plast India 2012 Free -2 Plexpo 2013 100 Heavy discount
in spare part3 Advantage Maharashtra Expo 2014 Free -
Safety standards in the Company:Manufacturing Op-erations
Possible accidents / hazards
Safety measures in the company
Remedies / Medication
Manufacturing Fire Fire Extinguisher First Aid Kit
Marketing and Branding:logo of company:
Effectiveness of the company logo Medium. No need to focus on Brand-ing and Marketing as it is a B2B business and Brand awareness of the company is high in its target market.
Describe the Company’s Target Market: Auto Auxillary manufacture
Brand Awareness in respective markets; whether B2B or B2C
High
Initiatives taken to promote the Brand and Respective expenses
• Online marketing• Most Important satisfactory
customer• Person to person marketing
Online services No
Company Packaging: Supplied by Customer
153 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Finance & AccountsProduct Pricing: Product Pricing of plastic product mainly depends upon its weight and type of machine requires to produce that part.Item Name Unit CapMaterial - PPCPColour - NaturalNet Wt. gms 1.0Runner gms 15Shot wt. gms 1.47Process loss % 1%Recon Wt. gms 1.0Raw Matl. Cost Rs/Kg 127.00Raw Matl. Cost / piece Rs/piece 0.1RM Profit 3% 0.01Net RM Cost per PC 0.14M/C used Tonns 180M/C tariff Rs/shift 1980cavity nos 32Cycle time secs 48Prod. per shift nos/shift 19200Production @ 90% effeciency nos/shift 17280Moulding cost Rs/piece 0.1Rejection @ 3% Rs/piece 0.00Profit 10% on Conv Cost Rs/piece 0.01Moluding Cost Rs/piece 0.13Cost of RM + Conv Rs/piece 0.27Mould Cost(One year) Rs/piece 0.04Inspection cost Rs/pieceFreight cost Rs/pieceTotal Component cost Rs/Piece 0.31
Terms & Conditions# - Freight & Packing cost is not included.# - Above price is basic price Ex. our Works. Other taxes will be as applicable.# - For supply of components payment within 30 days after dispatch from our end.
Distribution process: Finished product dispatched to customer by transport or customers directly purchased from our factory premises by their own vehi-cle.
Human Resource ManagementEmployment recruitment rules Competence requirement of supervisor:
1. Minimum 8 yr of work experience2. Good manpower handling skill3. Well knowledge of plastic injection moulding.
Training Policy for the new recruits/already employed with the company:For New Recruits For Already Employed
Machine Operator Work Experience Work ExperienceSupervisor Work Experience Work ExperienceManager Work Experience Work ExperienceHelper/Cleaning Staff N. A. N. A.
Leave Policies:Staff Leave PolicyMachine Operator Inform before 10-15 daysSupervisor Inform before 10-15 days
Manager Inform before 10-15 daysHelper/Cleaning Staff Inform before 10-15 days
Overtime Policy: Overtime is given as per their working hours
Insurance/Medi-claim Policy: United India Insurance Company
154 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Wage Rate Policy: As per the skill
Salary Structure:Staff For Fresher
(Rs.)With experience of min. 3 years (in Rupees)
Training required, if yes then please mention the training
Machine Operator 150/shift 190/shift YesSupervisor 200/shift 250/shift YesManager 300/shift 400/shift YesHelper/Cleaning Staff 120/shift 150/shift Yes
Male & Female Employees:Staff Number
of staffProfile (Machine Oper-ator / Supervisor / Man-ager / Helper / Cleaning Staff)
Hometown (Aurangabad/Outside Aurangabad but within Maharashtra/Out-side Maharashtra)
Years of experience in the Company
Male 08 Operator Outside Aurangabad but within Maharashtra
1.5 years
Female N. A. N. A. N. A. N. A.
Covered under ESI/EPF/Gratuity: N. A.
Contract Worker Policy: N. A.
Assistance required from Government in the following areas:• Various schemes to be informed by any communication medium• Reduce Electricity rate• Reduce water rate
Assistance by CIPET, Aurangabad: Various training is carried out in CIPET for worker.
Assistance by IGTR, Aurangabad: N. A.
Assistance by ITI, Aurangabad: N. A.
Assistance by MCED, Aurangabad: Many Entrepreneur development training
and other useful workshop is carried out.
SWOT Analysis of the CompanySTRENGTHS• Customer satisfaction• Quality Material• Good reputation among customer
WEAKNESSES• Number of competitor• Unskilled labour• Insufficient capital
THREATS• Competitor sale product on lesser
amount• Credit sale recovery
OPPORTUNITIES• Export the product• Scope in own product
Future Plan of the CompanyTime-lines
Plan Assistance required by the Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months Design & development Finance Improvement in turnover
1 year Purchase new 450 tons machine
Finance Improvement in turnover
3 years Expansion of new unit Finance Improvement in turnover
5 years Increase more machine Finance Improvement in turnover
Product Design BriefDesign Brief 1
Proposed product is having heavy requirement in market
Design Brief 2
It is an automobile part of two wheeler.
Design Brief 3
Very few manufacturer are their for proposed product and supply to direct market will give more profit
155 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Design Brief 4
Cost of product will be very less for direct customer.
Plan of the Design ProjectProduct Design Brief specifications
It is an automobile part used in head light area of two wheeler
Proposed Design Process Study and designing and researching according to actual available sample
Time-line 06 monthsBudget Rs. 15 to 20 lacsTeam members & Skills Required
Team includes 05 Members• Industrial Designer (two)• Technical Engineer (Two)• Marketing
Benefits for the Company Growth in profit as we will supply directly to main customer
156 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The main building of the unit.
Pile of boxes folded and kept right in-front of the entrance
The reception area of the unit
Raw material is arranged well
157 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Raw material: PP by Reliance Industries
Raw material: ABS by lG Chem.
158 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Workers assembling the Air filter Case
159 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Workers masking the front cowl for finishing purpose
Well maintained tool board
Quality inspection in progress
160 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The fire extinguisher is not easily visible.
Good practice of maintaining separate area for tiffin area.
161 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Separate and well maintained area for keeping boxes of finished goods.
Security camera in the work area but not functioning
Well defined for raw materials
162 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement • Space arrangement is a concern as the
plant area is congested• No use of Natural light
New Product Development No in-house product development process followed
Packaging Need to improveMarketing • Market awareness is a problem. No
marketing for business growth• Good branding material available• Sample swatches are available
Human Resource • Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: Three major categories where the company focuses on are:i) Automobile, ii) Electrical and iii) luggage. In order to provide regular fund-ing, the company may be linked to the respective corporate houses as dedicat-ed vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to get into household products, it can also explore product diversification in the home decor and kitchen products.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• Website need to be developed to showcase the product portfolio and con-
nect to the buyers and customers.• Branding exercise needs to be conducted on priority basis as the company
aspires to get into the household product segments. Trademark registration should be taken to protect equity and prevent litigation in future.
• There is a huge dependence on one customer which might harm the busi-ness in the long run. Increasing the customer base is mandatory for long term sustenance and growth.
• Assistance should be provided to the company to set up their stall in exhi-bitions to highlight their products to the retail and manufacturing partners.
• Re-structuring of the website to increase vendor accessibility.• As the company plans to get into retail consumer segments like plastic
buckets, jugs, mugs etc. it should develop its distribution channel to reach out to the right target market.
163 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
31
Claims:
An improved safety shaving disposal razor comprising:
• at least one disposal blade sandwich assembly• at least one sandwich assembly holder• at least one piece of shaving blade• a flap• at least one pivot pin or rivet
13M
oraz
Plas
tics
164 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Moraz PlasticsAddress of the Company: Yeshwant Nagar, Navle, PaithanLandline number: N. A.Mobile Number: 9028173531Company e-mail id: [email protected] Website: N. A. Company started in: In process
Type of Company: Proprietership
Company’s Specialization/Product/Services: Safety razor
Affiliated units/sister concern/subsidiary: N. A.
Details of the Owners / Partners: Vilas More
Abstract of the Innovation:The present invention [particularly discloses the said safety is fold-able device which is mainly used in saloon and parlours for shaving purposes. It comprises of a flap meant for accommodation the disposable blade sandwich assembly along with the sandwich assembly holder. The disposal blade sandwich assembly is snap fitted in the sandwich assembly holder. The sandwich once snap fitted cannot be removed for changing the blade and if any body tries to do so, the snap breaks from its base, thereby avoiding its further use or reuse by inserting a new blade or further use or reuse of said
Moraz Plastic (Innovator)Paithan, Aurangabad
disposable blade sandwich assembly.
Thus it provides a safety to the user which avoids spreading of various dan-gerous and incurable diseases like AIDS, Hepatisis, etc. which are likely to be spread because of the residues remains on the razor blade assembly through infection and contamination while conducting shaving different persons.
Note: limited study has been conducted on this unit as the product develop-ment is in progress.
165 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
166 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
12M
ould
Tech
nolo
gy
167 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Mould TechnologyAddress of the Company: W – 74 MIDC Waluj, Aurangabad, MaharashtraLandline number: N. A.Mobile Number: 9370656737 Company e-mail id: [email protected]
Website: N. A. Company started in: 2009
Type of Company: Partnership
Company’s Specialization/Product/Services: Mould Making and products manufacturing
Affiliated units/sister concern/subsidiary: N. A.
Details of the Owners / Partners:
Sr. N
o.
Nam
e of
Ow
ner
/ Pro
prie
tor /
Pa
rtne
rs /
Di-
rect
or
Age
(yea
rs)
Stat
us (O
wne
r /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
peri
-en
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail
Id.
Phon
e nu
mbe
r
1 Bhalchandra Bhandare
40 Owner Diploma in Mechanical Engineering
10 -- 9370656737
Mould TechnologyMIDC, Waluj, Aurangabad
Company’s Initial Investment: 25 lacs
loan/Financial Assistance taken since the start of the company:Sr. No.
Bank Name / Govt. Assistance
Year Purpose Amount (Rs.)
Status (Active/Closed)
1 Shyamrao Vithal Co op bank
2010 Purchase of machinery
25 lacs Paid
2 Bank of Maharashtra 2013 18 lacs Cash credit
Customer Details: Sanjay technoplast, Savera moulding, Varroc, Videocon, Ultima plastics, Higher appliances and Aurangabad Electricals ltd.
Production capacity of the Unit: 8-10 moulds/month
Types of Customer: OEM, Tier 1, 2 and 3 suppliers to OEMs.
Types of Business: OEMs in Aurangabad and Ranjangaon
Turnover of the Unit (in Rupees):Year Annual Turnover2009-2010 40 lacs2010-2011 1 crore2011-2012 1.5 crores2012-2013 1.6 crores2013-2014 (expected) 2 crores
168 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Certifications: ISO certificate in 2010
Business Competitors:• Kishor Industries• Marvel Moulds
Machineries & raw materialsTypes of machineries:• Surface grinder• Drilling machine• Milling cum Drilling machine• Vertical milling machine (Rough milling)• Vertical milling machine (for parallelity)• lathe machine• Injection moulding machine• Grinding machine• Buffing machine• VMC (CNC) machine• EDM machine• Compressor
Raw materials: P-20, Mild steel, OHNS, Copper for moulds and ABS, PP & HIPs for production
Human Resource ManagementShift Timings: 7 am to 7 pm
Total number of Employees at the company: 10 Males ( for Machine opera-tors, tooling & assembly) & 2 Females (for Packing job)
Salary Structure: Rs. 5000 to 7000 for Machine operators & Rs. 10000 for supervisors
Covered under ESI/EPF/Gratuity: N. A.
Compensation Plan for workers in case of injury or accidents: N. A.
Career Graph Plan for Employees: N. A.
Retention Policies and Welfare Schemes: N. A.
Assistance required from Government in the following areas: Taxation need to be simplified w
R&DBudget allocated of Research & Development (Annually in Rs.): 7-10 lacs
Exhibition/trade shows visits (mention name and place): Yes, attended Plas-tvision as a visitor in 2013
Marketing and Brandinglogo of company:
Effectiveness of the company logo Medium
Brand Awareness in respective markets; whether B2B or B2C
Medium
169 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Online services No
Company Label • Company ‘OK’ labels for cardboard boxes• Injection moulded parts being packed
in plastic bags and further packed in cardboard boxes
• Polythene bags for injection moulded parts
SWOT Analysis of the CompanySTRENGTHS• Skilled workers, so always ready to
accept the new challenges• Ready to spend on the innovations• Positive attitude towards the
challenges
WEAKNESSES• Attrition rate is high• More time required to train the
new operator
THREATS• Frequent rate changes of the raw
material, leads to variation in the prise
OPPORTUNITIES• New product development in
the household category
Future Plan of the CompanyTime-lines
Plan Assistance required by the Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months N. A. N. A. N. A.1 year Purchase of machinery
1 VMC and 1 EDMYes N. A.
3 years N. A. N. A. N. A.5 years N. A. N. A. N. A.
Product Design BriefDesign Brief
Poultry related injected moulded product made with injection moulding technology
Plan of the Design ProjectProduct Design Brief specifications
Injection moulded parts, almost 50 parts
Proposed Design Process N. A.Time-line 12 monthsBudget Rs. 10 lacs plus the mould expenditure is 1 croreTeam members & Skills Required
Team includes 05 Members• Industrial Designer (two)• Technical Engineer (Two)• Marketing
Benefits for the Company Growth in profit as we will supply directly to main customer
170 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The main building of the unit.
lathe machine for rough machining
No safety gears used while working on the machine.
The scrap is not collected properly.
171 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Centre table for finishing workFinishing process
Surface grinder for achieving parallelity
172 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
No safety gears used while working on the machine.
No safety gears used while working on the machine.
173 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Vertical milling machine (Computer numerical control)
Mould part is being machined
174 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The work area for moulds assembly as seen from the top. Mould parts and tools scattered all over the working area and walk way.
Machine area is not clean and it can become a big hygiene issue.
The machine parts and scrap material lying unattended around the machines
175 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Centre table (bench work) for fitting, assembly, filing and finishing work.
Vertical table top height-gauge in use
176 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The marking for the switches is not shown. It needs urgent attention and maintenance.
Injection moulding area is cluttered and needs proper arrangement for moulds space management.
The machine is not maintained. Needs regular maintenance and the floor needs to be maintained.
The floor needs to be maintained.
177 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Metal part inserts for inhjection moulded parts
Runner and spruce being removed from the Injection moulded parts
Part de-flashing in progress. No safety measures followed
The posture of the worker for long hours will make them suffer from work-related diseases.
178 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Injection moulded parts being packed in plastic bags and further packed in cardboard boxes
Company ‘OK’ labels for cardboard boxes
179 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement Space arrangement is a concern as the plant
area is congestedNew Product Development No in-house product development process
followedPackaging Need to improveMarketing Market awareness is a problem. No marketing
for business growthHuman Resource Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Need to develop
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space
allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: Three major categories where the company focuses on are:i) Automobile, ii) Electrical and iii) Poultry. In order to provide regular fund-ing, the company may be linked to the respective corporate houses as dedicat-ed vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to get into household products, it can also explore product diversification in the home decor and kitchen products.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• A website need to be created on urgent basis so that the customer reach can
be extended.• As the company is venturing into other household products like mugs, it
requires more publicity on retail level. A proper branding strategy should be formalised to get maximum visibility in the market.
• A logo needs to be more creative, to make a place in the customers percep-tion.
• A proper career growth plan should be formalised, so that the attrition rate is reduced.
• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers.
• A company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the de-velopment process.
180 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
31
2
13Pl
ast T
ech
181 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Plast TechAddress of the Company: C-252/6 A4, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9326206512
Company e-mail id: [email protected]
Website: NA Company started in: 2003
Type of Company: Proprietorship
Company’s Initial Investment: Rs. 50000
Company’s Specialization/Product/Services• Spare parts of appliances
Details of the Owners / Partners:
Sr. N
o.
Nam
e of
Ow
n-er
/ Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wne
r / P
artn
er)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 laxman Mandkar
42 Owner N. A. 8 years in Videocon
9326206512
Plast TechMIDC, Waluj, Aurangabad
Loan/Financial Assistance taken since the start of the company: Not taken
Types of Customer:Type Total number
of CustomersNames/List of Cus-tomers
Products Manufactured
Household Products
- - Plastic Moulded Product
Area of the Unit:Plot Area 1700 Sq. feet.Total Built-up Area 1350 Sq. feet.
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2010-2011 40,00,000/- N. A. N. A.2011-2012 60,00,000/- N. A. N. A.2012-2013 42,00,000/- N. A. N. A.2013-2014 (expected) 50,00,000/- N. A. N. A.
Certifications: None
Types of Machines: Injection moulding, (3 vertical, 2 horizontal), grinding m/c, cooling plant
Raw materials: PP, Nylon, plastic, High impact polystyrene
182 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Safety standards in the CompanyManufacturing Operations
Possible accidents / hazards
Safety measures in the company
Remedies / Medication
Manufacturing Fire No Fire Extinguisher No first Aid
Marketing and Branding:logo of company:
Effectiveness of the company logo High
Brand Awareness in respective markets; whether B2B or B2C
Medium
Do you operate Online? No
Human Resource ManagementEmployment recruitment rules
• Minimum 3 yrs of work experience • Good manpower handling skill• Well knowledge of plastic injection Moulding Machine
Overtime Policy: Overtime is given as per their working hours
Workers: Makes (8) and Females (2)
Insurance/Medi-claim Policy: United India Insurance companyWage Rate Policy: As per their skill. Machine operators are paid Rs. 8000/mth
Shift Timings: 7 am to 7 pm and 7 pm to 7 am
Views on Govt. Initiatives taken so farAssistance required from Government in the following areas:• Electricity Rate Very High Compare to other State• Government Scheme is not aware of new business men• Road Facility is not good for transport
Assistance by CIPET, IGTR, ITI, MCED Aurangabad: None
SWOT Analysis of the CompanySTRENGTHS• Excellent product quality• Prompt service• Customer Satisfaction
WEEKNESSES• Insufficient Funds• Un-skilled labour
THREATS• Competitor sale product on lesser
amount• Credit sale recovery
OPPORTUNITIES• To achieve zero customer returns.• To achieve 100 % compliance of
deliveries on scheduled time • To improve machine up time.• Reduction in internal non-
conformities.
Future Plan of the CompanyTime-lines
Plan Assistance required by the Govt. (Finance/Training/Design Assistance, etc.)
Benefits for the Company
1 year Purchase new machine
Finance Improvement in turnover
2 years Expansion of new unit
Finance Improvement in turnover
183 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The main building of the unit.
The working area as seen from top
184 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Injection moulding machine
The injection moulded parts on zig to set the shape
Runner and spruce being removed from the Injection moulded parts
Oil leakage and the scrap on the machine.
185 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The marking for the switches is not shown. It needs urgent attention and maintenance.
The glass is damaged and the process is not visible.
Cloth is tied on the screw to maintain proper injection of raw material.
186 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Hopper is tied with strings to the machine and is also difficult for the workers to feed raw material in the feeder fitted much higher than their reach.
Waste material and scrap material is seen inside the machine
The moulds area is not maintained properly. Water spillage is seen near the moulds
187 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Safety precautions taken while de-flashing the parts
The gap between the wall and the machine is blocked because of the pipes hanging loosely
The cardboard box material for product packaging
188 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Safety kits are not provided to the operatorsPlant layout Improvement Space arrangement is a concern as the plant
area is congestedNew Product Development No in-house product development process
followedPackaging Need to improveMarketing • Market awareness is a problem. No
marketing for business growth• No branding material available
Human Resource Focus on manpower training by chalking out customized training programs and evaluation of the workers after undergoing the programs.
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Needs up-gradation
RecommendationsInfrastructure & Technology:Machines are not maintained properly. Water spoilage near moulds may rust
the mould, so more intense cleaning operation need to be carried out. Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: There is no initiative on the new product development so R&D activities need to be carried out for product diversification.
No certification has been taken for the process or product. This needs to be tackled on priority basis
Human Resource: Training period for workers to be increased to avoid the wastage of raw mate-rial, as well as other training on regular basis to be carried out to up-grade the skill of workers.
Marketing:No marketing activities are carried out by the company, no branding is done. So to increase market share or to acquire more customers, proper market-ing activities need to be carried out. A website needs to be designed. Various exhibitions need to be visited by company official and a stall may be put up for awareness among customers.
Considering the long term plan , own transport vehicle need to be purchased for carrying the finished goods so that the transportation cost can be reduced.
189 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
2
31
14Ru
pesh
Enter
prise
s
190 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Rupesh EnterprisesAddress of the Company: Plot No. D–51/10, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: 0240-2476895Mobile Number: 9881243938Company e-mail id: [email protected]
Website: N. A. Company started in: April 2006
Type of Company: Proprietorship
Company’s Specialization/Product/Services• Automobile components• Electrical Components• Appliances Components• Plastic Packing components• Pharma Packing
Details of the Owners / Partners:
Sr. N
o.N
ame
of O
wn-
er /
Prop
riet
or
/ Par
tner
s /
Dir
ecto
r
Age
(yea
rs)
Stat
us (O
wne
r / P
artn
er)
Educ
atio
nal
Qua
lifica
tion
Pers
onal
Em
ail
Id.
Phon
e nu
mbe
r
1 Godavari Dattarao Narwade 36 Owner SSC [email protected]
9881243938
Rupesh EnterprisesMIDC, Waluj, Aurangabad
Details of the Owner/Director Family members:
Sr. N
o.Fa
mily
Mem
ber
Rel
atio
n to
the
Ow
ner o
f the
C
ompa
ny
Age
(in
Year
s)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
join
ing
the
Com
pany
Invo
lved
in
Com
pany
’s bu
si-
ness
act
iviti
es
Pers
onal
Em
ail
Id.
Phon
e nu
mbe
r
1 Dattarao Narwade
Spouse 42 ITI, HSC
11 Yes [email protected]
9881243938
Company’s Initial Investment: 27.55 lacs
Loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name /
Govt. AssistanceYear Purpose Amount (Rs.) Status (Ac-
tive/Closed)1 State Bank of
Hyderabad2010 Term loan 15.75 lacs N. A.
2 State Bank of Hyderabad
2010 Cash Credit 3.00 lacs N. A.
Affiliated units/sister concern/subsidiary:Sr. No
Unit Name Product / Service Address Contact
1 Nitesh Enter-prises
Mfg. Plastic moulding dies, break liner, press tool, Jigs fixtures
Plot No. 79, CIDCO Service Indl. Area, Au-rangabad
9881243938
Vendor Code Details: N. A.
191 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Production capacity of the Unit:Year Production capacity2013-2014 85 qt.(Proj Sales Rs. 25.00 lacs)2013-2012 70 qt.(Sales Rs. 19.55 lacs)2012-2011 78 qt.(Sales Rs. 23.45 lacs)2011-2010 72 (Sales Rs. 19.51 lacs)2010-2009 60 (Sales Rs. 16.65 lacs)
Types of Customer:Type Total number of
CustomersNames/List of Customers Products
ManufacturedAutomotive 15 Snehal Autoparts, Shri Ganesh
Ind., Samarth tool• Dies, Press tool
dies
Total number and List of Vendors or Suppliers:• Design steel Pvt. ltd. - Waluj, Aurangabad• Gaurav Enterprises - Waluj, Aurangabad• Shree Sai Cutting tools - Waluj, Aurangabad• Trigon Enterprises - Pune
Total number of Employees at the company: Worker 3 (Supervisor: 01, Oper-ator: 02, Helper: 01)
Types of Business: Tier 2 supplier
Area of the Unit (in Sq. Ft.):Plot Area 650Total Built-up Area 650
Turnover of the Unit (in Lacs):Year Annual Turnover Gross Profit Net Profit2011-2012 23.45 9.86 3.05
2012-2013 19.55 9.33 3.32
2013-2014 (expected) 25.00 11.90 4.20
Company Plant and Process FlowCompany’s Plant layout:
Office
VMC Machine
Entry Gate30 feet MIDC Road
Working Table
Finished Goods
Surface Grinder
Bathroom
RawMaterial
Bench Grinderlathe
Machine
Milling Machine
Comp-ressor
Types of Machines
Sr. N
o.N
ame
of
Mac
hine
Qua
ntity
Mak
e of
m
achi
ne
Spec
ifica
-tio
n
Pric
e of
th
e M
a-ch
ine
Year
of
Purc
hase
Loan
/ by
Self
1 Milling M/c 1 Kirloskar, India 1mtr X 400mm X 350mm
3.50 lacs 2006 Self
2 Surface Grinding M/c
1 Bhurji Machine Tools, India
500mm X 270MM
1.75 lacs 2006 Self
3 Bench Grinder 1 Rajkot , India 0.15 lacs 2006 Self4 VMC M/c 1 Parattech,
Taiwan900mm X 600mm X 550mm
22.50 2010 Term loan of 15.75
192 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Types of ToolsSr
. No.
Nam
e of
M
achi
ne
Qua
ntity
Mak
e of
m
achi
ne
Spec
ifica
-tio
n
Pric
e of
the
Mac
hine
(R
s.)
Year
of
Purc
hase
Loan
/ by
Self
1. Hand Grinder 1 Max India, India 4 inch Grinder 0.02 2011 Self
2. Hand drill 1 Max India, India 5 mm drilling 0.02 2011 Self
3. Air blow 1 Prakash, India 0.02 2011 Self4 Bench Grinder 1 Rajkot, India 200mm X
31.75mm X 20mm
0.15 2009 Self
5 Pencil Grinder 1 Hitachi, India 6 mm
Raw materials
Sr. N
o.
Raw
Mat
eria
l
Cur
rent
Rat
e (R
s. Pe
r Kg)
Supp
lier’s
Nam
e
Min
imum
qua
n-tit
y m
aint
aine
d in
the
com
pany
pe
r mon
th
Prod
uct M
anu-
fact
ured
with
the
mat
eria
l
1 Mild Steel, WPS (Die Steel), OHNS (Oil Hardening Non Shrinking Die Steel), EN-31 (high carbon alloy steel), EN-8 (medium carbon steel), Copper
AVG. Rs. 1000
Design steel pvt. ltd, Gaurav Enterprises, Shree sai cutting tools, Trigon Enter-prises
Rs. 1.50 lacs Dies, Moulds, Jigs, Fixtures
Information of Workers, Supervisors, Managers and Staff for cleaning
Sr. N
o.N
ame
of
wor
ker
Age
(yrs
)
Gen
der (
M/F
)
Wor
kers
/ Su
perv
isor
/M
anag
er /
Staff
Qua
lifica
tion
Ope
ratio
n /
Func
tion
Year
s of
expe
rien
ce in
In
dust
ry
Wor
king
ho
urs /
day
1 Dattarao Narwade 42 M Supervisor HSC, ITI Supervisor 18 82 Jadhav S.A. 30 M Operator SSC M/c Operator 10 83 Shingade A.S. 41 M Operator Dip. Mech M/c Operator 16 84 Santosh Gadekar 32 M Helper SSC Helper - 8
Functions/Operations in the company:Function / Operation
Required Qualification of workers
Required number of workers
Shortfall of workers
Number of hours /shift
Number of shifts/day
Designing of plastic moulds, jigs, fixtures
BE DME 02 02 8 1
Business Process Flow
Acquired Purchase Order From Customer
Design & Drawings as per customer requirement
Raw Material Purchase
Cutting
Turning
Milling & Grinding
Drilling
Wire Cutting
VMC Machining
Heat Treatment
Assembly
Dispatch
193 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Manufacturing Process FlowRaw Material Purchase
Cutting
Turning
Milling & Grinding
Drilling
Wire Cutting
VMC Machining
Heat Treatment
Assembly
Dispatch
Machine operations:Sr. No.
Machine name No. of labours required per machine
Time required for process
Idle time per shift of 8 hrs
Wastage %
1 Milling Machine 01 As per product (Min. 1hr or max.8 hr)
N. A. 6%2 VMC Machine 01 N. A. 2%3 Surface Grinder 01 N. A. 2%
Products manufactured at the Company:Sr. No.
Product Name Cost to Company
Price to Customers
Repeat Order
Supplied to
1 Dies Moulds, Jigs, Fixtures
1.07 lacs 1.32 lacs Yes Automobile, plastic in-dustries @ Maharashtra
Quality Control PlanProject DocumentationDoes the company maintain Documents for every Project?
No
Quality Control Procedure: (In house/ External agency)
As per customer requirement
Testing of Raw Materials (Incoming - Quality Control Techniques)
Raw material quality control done by the suppliers
Name of Testing Labs for Raw Mate-rials (tie-ups for Raw Materials)
N. A.
Name of Testing Labs (tie-ups for Finished Products)
N. A.
Testing of Finished Products It is done in house by manually or done by outside
Design & DevelopmentWhat is Design? N. A.
Design Process: Presently design process not done.
Design Process / Plan for a new Product innovation:Design process will be done in house by using technical & qualified employee, and we will developed new design in plastic Agricultural products, household & other products.
Budget allocated for Research & Development (Annually in Rs.)
Rs.15,00,000/- (proposed plan for development)
IT/CAD/Softwares/CAM used in the Company
Presently used DElCAM software for VMC machining programme
194 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Exhibition/trade shows visits:Sr
. No.
Exhi
bitio
n /
Show
Part
icip
ant /
V
isito
r
Last
atte
nded
(Y
ear)
Fees
(in
case
th
e co
mpa
ny
part
icip
ated
)
Bene
fits
1 Advantage Maharashtra Expo 2014
Dattarao Narwade
2014 Not participated
New design & development
Marketing and Branding:logo of company:
Effectiveness of the company logo
Medium. No need to focus on Branding and Mar-keting as it is a B2B business and Brand aware-ness of the company is high in its target market.
Describe the Company’s Target Market:Export the product and develop new products in automobile & plastic & other industries.
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
N. A.
Do you operate Online? No
Company Label & Packaging: N. A. (Not required for moulds)
Finance & AccountsCosting for Die weight 150kgsSr. no. Description Rs.1 Cost of raw material 0.352 +Processing cost 0.623 +labour Cost (wages) 0.104 Total Cost to company 1.075 Margin 0.256 Selling Cost 1.32
Distribution Process:Finished material dispatched to customer by transport or customers directly purchased from our factory premises.
Human Resource ManagementEmployment recruitment rules
No any specific recruitment rules. Employee’s selection on their skilled and work efficiency.
Training Policy for the new recruits and already employed with the company:For New Recruits For Already Employed
Machine Operator Work experience / trail run Work experienceSupervisor Work experience Work experienceManager Work experience Work experienceHelper/Cleaning Staff Work experience Work experience
Leave Policies: 4 days in month and Public holiday for All.
Overtime Policy: Staff Leave Policy
195 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Machine Operator Wages per hourSupervisor Wages per hourManager Salary per hourHelper/Cleaning Staff N. A.
Insurance/Medi-claim Policy: N. A. (Proposed to start)
Wage Rate Policy:Staff Wage Rate PolicyMachine Operator On work experience or fixed on Rs.6000-7000 p.m.Supervisor On work experience or fixed on Rs.9000-10000 p.m.Manager On work experience or fixed on Rs.10000-12000 p.m.Helper/Cleaning Staff Helper / cleaning fixed Rs. 3000-4000 p.m.
Staff Rs.6000 - 7000 p.m.
Salary Structure:Staff For Fresher (in Rs.) With experience
of 3 years (in Rs.)Training required, if yes then please mention the training
Machine Operator
6000-7000 p.m. 7000-8000 p.m. Practical work done
Supervisor 9000-10000 p.m. 10000-12000 p.m. HRMManager 10000-12000 p.m. 11000-13000 p.m. Business Management train-
ingHelper/Clean-ing Staff
4000-6000 p.m. 6000-8000 p.m. For staff - as per post training
Male & Female Employees:Staff Number
of staffProfile (Machine Operator / Supervisor / Manager / Helper / Cleaning Staff)
Hometown (Aurangabad/Outside Aurangabad but within Maharashtra/Outside Maharashtra)
Years of experience in the Company
Male 04 Supervisor / Manager / Staff
Aurangabad 2 yrs - 3 yrs
SWOT Analysis of the Company
STRENGTHS• Good reputation among customer• Huge works order in hands• Use pure raw material for produc-
tion, not mix any default material like other customer
WEAKNESSES• Unskilled labour• Insufficient capital
THREATS• Competitor sale produce in lesser
amount• Recovery of Credit Sales
OPPORTUNITIES• Export the products• Design & Develop new Products
Future Plan of the CompanyTime-lines
Plan Assistance required by the Govt. (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months ISO Certification -- Develop material quality
1 year Design & develop new products
Finance / Training / Design Assistance
Acquired new work orders
3 years Export sales Finance Export order
Product Design BriefDesign Brief Design & development of new plastic products
Plan of the Design ProjectProduct Design Brief specifications Various types of Plastic productsProposed Design Process N. A.Time-line 2 - 3 yrsBudget Rs. 15,00,000/-Team members & Skills Required 03Benefits for the Company Develop new products
196 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Vertical Milling Machine
CNC Wire-cut
197 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Better Scrap collection process need to be introduced.
The moulds are lying unattended on floor
198 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The compressor is right at the entrance blocking the entrance
The entrance of the unit is not well lit
199 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement • Space arrangement is a concern as the
plant area is congested• Proper use of Natural light
New Product Development No in-house product development process followed
Packaging Need to improveMarketing • Market awareness is a problem. No
marketing for business growth• Good branding material available• Sample swatches are available
Human Resource • Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII, FICCI and build associations with design insti-tutes, national innovation foundations, etc.
Product: Close tie up needed with companies in FMCG, household products manufac-turers, medical products and relevant industries. New product development and business process needs to be top priority.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• Branding exercise needs to be conducted on priority basis as the company
aspires to get into the household product segments. Trademark registration should be taken to protect equity and prevent litigation in future.
• There is a huge dependence on one customer which might harm the busi-ness in the long run. Increasing the customer base is mandatory for long term sustenance and growth.
• Assistance should be provided to the company to set up their stall in exhi-bitions to highlight their products to the retail and manufacturing partners.
• Re-structuring of the website to increase vendor accessibility.• As the company plans to get into retail consumer segments like plastic
buckets, jugs, mugs etc. it should develop its distribution channel to reach out to the right target market.
200 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
31
2
15Se
jal P
lastic
201 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Sejal PlasticAddress of the Company: D -81, MIDC, Shendra, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9370150700
Company e-mail id: [email protected]
Website: NA Company started in: 2009
Type of Company: Proprietorship
Company’s Initial Investment: N. A.
Company’s Specialization/Product/Services• Woven Plastic Mats & Mandap Rolls
Details of the Owners / Partners:
Sr. N
o.
Nam
e of
Ow
n-er
/ Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wne
r / P
artn
er)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Santosh Vajantrao Joshi
46 Owner Engineer Produc-tions
- - 9370150700
Sejal PlasticMIDC, Shendra, Aurangabad
Loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name / Govt. Assistance Year Purpose Amount (Rs.) Status1 Mortgage of Plot and Building - - 30 lacs Not Closed2 Transferred by MIDC as a Tri-
party Agreement- land - -
Production capacity of the Unit: Mat size=4 ft*6 ft; 1 machine produces 80 mats. Total 960 mats produced in a day.
Types of Customer:Type Total number
of CustomersNames/List of Customers Products
ManufacturedConsumer Products
N. A. Main markets in Hyderabad, Bangalore and Mumbai
N. A.
Area of the Unit: 800 sq metres
Turnover of the Unit (in Rupees):The expected amount is Rs. 65-70 lacs
Types of Business (give product’s name and its buyer): Mats and Mandap Rolls. Main markets in Hyderabad, Bangalore and Mumbai
Types of Machines: Injection moulding, (3 vertical, 2 horizontal), grinding m/c, cooling plant. A total of 12 local made machines: Avg Price- Rs 1.2 lacs to 2.5 lacs produces 3.5 kgs of mats/hour
Raw materials: Avg Cost of Virgin Material = Rs 55/kg. The main raw materi-als are Polypropelene, Tapes, Cotton and Nylon
202 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Business Competitors: Total No.: 40, the main competitors being Sapna, Satyam ad general Mats
Organization ChartBoss
Manager
Supervisor Supervisor
21 workers
Business process - flow chartProducts manufactured
Transported to local hubs like Shendra/Waluj/ Chikalthana
Wholeseller
Retailer
Design & DevelopmentWhat is Design? Quality in focus, useful to consumers,
aesthetic appeal and longer shelf life
IT/CAD/Softwares/CAM used in the Company
Design software outsourced from Sholapur
Marketing and Branding:logo of company:
Effectiveness of the company logo High
Brand Awareness in respective markets; whether B2B or B2C
Medium
Do you operate Online? No
Exhibition/trade shows visits (mention name and place): Not attended till date
Packaging: 80 mats in one High Density Propylene is used
Pricing:Tax Calculation, VAT, Income Tax, Daily Accounts are done by a hired CA. CA is paid Rs 4000/- to 5000/- per month.Cost = Raw Material+ Power+ labor+ Operating Expenses\
Price= Cost+ Profit
203 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Human Resource ManagementEmployment recruitment rules
• Minimum 3 yrs of work experience • Good manpower handling skill• Well knowledge of plastic injection Moulding Machine
Overtime Policy: Generally 1.5 times of regular salary but overtime not al-lowed for more than 4 hours
Employees: 25
Insurance/Medi-claim Policy: Nil
Wage Rate Policy: As per their skill. Machine operators are paid Rs. 8000/mth
Shift Timings: 7 am to 7 pm and 7 pm to 7 am
Leave Policies: Government leaves are given to workers
Salary Structure: Rs. 250/day for 25 days in a month for Machine operators and Rs, 12000 for supervisors.
Views on Govt. Initiatives taken so farCommunication of Govt. initiatives is not done properly. Most of the times they are not aware about the schemes. They are not aware about the process or even whom to approach.
Assistance required from Government in the following areas:Transportation of laborsAssistance in payment cycleWater supply issues
Assistance by CIPET, IGTR, ITI, MCED Aurangabad: None
SWOT Analysis of the CompanySTRENGTHS• Experience in the business• Marketing Expertise• Quality of products manufac-
tured
WEEKNESSES• Unskilled labors• Absenteeism due to lack of con-
veyance issues
THREATS• Break in Payment Cycle• Recession in the Industry
OPPORTUNITIES• Design and Raw Material
Improvement
Future Plan of the Company
Time-lines Plan6 months Streamline operations1 year Purchase new machine2 years Expansion of new unit
Product Design Project Brief: N. A.
204 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
No name plate on display
Extrusion process for making hollow strips
205 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
A lot of clutter is seen in the working area. The floor needs maintenance
Continuous water leakage in the work area.
206 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Bundling of strips in progress. A lot of wastage is seen.
The work area around the machine is not free and clean.
207 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
A lot of wastage seen around the work area
The scrap is not properly collected
208 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
A lot of clutter and wastage seen around the work area
209 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Sharp shaving blades is used for finishing the edges of the plastic mat.
The posture of the workers for long hours will make them suffer from work-related diseases.
Hot-wire cutting machine for the mats Stitching machine to close
the edges of the mat
210 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The package design is not appealing. The brand name is not easily readable
211 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Need urgent attention for the proper wiring to avoid fire or any kind of accident.
212 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The marking for the switches is not shown. It needs urgent attention and maintenance.
Sharp shaving blades is seen thrown on the floor unattended
Scrap material is thrown at the entrance
213 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality Needs up-gradationOperations As per the product requirementsWorkplace & Ergonomics Need to improvePlant layout Improvement Well plannedNew Product Development No dedicated Product Development wingPackaging As per requirementMarketing Brand awareness is high in the B2B marketHuman Resource Needs to improve
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: There is a need to invest in premium and more technologically advanced machines as product differentiation is the key to achieve competitive growth in this market. Technology can also enable the company to enter into online operations which it has still not explored.
Supply Chain & Operations: Exploring new raw material vendors and tapping new customers is essential for increasing the market share and be competitive in the industry.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: The company needs to set up a dedicated product development wing and even collaborate with Govt. bodies to take up consultancy projects for new product development.
It can also look at creating new patterns and weaves. Product diversification into the Home Decor industry will enable the company to enter into new mar-kets and de-risk business by reducing dependence only on one or two product categories.
Human Resource: Investment in manpower training, adopting safety measures and providing insurance/medi-claim facilities is crucial. Moreover, the company also needs to chart out career progression path to retain talent.
Marketing:The company is banking heavily on its brand awareness in the current target market. However, it should not become complacent as new competitors with greater marketing efforts might erode its equity in future.
Participation in trade shows and online marketing might be effective solutions to tackle the issue.
214 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
31
2
16Sid
dhi
Polyw
eave
215 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Siddhi PolyweaveAddress of the Company: Plot No: l-18/1, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 09970053151Company e-mail id: [email protected]: N. A. Company started in: 2012
Type of Company: Proprietorship
Company’s Specialization/Product/Services: Plastic Mats
Affiliated units/sister concern/subsidiary: N. A.
Details of the Owners / Partners:
Sr. N
o.N
ame
of O
wne
r /
Prop
riet
or /
Part
-ne
rs /
Dir
ecto
r
Age
(yea
rs)
Stat
us (O
wne
r /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
peri
ence
pr
ior t
o st
artin
g/jo
inin
g th
e C
om-
pany
Pers
onal
Em
ail
Id.
Phon
e nu
mbe
r
1 Shashikant Nagnathrao Ernale
44 Owner BE Me-chani-cal
Sapna Polyweave & Chandra Mats for 12 yrs
09970053151
Siddhi PolyweaveMIDC, Waluj, Aurangabad
Details of the Owner/Director Family members:
Sr. N
o.Fa
mily
Mem
ber
Rel
atio
n to
the
Ow
ner o
f the
C
ompa
ny
Age
(in
Year
s)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
join
ing
the
Com
pany
Invo
lved
in
Com
pany
’s bu
si-
ness
act
iviti
es
Pers
onal
Em
ail
Id.
Phon
e nu
mbe
r
1 Kavita Shashikant Ernale
Wife 36 B. Com. N. A. Accounts N. A. N. A.
Company’s Initial Investment: 50 lacs
Loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name / Govt.
AssistanceYear Purpose Amount
(Rs.)Status (Active/Closed)
1 State Bank of India 2012 Machineries 50 lacs Taken 24 lacs20 lacs CC
Production capacity of the Unit:Year Production capacity2013-2014 7.5 lacs worth of Plastic Mats monthly
Types of Customer:Type Total number of
CustomersNames/List of Customers Products
ManufacturedHousehold Products
Many Distributors across India
Kerala, Karnataka, Aurangab-ad(RM Sales, Super Kirana) and Ferry wallas (door to door selling)
Plastic Mats
216 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Total number and List of Vendors or Suppliers: 8 Suppliers from Hyderabad, Umnabad in Karnataka
Total number of Employees at the company: 18
Organization Chart
Proprietor
Jobber (1)
Extruder Operator (2)
Parker (1)
Weaving Operator (4)
Packaging (2)
Types of Business: OEM. Plastic mats are supplied to the Dealers across India
Area of the Unit: 750 Sq. mtr. Built-up area is 49% of the total area.
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2013-2014 (expected) 90 lacs N. A. 5% - 8%
Certifications: None
Business Competitors: Total 40 Mat companies in Aurangabad district
Sr. No.
Competitor’s name
Competitor’s Prod-uct Specialization
Type of Business (Exporter/OEM/Tier 1 Supplier/Tier 2 Supplier / Tier 3 Supplier
1 Sapna Polyweave Mats OEM2 Kesona Mats Mats OEM3 Chandra Mats Mats OEM
Types of Machines
Sr. N
o.N
ame
of
Mac
hine
Qua
ntity
Mak
e of
m
achi
ne
Pric
e of
th
e M
a-ch
ine
Year
of
Purc
hase
Loan
/ by
Self
1 Mixer 1 Tejal Engineering, Aurangabad 60000 2012 loan
2 Grinder 1 Tejal Engineering, Aurangabad 15000 2012 loan
3 Compressor 1 Skyline distributor, Aurangabad 67000 2012 loan4 Extruder 5 Tejal Engineering, Aturangabad 450000 2012 loan5 Weaving Machine 8 Tejal Enginrreing waluj, Pooja
Enginering, Chikalthana1350000 2012 loan
6 Cutting machine 1 Tejal 20000 2012 loan7 Stitching Machine 1 12000 2012 loan8 Joining machine 1 Yamoto 25000 2012 loan
Types of Tools: Grinding machine, Scissors, Blades
Raw materials: low Density Polypropylene from Hyderabad company, HDPE Bags, PP Bags, Tapes and Yarns- low Density Polypropylene
Information of Workers & Staff:
Shift Timings: 7 AM to 7 PMNumber of Shifts per day: 2Male & Female Ratio: 9 Males & 1 Females
217 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Sr. N
o.
Nam
e of
w
orke
r
Age
(yrs
)
Gen
der
(M/F
)
Wor
kers
/ Su
perv
isor
/M
anag
er /
Staff
1 Raju Piwal 35 M Jobber2 Ramdas Shinde 32 M Extruder Operator3 Shankar Pujari 34 M Extruder Operator4 Pratap Rajput 25 M Weaving Operator5 Chandra Rajput 21 F Parker (Pipes collection and putting in weaving section6 Sharma 30 M Weaving Operator7 Jitendra Patil 23 M Weaving Operator8 Swapan
mandavgadh33 M Weaving Operator
9 Namdev Kalwani
31 M Packaging
10 Daneshwar Kalwani
36 M Packaging
Quality Control PlanProject Documentation Yes. In-house Quality Control Procedure: (In house/ External agency)
The raw materials are sourced from reliable vendors. Hence, no quality check is done
Testing of Raw Materials (Incoming - Quality Control Techniques)
Weight and Quality reading is taken on an hourly basis at the extruder machine.
Design & DevelopmentWhat is Design? Design means Innovation
Design Process/Plan for a new Product innovation: Designs and patterns are outsourced due to cost implications.
Budget allocated for Research & Development (Annually in Rs.)
No
IT/CAD/Softwares/CAM used in the Company
Tally for Accounts and Microsoft Office
Exhibition/trade shows visits: Plast India as a visitor
Safety measures: Fire Extinguisher & First Aid available in the work area
Marketing and Branding:Describe the Company’s Target Market: Middle class households
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
Word of Mouth Publicity
Online services No
Company Label: Company Branding is done on the bags and on the taped margins of the mats.
Pricing: RM+ labor+ Electricity+ Overheads+ Profits = Price
Human Resource ManagementEmployment recruitment rules Direct Recruitment
218 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Leave Policies: Weekly off and additional 20 days in the year
Overtime Policy: Payment according to overtime hours
Insurance/Medi-claim Policy: None
Salary Structure: An average of Rs. 10000 per month. Rs. 300/day for 26 days in a month.
Views on Government Initiatives taken so far:The Govt. subsidies have not been availed so far but would now like to take advantage of the same.
Assistance required from Government in the following areas:• Financial Aid• lower Interest Rate• Awareness about new Technology and quality of Raw Materials
SWOT Analysis of the CompanySTRENGTHS• Good quality Product at low
price• Hard-working team
WEAKNESSES• Financial backing is weak• Margins are very thin (operat-
ing at 5%-8% while it should be around 10%)
• Safety measures• No security at the unit• No design team
THREATS• Prices are moderate. Competitors
sell mats at lower prices.
OPPORTUNITIES• Good market opportunity• Huge demand (currently not able
to fulfil the market demand)
Future Plan of the CompanyTime-lines Plan6 months Tying up with Govt. bodies for availing the benefits of Govt. schemes.
Introduce virgin materials in manufacturing Plastic Mats1 year Plant expansion : Expansion by investing in 8 more machines3 years 5 cr turnover to be achieve5 years Diversification in other engineering product line
219 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
No name plate on display
Extrusion process for making hollow strips
A lot of wastage seen around the work area
A lot of wastage seen around the work area
220 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
A lot of wastage seen around the work area
The space in the plant is not utilized efficiently
A lot of wastage seen around the work area. The spillage of water is a big issue all around the work area
221 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Bundling of strips in progress. A lot of wastage is seen.
The scrap is not properly collected
222 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The scrap to be properly collected
The scrap to be properly collected. The tools are lying around on floor unattended
223 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Sharp shaving blades is used for finishing the edges of the plastic mat.
The posture of the workers for long hours will make them suffer from work-related diseases.
The work area around the machine is not free and clean.
224 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Hot-wire cutting machine for the mats
225 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Stitching machine to close the edges of the mat
The package design is not appealing. The brand name is not easily readable
Finished rolls of plastic mats
226 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The marking for the switches is not shown. It needs urgent attention and maintenance.
Water is removed from inside of the hollow pipes used in the plastic mats
Area around the compressor is filled with granules bags. There is no free space around it.
227 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement • Space arrangement is a concern as the
plant area is congested• No use of Natural light
New Product Development No in-house product development process followed
Packaging Need to improveMarketing • Market awareness is a problem. No
marketing for business growth• Good branding material available• Sample swatches are available
Human Resource • Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: Three major categories where the company focuses on are:i) Automobile, ii) Electrical and iii) luggage. In order to provide regular fund-ing, the company may be linked to the respective corporate houses as dedicat-ed vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to get into household products, it can also explore product diversification in the home decor and kitchen products.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• Branding exercise needs to be conducted on priority basis as the company
aspires to get into the household product segments. Trademark registration should be taken to protect equity and prevent litigation in future.
• There is a huge dependence on one customer which might harm the busi-ness in the long run. Increasing the customer base is mandatory for long term sustenance and growth.
• Assistance should be provided to the company to set up their stall in exhi-bitions to highlight their products to the retail and manufacturing partners.
• Re-structuring of the website to increase vendor accessibility.• As the company plans to get into retail consumer segments like plastic
buckets, jugs, mugs etc. it should develop its distribution channel to reach out to the right target market.
228 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
31
2
17Sn
ehal
Plas
tic
Indu
stries
229 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Snehal Plastic Industries (10 years back was Sachin Plastic Industries)Address of the Company: M – 127, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9325212359, 8888837992Company e-mail id: [email protected] No.: N. A.Website: www.snehalplasticindustries.bizporto.com Company started in: 1993
Type of Company: Proprietorship
Company’s Specialization/Product/Services• Injection Moulding (Castor wheel)•Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Bharat Sindi Kumate
N. A. Owner High School
1 N. A. 08888837991
Company’s Initial Investment: 35000
Snehal Plastic IndustriesMIDC, Shendra, Aurangabad
loan/Financial Assistance taken since the start of the company:Sr. No.
Bank Name / Govt. Assis-tance
Year Purpose Amount (Rs.) Status (Ac-tive/Closed)
1 Bank of Baroda N. A. Expansion 80 lacks 15 lacs Paid
Production capacity of the Unit: 5000 Castor Wheel per day
Types of Customer:Type Total number of
CustomersNames/List of Custom-ers
Products Manufactured
Automotive 2 Sanjay Techno Products • Mirror for two wheeler
• Protective Packing for shafts & gears
Agricultural/Irrigation
1 Disha Industries Dripper
Household Products
1 Yashoda Industries Washing Machine Components
Industrial Appliances
2 • Yashoda Industries • lunar Ele. Pvt. ltd.
TV Parts Refrigera-tor Parts
Pharmaceutical 1 Navketan Pharmaceuti-cal Pvt. ltd.
Bottles
Total number and List of Vendors or Suppliers: Two
Total number of Employees at the company: 15
230 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Organization Chart:
Owner(Bharat Sindikumate)
Machine operator Service & main-tenence staff
Accountant & Admin staff
Snehal Plastic Industries
Types of Business:Business Type Products Products supplied toAs a Tier 1 Supplier to OEM Castor Wheel, Spare
Part of Cooler, Mixer and some part of light
Vidieocon, K-stars, Bajaj, Wipro lighting
Area of the Unit: 10000 sq ft
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2012-2013 2.5 crores N. A. 30 lacs (aprox.)
2013-2014 (expected) 3.5 to 4 crores N. A. N. A.
Certifications: ISO9001
Business Competitors: Twenty-five
Machines & raw materialsTypes of Machines: Buffing M/c, Milling M/c, Drilling M/c and lathe M/c
Raw materials: Acrylic, GPPS, PP, PPCP, HD, HD block, Nylon, etc.
Quality Control PlanProject DocumentationDoes the company maintain Documents for every Project?
No
Quality Control Procedure: (In house/ External agency)
No
Testing of Raw Materials (Incoming - Quality Control Techniques)
No
Name of Testing Labs for Raw Materials (tie-ups for Raw Materials)
No
Name of Testing Labs (tie-ups for Finished Products)
N. A.
Testing of Finished Products Takes place at the buyers place
Quality Standard for Product:Sr. No. Product name Specification Strictly followed1 Pulsar Housing Free from Flash, Welding flow
marks, silver marks Yes
2 612 Holders Free from defect and flash Yes3 Automotive casting Free from silver marks flash Yes4 Dripper Free from flash Yes5 Bottles Free from damage and over deflash-
ingYes
6 Protective Sleeves Free from flash Yes
R & DBudget allocated for Research & Development (Annually in Rs.)
N. A.
231 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
IT/CAD/Softwares/CAM used in the Company
N. A.
Exhibition/trade shows visits
Sr. N
o.
Exhi
bitio
n /
Show
Part
icip
ant /
V
isito
r
Last
atte
nded
(Y
ear)
Fees
(in
case
th
e co
mpa
ny
part
icip
ated
)
Bene
fits
1 Goregaon, Mum-bai
Visitor 2013 N/A Information about latest Technology
Marketing and Brandinglogo of company:
Effectiveness of the company logo Medium
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
N. A.
Online services Yes
Human Resource ManagementEmployment recruitment rules On The Basis of
• Education• Work Experience in which company• Asking questions• Practical test
Male & Female Employees: 14 Males & 1 Female
Covered under ESI/EPF/Gratuity: No
Contract Worker Policy: N. A.
Assistance required from Government in the following areas:• Expansion• Up-gradation• Subsidies on raw material, new product development and business devel-
opment Assistance by CIPET, IGTR, ITI, MCED Aurangabad: N. A.
SWOT Analysis of the CompanySTRENGTHS• Quality – satisfactory customers• Advanced technology• Experienced & trained staff• Development strategies and plans
WEAKNESSES• Financial crunch• No own factory land
THREATS• Development of the firm’s new
design & components (copying) by other competitors.
OPPORTUNITIES• Support from government &
other initiatives for development of the firm
232 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
CostingThe cost of the unit product depends on the design and quality required by the customers. Basic costing depends on the following components such as Raw material cost + pigment (master batch) cost + runner cost + cavity cost + machine shift cost + machine tonnage cost + cycle time (as per hours) + (-) efficiency + finishing + packaging + 5% to 10 % profit + cost of imported component (if applied)
Future Plan of the CompanyTime-lines
Plan Assistance required by the Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months Purchasing of new land for factory premises and new product development
Finance & Design Assistance Growth of sales & promotion
1 year ISO certification, Building infrastructure development
Finance Better Produc-tivity and build trust and value in market
3 years New product develop-ment and machinery
Finance Growth of sales & promotion
5 years New product develop-ment and machinery
Finance Growth of sales & promotion
Product Design BriefDesign Brief 1
New filter development for 2-wheeler vehicles to increase the mile-age, life and pick up of the vehicle.
Design Brief 2
New design and development of castor wheels
Plan of the Design Project
Product Design Brief specifications
Injection moulded parts
Proposed Design Process Study and designing and researching according to actual available sample
Timeline 1 yearBudget Rs. 15 lacsTeam members & Skills Required
Team includes 5 Members• Designer (2)• Technical Engineer (2)• Marketing (1)
Benefits for the Company It will create brand value inhale confidence and more profitability
233 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Raw material bags
Injection moulding machine
234 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The posture of the workers for long hours will make them suffer from work-related diseases.
The posture of the workers for long hours will make them suffer from work-related diseases.
The marking for the switches is not shown. It needs urgent attention and maintenance.
235 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The posture of the workers for long hours will make them suffer from work-related diseases.
Injection moulding machine
The posture of the workers for long hours will make them suffer from work-related diseases.
There is no enough light to do the finishing job such as de-flashing.
The finished items are being packed and weighed
236 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Clutter seen around the working area
The bags are being readied for transportation
The shelves are not properly marked. It is difficult to find the items from the clutter.
The grinder is kept on floor. Needs proper care to avoid any accident
237 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The tool board is not well maintained
The moulds needs to be arranged properly to avoid damage to the mould and avoid accidents with the working area.
238 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Annealing method developed in-house
Need urgent attention for the proper wiring to avoid fire or any kind of accident.
Oil spillage seen around the machine.
239 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Need urgent attention for the proper wiring to avoid fire or any kind of accident.
The finished products are loaded on thwe tempo to be transported to the clients
The unit has maintained a beautiful garden within the campus
The walk way is occupied with the items produced and the scrap material
240 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement Space arrangement is a concern as the plant
area is congestedNew Product Development No in-house product development process
followedPackaging Need to improveMarketing Market awareness is a problem. No marketing
for business growthHuman Resource Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Needs to improve
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space
allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: Company is dependent on only one type of product, it should think about venturing into other products with the existing setup of machineries to reduce the business risk.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• Website need to be up-graded on urgent basis so that the customer reach
can be extended.• The company requires more publicity on retail level. A proper branding
strategy should be formalised to get maximum visibility in the market.• The logo needs to be more creative, to make a place in the customers per-
ception.• A proper career growth plan should be formalised, so that the attrition rate
is reduced.• Emphasis should be given on the putting the stall in the exhibitions to cre-
ate awareness among probable customers.• The Company can tie-up with the trade bodies, which give funding for
the new product development, this will be very beneficial to speed up the development process.
241 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
31
2
18Su
nrise
Auto
Pac
k
242 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Sunrise AutopackAddress of the Company: F – 16/4, MIDC, Chikalthana, Aurangabad, Pin: 431 210, Maharashtra, IndiaLandline number: 0 240 - 2482097Mobile Number: 8888864242, 95951 74242, 94222 94242Company e-mail id: [email protected]
Website: www.sunriseautopack.com Company started in: 2008
Type of Company: Proprietorship
Company’s Specialization/Product/Services• PET Packaging machinery manufacturer & Bottling machine
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Raju Neele Owner Grad-uate
4 -- 8888864242
Company’s Initial Investment: 2.5 lacs
Loan/Financial Assistance taken since the start of the company: Not taken
Production capacity of the Unit: 150 bottles per minutes
Types of Customer: B2B
Total number of Employees at the company: 15 Males (14) and Female (1)
Area of the Unit:Plot Area 8000 Sq. ft.Total Built-up Area 3600 Sq. ft.
Turnover of the Unit (in Rupees): Rs. 1.5 crores in 2012-13 with a net profit of 4 lacs
Certifications: No
Types of Machines: Buffing m/c, Milling m/c, Drilling M/c and lathe m/c
Raw materials: Stainless Steel, Mild Steel, High Density polymer
Quality Control PlanDocumentation of every Project
No
Quality Control Procedure: (In house/ External agency)
No
Sunrise Auto PackMIDC, Chikalthana, Aurangabad
243 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Testing of Raw Materials (Incoming - Quality Control Techniques)
No
Name of Testing Labs for Raw Materials (tie-ups for Raw Materials)
N. A.
Name of Testing Labs (tie-ups for Finished Products)
N. A.
Testing of Finished Products • Visual Inspection• Dimension & Weight measurement
Design & DevelopmentDesign Process/Plan for a new Product innovation
No
Budget allocated for Research & Development (Annually in Rs.)
N. A.
IT/CAD/Softwares/CAM used in the Company
No
Marketing and Branding:logo of company:
Effectiveness of the company logo Medium
Exhibition/trade shows visits: Yes as participant
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
No
Online services No
Human Resource ManagementShift Timings: 9 AM to 5:30 PM
Overtime Policy: Payment according to overtime hours
Insurance/Medi-claim Policy: No
Covered under ESI/EPF/Gratuity: No
Contract Worker Policy: No
Career Graph Plan for Employees: Growth & continues development under motivation & guidanceRetention Policies and Welfare Schemes: Insurance Policies
Assistance required from Government in the following areas:• Guidance about new product development • Awareness about the new schemes and training programs organized by
various agencies
244 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Future Plan of the CompanyTimelines Plan Assistance required by the
Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months Capacity increase, purchase of Blow moulding machine
Yes N. A.
1 year Purchase of injection moulding machine
Yes N. A.
Product Design Brief: N. A.
245 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The workers are too close to each other and to adjacent machines.
No safety gears used while working on the vertical milling machine.
246 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
No safety gears used while working on the machine.
No safety gears used while working on the machine.
Turning process
247 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The posture of the workers for long hours will make them suffer from work-related diseases. Also, the machines parts are seen unattended in the working area.
248 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The main switch board is not maintained.
No safety gears used while working on the machine.
Drawing prepared by the workers
Drawing in progress
249 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Wires are seen hanging loosely around the main switch board leading to a risk of accident and fire.
The flat grinding belt has temporary arrangements.
The ready parts are spread all over the floor.
The table is temporarily built to carry out maintenance and finishing work
250 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The scrap is not collected properly.
The work area as seen from the top.
Tool table is cluttered.
251 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology As per standardAesthetics Good Quality SatisfactoryOperations Safety kits are not provided to the operatorsWorkplace & Ergonomics NeededPlant layout Improvement • Space arrangement is a concern as there is
lot of congestion of machine.• No use of Natural light.
New Product Development Yes, R & D in process for bottling machineryPackaging Yes, goodMarketing Good market presence in bottling automationHuman Resource 1 year training is provided to new recruit
Business DesignMarketing Yes, need to improvelogo Design NoVisiting Card NoBrochures & leaflets NoWebsite Yes
Recommendations• As company has plan for huge expansion, company logo has to more
creative and need to be protected. it has good visibility in market, need to capitalise on that.
• Production layout is not so good. Sufficient space has to be kept between machinery so the better working condition.
• Very less safety precautions are taken by workers, this need to be improved
by providing gloves and other safety gears to workers.• The work area need to be cleaned regularly and scraps and used tools re-
moval process has to be planned. • Need to focus on regular maintenance and servicing of machines to avoid
pre-mature wear and tear.• There is an urgent need for the certification of the company as this will
improve the image of the company in the market. For this proper record keeping in all departments is needed.
• No testing is done on the product during production, so proper quality control procedures need to be formed.
252 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
2
31
19Su
shm
aIn
dustr
ies
253 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Sushma Industries (sister concern of Jyoti Industries)Address of the Company: D – 95, MIDC, Shendra, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 8928187703, 9404012247, 9822193777Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: 2007
Type of Company: Proprietorship
Company’s Initial Investment: 35 lacs
Company’s Specialization/Product/Services: PVC Pipes
Affiliated units/sister concern/subsidiary: Jyoti Industries
Details of the Owners / Partners:
Sr. N
o.
Nam
e of
O
wne
r /
Prop
riet
or
/ Par
tner
s /
Dir
ecto
r
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Parvati Mahadeo Funde
45 Owner 9th std. [email protected]
9404012247, 9822193777
loan/Financial Assistance taken since the start of the company:
Sr. No. Bank Name / Govt. Assistance
Year Purpose Amount (Rs.)
Status (Active/Closed)
1 Khamgaon Urban Cooperative Bank ltd
2007 Building and Machinery
17.5 lacs Active, Current EMI approx. Rs. 22000/- per month
Types of Customer:Type Total number
of CustomersNames/List of Customers Products
ManufacturedAgricultural/Irrigation
1 Biggest customer Rajput from Naregaon, Customers from Pachur, Paithan, Jalgaon, Nanded, Beed etc
PVC Pipes
Production capacity of the Unit: 75mm- 6m length- 150 units; 32mm- 6m length- 175 units
Total number of Employees at the company: 13
Area of the Unit: 800 sq. mt
Turnover of the Unit (in Rupees):Year Annual Turnover2009-2010 40 lacs2010-2011 45 lacs2011-2012 50 lacks
2012-2013 75 lacks
2013-2014 (expected) 1 crore
Business Competitors: Kanak
Sushma IndustriesMIDC, Shendra, Aurangabad
254 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Certifications: ISO
Types of Machines: Extrusion machine, Mixer, Heater, Firing, Injection, Cut-ter, Socket, Grinder, Screen Printing
Types of Tools: Complete tool box
Raw Materials: PVC Granules, Titanium, Carbon, Master Batch, Calcium, Wax
Business Process FlowSample is shown
Production begins
Quality Inspections & Finishing
Quality and rates are negotiated and finalize
Sorting and packaging
Dispatch
Quality Control PlanProject Documentation:Does the company maintain Documents for every Project?
Yes
Quality Control Procedure: (In house/ External agency)
• Visual Inspection• Finishing • Dimension Checking & other defects
Testing of Raw Materials (Incoming - Quality Control Techniques)
• Weight measurement• Strength and moisture checking• Brand name is an indicator of quality
Name of Testing Labs for Raw Materials (tie-ups for Raw Materials)
N. A.
Name of Testing Labs (tie-ups for Finished Products)
N. A.
Testing of Finished Products • Visual Inspection• Dimension & Weight measurement
Safety standards: Fire extinguisher and First aid box is inside the factory premises and all medical expenses are reimbursed.
Marketing and Brandinglogo of company:
Effectiveness of the company logo Medium
Company’s Target Market: Farmers
Brand Awareness in respective markets; whether B2B or B2C
High
Initiatives taken to promote the Brand and Respective expenses
Promotion through Direct Meetings, Branding on Key Chains, Calendar, Watches given as gifts
255 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Online services Not yet
Packaging: The packaging is open and a minimum of 10 pipes are bundled/tied together
Exhibition/trade shows visits:
Sr. N
o.
Exhi
bitio
n /
Show
Part
icip
ant /
V
isito
r
Bene
fits
1 Exhibition Participant Knowledge about new machines2 Training on new machines
handling organized by CIPETParticipant
CostingRaw Material cost + 15% Mark-up
Human Resource ManagementShift Timings 9 AM to 6 PM
Number of Shifts per day: 1
Employment recruitment rules Direct Interview and referrals
Leave Policies: • WeeklyoffonFriday• Holi-2Days• 26thJan• 1stMay• Dussehra• Diwali
Salary Structure: Rs. 5000 to 12000 for Machine operators
Assistance required from Government in the following areas:• More awareness for programmes and training workshop initiatives run by
the government• Discount the VAT charges
SWOT Analysis of the CompanySTRENGTHS• Quality of products• Brand awareness• Cheaper products as lesser no. of
people employed which results in cost cutting
WEAKNESSES• Competitors using better ma-
chines• Availability of trained manpower
THREATS• Increase in rates of electricity
OPPORTUNITIES• Support from government &
other initiatives for development of the firm
Future Plan of the CompanyTime-lines Plan6 months Manufacturing of Solution and Dripper1 year Insurance and Mediclaim for employees
Increase in no. of machines5 years Making all the products required for operations In-house. No procure-
ment from vendors.
Market expansion to target markets out of Maharashtra.
Product Design Brief: N. A.
256 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Stock of pipes kept near the entrance
Financial institution’s mention on the wall inside the unit
Group of workers separates the stones and metals from the scrap of plastic pipes
257 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Extrusion machine for the plastic pipes
Storage area for finished plastic pipes
Heating the plastic pipes
The heated pipe is put on die to increase the diameter of the plastic pipe
258 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Damaged plastic pipes during production because of power cuts
The fire extinguisher is hidden behind the bags of raw material. Need to make it easily accessible in case of emergency.
Company’s own transport vehicle with company’s branding on it.
Company’s own calender for branding purpose.
259 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Need to improveWorkplace & Ergonomics Need to improvePlant layout Improvement Well plannedNew Product Development No in-house product development process
followedPackaging As per requirementMarketing Brand awareness is high. Kisan PVC Pipes is a
well known brandHuman Resource Needs improvement
Business DesignMarketing Satisfactorylogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Needs to make greater investment in machinery in future to keep pace with the market needs and for scaling up the business.
No software is being used currently. But technology will have to be adopted to manage the business efficiently.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: Three major sectors where the company’s products are used: i) Irrigation, ii) Drinking Water and iii) Electrical. In order to provide regular funding, the company may be linked to the respective corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to become self-sufficient in all the products re-quired for business, they need to undergo product training and even evaluate the feasibility of entering into all the categories vis-a-vis outsourcing the prod-ucts. The balance needs to be worked out.
Human Resource: Currently the number of employees is only 10. Three members of the family manage the business operations. The company perceives it to be a cost advan-tage. However, the outlook needs to change and more number of qualified people need to be hired to strengthen the business and enter into new markets.
Marketing:The company is banking heavily on its brand awareness in the current target market. However, it should not become complacent as new competitors with greater marketing efforts might erode its equity in future. Participation in trade shows and more online marketing might be effective solutions to tackle the issue.
260 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
2
31
20Su
yog
Plas
tics
261 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Suyog PlasticsAddress of the Company: E – 70/27, MIDC, Waluj, Aurangabad, Pin: 431136, Maharashtra, IndiaLandline number: 9923143839Mobile Number: 9923143839Company e-mail id: [email protected] No.: N. A.Website: www.suyogplastics.com Company started in: 2008
Type of Company: Partnership
Company’s Specialization/Product/Services• Automobile components• Electrical Components• Appliances Components• Plastic Packing components• Pharma Packing
Affiliated units/sister concern/subsidiary: N. A.
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Vinay Walandikar
24 Partner BBA, MBA
2 Years [email protected]
09923143839
2 Anand Walandikar
21 Partner B.Tech - [email protected]
07798267067
Details of the Owner/Director Family members:
Sr. N
o.Fa
mily
Mem
ber
Rel
atio
n to
the
Ow
ner o
f th
e C
ompa
ny
Age
(in
Year
s)
Educ
atio
nal Q
ualifi
catio
n
Wor
k Ex
peri
ence
pri
or to
jo
inin
g th
e C
ompa
ny
Invo
lved
in C
ompa
ny’s
busi
ness
act
iviti
es (Y
es/N
o)
Rol
e in
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Vaibhav Walandikar
Brother 18 12th - No No - 09404001539
2 Sudha Walandikar
Mother 51 Bcom, llB
- No No - 09960411602
3 Prakash Walandikar
Father 61 Bsc, Msc
- No No - 09421405614
Company’s Initial Investment: 30 lacs
loan/Financial Assistance taken since the start of the company:
Suyog PlasticsMIDC, Waluj, Aurangabad
262 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Sr. No. Bank Name / Govt. Assistance
Year Purpose Amount (Rs.) Status (Ac-tive/Closed)
1 SBI 2012 C. C. 2400000 Active2 SBI 2013 C. C. Extended 3500000 Active
3 SBI 2013 Term loan 2400000 Active
Vendor Code Details:Vendor Code
Customer Issued in
Criteria/Guidelines to become the Vendor
Products Supplied
Last Audit by Customer
1 Sanjay Techno Products Pvt ltd
2010 ISO Certified Automo-bile
8 months
2 Forcas Impex Pvt ltd
2010 ISO Certified Electrical 1 year
3 Devgiree Forging Pvt ltd
2009 ISO Certified Packaging 2 months
Production capacity of the Unit:Year Production capacity2013-2014 150 M / Tons - Year2013-2012 125 M / Tons - Year2012-2011 100 M / Tons - Year2011-2010 75 M / Tons - Year2010-2009 50 M / Tons - Year
Types of Customer:Type Total number of
CustomersNames/List of Customers Products
ManufacturedAutomotive 2 Sanjay Techno Products • Mirror for two
wheeler• Protective Packing
for shafts & gearsAgricultural/Irrigation
1 Disha Industries Dripper
Household Products
1 Yashoda Industries Washing Machine Components
Industrial Appliances
2 • Yashoda Industries • lunar Ele. Pvt. ltd.
TV Parts Refrigerator Parts
Pharmaceutical 1 Navketan Pharmaceutical Pvt. ltd.
Bottles
Total number and List of Vendors or Suppliers:• Devgiri Foreign (Aurangabad)• Navketan Research and Development Pvt. ltd. (Aurangabad)• Sanjay Techno Products Pvt. ltd. (Aurangabad)• John fowler Ocular lens Pvt. ltd. (Aurangabad)• SOM AutoTech Pvt. ltd. (Aurangabad)• l M Wind Power (Bangalore)• Forcas Impex Pvt. ltd. (Ahmednagar)• Nirmal Industries Controls Pvt. ltd. (Mumbai)• Kalyani Thermal Systems ltd. (Pune)• Bharat Forge ltd. (Pune)• Yashoda Industries (Ahmednagar)• FCI OEN Connectors Pvt. ltd. (Cochin)
Total number of Employees at the company: 18
Organization Chart:
Partners
Skilled SkilledUnskilled Unskilled
Manager Accounting Quality In-charge
Production In-charge
Suyog Plastics
263 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Types of Business:Business Type Products Products supplied toAs a Tier 1 Supplier to OEM Navketan Pharma
FCIOENBottlesRubber Bands
As a Tier 2 Supplier to OEM STPPlYashoda
Automobile componentsHousehold Appliances
Area of the Unit:Plot Area 5500 Sq. mtr.Total Built-up Area 3000 Sq. mtr.
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2009-2010 12 lACS 7 lACS 1 lACS2010-2011 36 lACS 12 lACS 1.8 lACS2011-2012 161 lACS 52 lACS 3 lACS
2012-2013 148 lACS 50 lACS 3.25 lACS
2013-2014 (expected) 200 lACS 65 lACS 4.5 lACS
Certifications:Certification Description of the Certification Year taken in Local AgentISO Certified Quality 9001 – 2008 2013 TUV India
Audit Reports: N. A.
Business Competitors:Sr. No.
Competitor’s name Competitor’s Product Specialization
Type of Business (Exporter/OEM/Tier 1 Supplier/Tier 2 Sup-plier / Tier 3 Supplier
1 Vishwas Moulders Automobile2 Marwel Industries Home Appliances3 Darshan Plastics Automobiles4 S R Plastics Irrigation
Company Plant and Process FlowCompany’s Plant layout:
Scrap area
Workers
Room
Toilet
Finished
Goods area
Dispatch
area
EntranceParking
Security
Accounts &
Office
M/C
1
M/C
2
M/C
3
M/C
5
M/C 6
M/C
4
Finishing
area Raw Material
area
264 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Types of MachinesSr
. No.
Nam
e of
Mac
hine
Qua
ntity
Mak
e of
mac
hine
Spec
ifica
tion
Pric
e of
the
Ma-
chin
e (R
s.)
Year
of P
urch
ase
Loan
/ by
Self
1. Injection Moulding
1 Rana and sons Engg Pvt ltd
60 tons 5 lacs 2009 Self
2. Injection Moulding
1 Rana and sons Engg Pvt ltd
80 tons 4.5 lacs 2008 Self
3. Injection Moulding
1 Rana and sons Engg Pvt ltd
100 tons 5 lacs 2009 Self
4. Injection Moulding
1 UA Polyplast Pvt ltd
150 tons 6.5 lacs 2010 Self
5. Injection Moulding
1 Cincinatee Mi-lacron
500 tons 12 lacs 2012 Self
6. Injection Moulding
1 Ferromatik Mi-lacron
200 tons 32 lacs 2013 loan
Types of Tools
Sr. N
o.
Nam
e of
Mac
hine
Qua
ntity
Mak
e of
mac
hine
Spec
ifica
tion
Pric
e of
the
Ma-
chin
e (R
s.)
Year
of P
urch
ase
Loan
/ by
Self
1. Weighing 2 Sharp Machines Heating Pur-pose
30000 2008 Self
2. Grinder 2 Rana and sons Engg Pvt ltd
Recycling Pur-pose
45000 2008 Self
3. Oven 2 Rana and sons Engg Pvt ltd
Heating 30000 2008 Self
Raw materials
Sr. N
o.
Raw
Mat
eria
l
Cur
rent
Rat
e (R
s. Pe
r Kg)
Spec
ifica
tion
Supp
lier’s
Nam
e
Min
imum
qua
ntity
mai
n-ta
ined
in th
e co
mpa
ny p
er
mon
th
Prod
uct M
anuf
actu
red
with
th
e m
ater
ial
Prod
uct S
uppl
ied
to (O
EM/
Tier
1 su
pplie
r/Ti
er2
Supp
li-er
/Tie
r 3 S
uppl
ier)
1 PPCP 108 Used for auto parts
Polygram India Pvt ltd
4500 kg Mirror housing, 6/2 Holders
STPPl
2 Derlin 105 Used for house-hold parts
Apex Poly-mers
2000 kg Yashoda Industries
3 Nylon 6/6 150 Used for auto parts
ShreeRam Polymers
7000 kg Casing Gas caps
STPPl
4 HDPE 110 Used for agri-parts
A. M. Traders
1000 kg Dripper Sleeves Bottles
Disha Ind. Devgiri Forging Navketan Pharma
Warehouse/Storage of Raw material (Inventory Control Techniques)
Order Quantity: As per customer requirement
Order Process: As per production Planning
Quality Control: ISO 9001:2008
Information of Workers, Supervisors, Managers and Staff for cleaning
Number of Shifts per day: 2
265 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Sr. N
o.
Nam
e of
wor
ker
Age
(yrs
)
Gen
der (
M/F
)
Wor
kers
/ Su
perv
isor
/M
anag
er /
Staff
for
clea
ning
Qua
lifica
tion
Ope
ratio
n / F
unct
ion
Year
s of e
xper
ienc
e in
In
dust
ry
Wor
king
hou
rs /
day
1 Gajanan Ghuge
26 M Manager Graduate Inhouse Manage-ment
7 12 hrs/day
2 A Deshpande 60 M Accounts Manager
Graduate Accounting 35 12 hrs/day
3 Suresh Ubale 26 M Quality Manager
Graduate Quality Checking
8 12 hrs/day
4 Gajanan Shilvant
28 M Prod. Man-ager
Graduate Production Incharge
10 12 hrs/day
5 Rakesh Rajput 23 M Supervisor 12th Pass Supervision 4 12 hrs/day6 Raju
Mahendrakar25 M Supervisor 12th Pass Supervision 5 12 hrs/day
7 Gajanan Kachgunde
24 M Worker 12th Pass Worker 5 12 hrs/day
8 Kamlesh Rajput
19 M Worker 10th Pass Worker 4 12 hrs/day
9 Ankush Kale 23 M Worker 10th Pass Worker 4 12 hrs/day10 Pramod Rajput 19 M Worker 10th Pass Worker 6 12 hrs/day11 Nirmal Rajput 19 M Worker 10th Pass Worker 4 12 hrs/day12 Nathulal
Rajput21 M Worker 10th Pass Worker 2 12 hrs/day
Functions/Operations in the company:Function / Operation
Required Qualification of workers
Required number of workers
Shortfall of workers
Number of hours /shift
Number of shifts/day
Store Keeping & Accounting
Graduate 2 0 12 hrs/day 1
Quality Inspection Graduate 1 0 12 hrs/day 1Production Incharge Graduate 1 0 12 hrs/day 1
Factory Inhouse Manager
Graduate 1 0 12 hrs/day 1
Business Process FlowCustomer
Mould Designing & Manufacturing
Quality Inspections & Finishing
Component Finalizing
Component Manufacturing
Dispatch
Manufacturing Process FlowRaw Material (Plastic Granules)
Injection of melted Plastic Granules
Quality inspections & Finishing
Raw Material Heating
Cooling
Finished Goods
Machine operations:
266 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Sr. No.
Machine name No. of labors required per machine
Time required for process
Idle time per shift of 8 hrs
Wastage %
1 Injection Molding M/C 1
1 30 Seconds 0 5%
2 Injection Molding M/C 2
1 18 Seconds 0 5%
3 Injection Molding M/C 3
1 14 Seconds 0 5%
4 Injection Molding M/C 4
2 40 Seconds 0 5%
5 Injection Molding M/C 5
1 10 Seconds 0 5%
6 Injection Molding M/C 6
1 180 Seconds 0 5%
Products manufactured at the Company:Sr. No.
Product Name Cost to Company
Price to Customers
Repeat Order
Supplied to
1 Pulsor Mirror Housing Rs. 5.86 5.99 Yes STPPl2 Automotive Rs. 4.35 4.45 Yes STPPl3 Decotrim Rs. 0.61 0.71 Yes Yashoda Industries4 612 Holder Rs. 1.06 1.10 Yes Disha Industries5 Dripper Rs. 0.28 0.35 Yes Disha Industries6 Bottles Rs. 7.99 8.20 Yes Navketan Pharma7 Protective Sleeves Rs. 12.25 12.40 Yes Devgiri Forging
Quality Control Plan
Quality Standard for Product:Sr. No. Product name Specification Strictly followed1 Pulsar Housing Free from Flash, Welding flow
marks, silver marks Yes
2 612 Holders Free from defect and flash Yes3 Automotive casting Free from silver marks flash Yes4 Dripper Free from flash Yes5 Bottles Free from damage and over deflash-
ingYes
6 Protective Sleeves Free from flash Yes
Does the company maintain Documents for every Project?
Yes. Quality control is process by which entities review quality of all factors involve entities review quality of all factors in-volved in production.Documentation includes testing of prod-ucts to uncover defects & reporting to management to make decision to allow product release. Possible quality defects of a component are noted & steps are taken to reduce or make quality defects. Master samples of each are kept & referred in case of a quality issue in a component.
Quality Control Procedure: (In house/ External agency)
• Visual Inspection• Finishing & Deflashing• Dimension Checking & other defects
Testing of Raw Materials (Incoming - Quality Control Techniques)
• Weight measurement• Strength and moisture checking
Name of Testing Labs for Raw Materials (tie-ups for Raw Materials)
N. A.
Name of Testing Labs (tie-ups for Finished Products)
N. A.
Testing of Finished Products • Visual Inspection• Dimension & Weight measurement• Deflashing & Finishing
267 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Design & DevelopmentWhat is Design? “Plan or drawing produced to show the look &
function of a component before it is built or made”
Design Process:
Feasibility
Research
Market Demand
Developing Design
Engg. and other Processes
Market Value
Developing Concept
Design Documentation
Development
Approved of Developed Design
Production
Budget allocated for Research & Development (Annually in Rs.)
50 - 60 lacs
IT/CAD/Softwares/CAM used in the Company
N. A.
Exhibition/trade shows visits:
Sr. N
o.
Exhi
bitio
n /
Show
Part
icip
ant /
V
isito
r
Last
atte
nded
(Y
ear)
Fees
(in
case
th
e co
mpa
ny
part
icip
ated
)
Bene
fits
1 Plastivision, Mumbai
Visitor 2013 250 Knowledge of advanced technologies
2 Maha Advantage Expo, Aurangabad
Visitor 2014 300 Knowledge of advanced technologies
Safety standards in the Company:Manufacturing Op-erations
Possible accidents / hazards
Safety measures in the company
Remedies / Medication
Injection molding process
Getting in contact with melted plastic granules
Shield, gloves & machine safety
First Aid Kit
Grinding Splitting of plastic gran-ules
Gloves & face shield provided
First Aid Kit
Oven Burn marks due to high temp inside oven
Providing of gloves First Aid Kit
Marketing and Branding:logo of company:
268 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Effectiveness of the company logo Medium
Describe the Company’s Target Market: Targeting Irrigation components & Automobile Industry
Brand Awareness in respective markets; whether B2B or B2C
High
Initiatives taken to promote the Brand and Respective expenses
• Online marketing• Most Important satisfactory customer• Person to person marketing
Online services Yes
Company label:Sr. No.
Labeling type
Label specification
Material used
Vendor name/ In house
Machine details if produced In house
1 Stick Paper label showing company name production & quality aspect
Automobile components
Sanjay Techno Products
Moulding ma-chines 60, 80, 100, 150, 500 tons
2 Stick Paper label showing company name production & quality aspect
Dripper Disha Industries Moulding machine 100 tons
Company Packaging:Sr. No.
Packaging type
Packaging specifications
Material used
Vendor name / In house
Machine details if produced In house
1 Gunny Bags Gunny Bags of standard size
Automobile components
Sanjay Techno Products
Moulding machines 60, 80, 100, 150, 500 tons
2 Boxes Boxes of standard size
Automobile components
Sanjay Techno Products
Moulding machines 60, 80, 100, 150, 500 tons
3 Polythene Bags
Blue & white colored
Automobile components
Sanjay Techno Products
Moulding machines 60, 80, 100, 150, 500 tons
4 Gunny Bags Gunny Bags of standard size
Dripper Disha Industries Moulding machine 100 tons
Finance & AccountsCosting: Calculating weight of components + Raw material charges + Moulding cost + Inspection / deflashing cost + Profit + Packing / Transportation Cost = Final pricing of a component Cost Sheet: Part name - 100 ml BottleMaterial Grade HDPENet wt. per piece gsm 10.00Runner wt. per piece gsm 10.00Shot wt. of piece gsm 20.00Insert wt. gsm 0.00No. of cavity nos. 1Total wt. of shot gsm 20.00Reconciliation wt. of piece gsm 10.40Raw material cost Rs./kg 110.00Machine used ltrs. 1lMachine tarrif Rs./Shift 1600.00Cycle time Sec. 25No. of shots/shift Nos. 1152No. of pieces/shift Nos. 1152Prod. quality efficiency@95% Nos. 1094Raw material cost Rs./piece 1.14Moulding cost Rs./piece 1.46Rejection@2% Rs./piece 0.06Deflashing/inspection Rs./piece 0.05Tool cost Rs./piece 1.67Total direct cost Rs./piece 4.38
269 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Profit@10% Rs./piece 0.44Packing cost Rs./piece 0.05Fright charges Rs./piece 0.05Total Cost Rs./piece 4.92Tool cost 40000Quantity.month 2000
Human Resource ManagementEmployment recruitment rules New recruitment are made based on
the qualities such as experience in the plastic industry leadership qualities good communication skills manpower management skills etc.
Training Policy for the new recruits and already employed with the company:For New Recruits For Already Employed
Machine Operator Training & general ma-chine instructions along with already employed person
Timely support & motivation for the further knowledge.
Supervisor Manpower management shift supervision
Training to understand better aspects of the firm
Manager In house firm manage-ment
Developing & Training for growth of the firm
Helper/Cleaning Staff
General cleaning instruc-tions
General instruction
leave Policies:Staff Leave PolicyMachine Operator 1 month in a yearSupervisor 1 month in a yearManager National Holidays and leave allowanceHelper/Cleaning Staff Not Applicable
Overtime Policy: Payment according to overtime hours
Insurance/Medi-claim PolicyStaff Leave PolicyMachine Operator ESICSupervisor ESICManager life InsuranceHelper/Cleaning Staff ESIC
Wage Rate Policy:Staff Wage Rate PolicyMachine Operator Daily Basis Salary PaymentSupervisor Fixed Monthly salary paymentManager Fixed Monthly salary paymentHelper/Cleaning Staff Daily Basis Salary Payment
Salary Structure:Staff For
Fresher (in Rs.)
With expe-rience of 3 years (in Rupees)
Training required, if yes then please mention the train-ing
Machine details if produced In house
Machine Operator
270 290 Machine operating & safety
Injection Mould-ing Machine
Supervisor 7000 8500 Shift supervision _Manager 10000 12000 Firm Management _Helper/Clean-ing Staff
250 260 Cleaning Instruc-tion
_
Male & Female Employees:Staff Number
of staffProfile (Ma-chine Operator / Supervisor / Manager / Helper / Clean-ing Staff)
Hometown (Aurang-abad/Outside Au-rangabad but within Maharashtra/Outside Maharashtra)
Years of experience in the Company
Machine details if produced In house
270 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Male 14 Includes all Aurangabad/Out-side Aurangabad but within Maharashtra/Outside Maharashtra
Depend on person to person
Mould-ing m/c (60,80,100, 150,200,500 tons)
Female 4 Includes all Aurangabad/Out-side Aurangabad but within Maharashtra/Outside Maharashtra
Depend on person to person
Mould-ing m/c (60,80,100, 150,200,500 tons)
Covered under ESI/EPF/Gratuity: Yes
Contract Worker Policy: N. A.
Compensation Plan for workers in case of injury or accidents: Covered in Insurance for all workers
Career Graph Plan for Employees: Growth & continues development under motivation & guidance
Retention Policies and Welfare Schemes: Insurance Policies
Assistance required from Government in the following areas:• Subsidy approvals and grant
Assistance by CIPET, Aurangabad:• Testing of Raw Material
Assistance by IGTR, Aurangabad:• Manufacturing of Moulds
Assistance by ITI, Aurangabad:• Helping in recruitment of New Employees (Technical)
Assistance by MCED, Aurangabad:
• Help in development and design in association with NID
SWOT Analysis of the CompanySTRENGTHS• Quality – satisfactory customers• Advanced technology• Experienced & trained staff• Development strategies and plans
WEAKNESSES• Financial crunch• No own factory land
THREATS• Development of the firm’s new
design & components by other competitors.
OPPORTUNITIES• Support from government &
other initiatives for development of the firm
Future Plan of the CompanyTimelines Plan Assistance required by the
Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months Purchasing of new land for factory premises and new product development
Finance & Design Assistance Growth of sales & promotion
1 year Purchasing of new machinery & other development
Finance Growth of sales & promotion
3 years New product develop-ment and machinery
Finance Growth of sales & promotion
5 years New product develop-ment and machinery
Finance Growth of sales & promotion
Product Design Brief
271 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Design Brief 1
The company has planned to develop an automatic dog food dis-penser. The actual sample has been imported from Canada. The samples is under research by the R&D team.
Design Brief 2
It contains a hopper of 4kg containing dog food. The dispenser works on an automatic timer system once the hopper is filled with dog food and the timer is set on the food is automatically dispensed in the tray. The main advantage of this dispenser is that it does not require time to time manual feeding. It will be very useful in day to days life and is an effective time saving idea. We will be the first on to develop this product in India.
Plan of the Design ProjectProduct Design Brief specifications
Automatic Dog food Dispenser. (six days food storage Timer based automatic dispensing sys-tem)
Proposed Design Process Study and designing and researching according to actual available sample
Timeline 3 monthsBudget Rs. 28 lacsTeam members & Skills Required
Team includes 3 Members• Designer• Technical Engineer• Marketing
Benefits for the Company It will create brand value inhale confidence and more profitability
272 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The gap between the wall and the rotomoulding machines is very less to walk through.
The product samples manufactured at the unit are displayed very well for reference and presenting to the clients.
273 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
White board for discussion and project planning in the mid-dle of the work area.
274 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Need better arrangement for the moulds and the exposed wires.
275 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The mould is lying in the middle of the walk way. Need to be placed in a safe area.
The walk way between the machines is blocked. Need proper place for the workers for finishing of the parts.
276 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The pores of the Inline Dripper are being cleared by the tip of a pen. It needs a better process for finishing the blockages.
De-flashing processes to remove the flash which occurs because to excessive injection pressure.
The moulds needs to be arranged properly to avoid damage to the mould and avoid accidents with the working area.
277 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The moulds are hidden under the stairs. Moulds needs to be arranged in its specified area to keep it damage-proof.
The wrong posture of the workers will make them suffer from work-related diseases, which are further complicated by social, psychological and physiological issues. Overall this will further affect the productivity of the unit
The wrong posture of the workers will make them suffer from work-related diseases, which are further complicated by social, psychological and physiological issues. Overall this will further affect the productivity of the unit
278 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The floor is temporarily covered with plywood sheets. Need to be fixed to avoid any accident.
The machines layout as seen from the top.
279 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Workplace need to be properly managedPlant layout Improvement • Space arrangement is a concern as there is
lot of congestion of machine.• No use of Natural light
New Product Development Yes, R & D in process Packaging Yes, goodMarketing Yes , need to upgradeHuman Resource 1 year training
Business DesignMarketing Needs to improvelogo Design GoodVisiting Card GoodBrochures & leaflets GoodWebsite Needs up-gradation
Recommendations• Company has only injection moulding. For product diversification, ma-
chinery expansion is needed. • No design development initiative, completely depend on other companies
for development.• Company needs to focus on becoming a Tier I supplier to increase the
profit margin which is just 2 % in Tier II supplier.
• Depend on the agent for importing moulds from China, and other compa-nies
• Financial planning need to be done for the new product development• Brand communication strategy need to be formalised, no visibility in mar-
ket as the company is tier II. As the company has plan for huge expansion, company logo has to more creative and need to be protected. it has good visibility in market, need to capitalise on that.
• Very less safety precautions are taken by workers, this need to be improved by providing gloves and other safety gears to workers.
280 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
2
31
21Sw
agat
Polym
ers
281 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Swagat PolymersAddress of the Company: Plot no. K-195-196, MIDC, Waluj, Aurangabad, Pin: 431136, Maharashtra, IndiaLandline number: 0240 - 2552347Mobile Number: 9822037318Company e-mail id: [email protected]: www.swagatpolymers.com Company started in: 2002
Type of Company: Proprietorship
Affiliated units/sister concern/subsidiary: N. A.
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Ashok Joshi 35 Owner M. Com. 15 yrs - 9822037318
Company’s Initial Investment: 3 lacs and the total internal investment is 1 cr.
Company’s Specialization/Product/Services:• Polythene Polybags• Stretch wrap film
Swagat PolymersMIDC, Waluj, Aurangabad
• UCI Bags, Rolls films• Air Bubble Bags & Rolls• Self Protective film
loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name / Govt.
AssistanceYear Purpose Amount (Rs.) Status (Active/
Closed)1 HDFC 2010 Cash Credit 130 lacs -2 SBI 2012 Housing 40 lacs -3 HDFC 2013 Car loan 12 lacs -
Vendor Code Details:Vendor Code
Customer Issued in Products Supplied Last Audit by Customer
1 Bajaj Auto 2005 Packaging Items -2 Varroc Group 2002 Packaging Items -3 Endurance 2002 Packaging Items -
Production capacity of the Unit:Year Production capacity2013-2014 1200 tons2013-2012 1200 tons2012-2011 1000 tons2011-2010 1000 tons2010-2009 800 tons
Types of Customer:
282 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Type Total number of Customers
Names/List of Customers Products Manufactured
Automotive 40 • Varroc Group • Endurance
Auto Parts
Pharmaceutical 3 • Savera Pharma • Atra Pharmaceutics
Medicine
Household Products 10 • Ultima Plastc • Aquara Moulders
Carrots & otherAppliances
Consumer Products 5 • B.G. Appliances • Videocon
Electronic Consumer Products
Food & Beverage 10 All Hotels
Total number of Employees at the company: 25 (15 workers, 2 supervisors, 2 dispatch, 1 accountant, 2 marketing, 1 security and head of departments)
Organization Chart:
Plant Head
Sales
Production
Dispatch
Purchase Dept. Marketing Dept. Accounts Dept.
CEO
Types of Business: OEM
Area of the Unit: 12000 sq. ft
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2009-2010 115000000 N. A. N. A.2010-2011 125000000 N. A. N. A.
2011-2012 135000000 N. A. N. A.
2012-2013 155000000 N. A. N. A.
2013-2014 (expected) 170000000 N. A. N. A.
Certifications: ISO and CRISIl
Business Competitors:• Multistar Polythene• SRK Polythene• Trimurti Polymers
Company Plant layout
Garden
Office
Cutting machine area
Finished Goods
Raw material
Securityroom
Tubing machine 1
Tubing machine 2
Tubing machine 3
283 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Types of MachinesSr
. No.
Nam
e of
M
achi
ne
Qua
ntity
Mak
e of
m
achi
ne
Spec
ifica
tion
Pric
e of
the
Mac
hine
(R
s.)
Year
of
Purc
hase
Loan
/ by
Self
1. Extrusion Machine
1 Vipul Engineer-ing, India
Tubing 500000 2000 loan
2. Extrusion Machine
3 Maitree Engi-neering
Tubing 2000000 2005 loan
3. Cutting & Sealing
4 Ashok Engineer-ing
Cutting & Sealing
1000000 2005 loan
4. Slitting Machine
1 Thakkar Engi-neering
Slitting Ma-chine
300000 2005 loan
Sr. N
o.
Raw
Mat
e-ri
al
Cur
rent
R
ate
(Rs.
Per K
g)
Spec
ifica
-tio
n
Supp
lier’s
N
ame
Min
imum
qu
antit
y m
aint
aine
d in
the
com
-pa
ny p
er
mon
th
1 llDPE 125 Granules Arihant Polymers 70 Ton
2 UPDE 126 Granules Arihant Polymers 10 Ton
3 lDPE 128 Granules Arihant Polymers 10 Ton
4 PP 128 Granules Arihant Polymers 10 Ton
Warehouse/Storage of Raw material (Inventory Control Techniques)Order Quantity: As per customer requirementOrder Process: As per customer requirementQuality Control: In house testing lab
Information of Workers, Supervisors, Managers and Staff for cleaning
Shift Timings: 7 AM to 7 PM
Number of Shifts per day: 2
Sr. N
o.
Nam
e of
w
orke
r
Age
(yrs
)
Gen
der
(M/F
)
Ope
ratio
n / F
unct
ion
Year
s of
expe
rien
ce
in In
dust
ry
Wor
king
ho
urs /
day
1 Operator (5) M Machine Oper-ator
8 years 8 hrs
2 Helper (5) M Cutting Packing 6 years 8 hrs3 Office Staff (7) M Staff 9 years 8 hrs
Business Process FlowMarketing In various Industries
Sample confirmation & price quoting
Production as per samples approved by
Samples collection Approval
Order Collection
Dispatch
Machine operations:Sr. No.
Machine name No. of labors required per machine
Time required for process
Idle time per shift of 8 hrs
Wastage %
1 Tubing Machine 3 24 hrs 8 hrs 1 %2 Cutting Machine 4 24 hrs 8 hrs 1 %
284 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
3 Slitting Machine 1 24 hrs 8 hrs 1 %
Products manufactured at the Company:Sr. No.
Product Name Cost to Company
Price to Customers
Repeat Order
Supplied to
1 Polythene Bags 140 150 Yes N. A.2 Stretch Film 145 160 Yes N. A.3 Air Bubble 130 145 Yes N. A.
Quality Control PlanProject Documentation
Quality Control Procedure: In-house testing facility available
Testing of Raw Materials (Incoming - Quality Control Techniques)
Material verified as per our requirement
Name of Testing Labs for Raw Materials (tie-ups for Raw Materials)
• Micrometer• Gauze Meter
Quality Standard for Product:Sr. No. Product name Specification Strictly followed1 Pulsar Housing Free from Flash, Welding flow
marks, silver marks Yes
2 612 Holders Free from defect and flash Yes3 Automotive casting Free from silver marks flash Yes4 Dripper Free from flash Yes5 Bottles Free from damage and over deflash-
ingYes
6 Protective Sleeves Free from flash Yes
Design & DevelopmentWhat is Design? “Design is a concept to create a plan
of new theme before it is made”
Budget allocated for Research & Development (Annually in Rs.)
5 lacs
Exhibition/trade shows visits:
Sr. N
o.
Exhi
bitio
n / S
how
Part
ic-
ipan
t /
Vis
itor
Last
at
tend
ed
(Yea
r)
Fees
(in
case
the
com
pany
pa
rtic
ipat
-ed
)
Bene
fits
1 Maha Expo Organisation
100 2010 15000 New customer added
Safety standards in the Company:Manufacturing Op-erations
Possible accidents / hazards
Safety measures in the company
Remedies / Medication
Tubing - - -Cutting Machine Scratches First Aid Box
Marketing and Branding:logo of company:
285 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Effectiveness of the company logo
Medium. No need to focus on Branding and Market-ing as it is a B2B business and Brand awareness of the company is high in its target market.
Online services Yes
Brand Awareness in respective markets; whether B2B or B2C
High
Online services Yes
Company Packaging:Sr. No.
Packaging type Packaging specifications
Material used
Vendor name / In house
Machine details if produced In house
1 Non woven snack bang
Woven Bag Orchid foam -
2 Corrugated Box Boxes Paper Box Safe Pack -
Overtime Policy: Payment according to overtime hours
Salary Structure:Staff For
Fresher (in Rs.)
With experi-ence of 3 years (in Rupees)
Training required, if yes then please men-tion the training
Machine details if produced In house
Machine Operator
10000 to 12000
290 Machine operating & safety
Injection Moulding Machine
Supervisor 10000 to 14000
8500 Shift supervision _
Manager 14000 to 16000
12000 Firm Management _
Helper/Cleaning Staff
250 260 Cleaning Instruction _
Number of Employees: 30
Covered under ESI/EPF/Gratuity: Yes
Assistance by CIPET, Aurangabad: Certifications of finished Goods
SWOT Analysis of the CompanySTRENGTHS• Positive Attitude towards New
Development
WEAKNESSES• Unable to capture Market
THREATS• New Competitors
OPPORTUNITIES• Target New customer
Future Plan of the Company
Time-lines Plan Assistance required by the Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months Development of Manufacturing capacity
Finance Financial position strong to increase in Manufacturing capacity
Product Design BriefProduct Design Brief specifications
PVC Plain wrap food grade film, PE food wrap firm (10 to 12 micron)
Budget Rs. 25 to 30 lacsTeam members & Skills Required
Team includes 3 Members• Designer• Technical Engineer• Marketing
Benefits for the Company
It will create brand value inhale confidence and more profitability
286 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The work area is not clean as a result the finished good may get spoiled. The area needs regular cleaning.
The worker’s clothes is seen hanging in the work area.
The filing cabinet is arranged properly.
287 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Worker is not equipped with hand gloves/safety equipments.
The wires and pipes are not arranged properly.
288 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The machine is temporarily adjusted with hand tools to function properly.
The floor is not maintained properly.
The packaging tape is kept on the level which disturbs the worker while operating the machine.
The machine is under maintenance.
289 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Slitting machine
The plastic sheet scrap is lying in the working area close to motor which can be hazardous. The area needs to be cleaned.
290 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The marking for the switches is not properly shown. It needs urgent attention and maintenance.
The marking for the switches is not properly shown. It needs urgent attention and maintenance.
291 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Needs proper disposal of used belts and machine parts.
Sealing machine
292 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The raw materials needs to be segregated according to the specification and stacked properly.
Tools are seen lying around after use and the wiring needs to be fixed. The working area not maintained properly.
293 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The pipes are not arranged properly.
The roller is damaged.
The marking for the switches is not properly shown. It needs urgent attention and maintenance.
The water filter for the workers.
294 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations SatisfactoryWorkplace & Ergonomics Need to improvePlant layout Improvement Space arrangement is a concern New Product Development In-house product development process not
strictly followedPackaging Need to improveMarketing Need to improveHuman Resource Training initiatives for the workers need to
improve
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Need to developWebsite Need to improve
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and
emergency situations.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: Company is producing very basic product in which there is lot of competition, so new product development should be looked into.
Human Resource: To reduce employee attrition rate, the salary levels need to be revised to attract better skilled manpower as well as a proper career growth plan should be for-mulised.
Marketing:• A website need to be up-graded on urgent basis so that the customer reach
can be extended.• Marketing is not so effective; it requires more publicity on retail level. A
proper branding strategy should be formulised to get maximum visibility in the market.
• A logo needs to be more creative, to make a place in the customers percep-tion.
• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers.
• A company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the de-velopment process.
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2
31
22Ti
rum
alaIn
dustr
ies
296 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Tirumala IndustriesAddress of the Company: Plot no. H-5/41, MIDC, Chikalthana, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9850963136, 7588534243Company e-mail id: [email protected], [email protected] No.: N. A.Website: N. A. Company started in: 2011
Type of Company: Proprietorship
Company’s Specialization/Product/Services• Plastic Water Tank
Affiliated units/sister concern/subsidiary: N. A.
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Ajay Annasaheb Pathrikar
48 Owner M. A., I. T. I.
2 years [email protected]
9850963136, 7588534243
Tirumala IndustriesMIDC, Chikalthana, Aurangabad
Details of the Owner/Director Family members:
Sr. N
o.Fa
mily
Mem
ber
Rel
atio
n to
the
Ow
ner o
f th
e C
ompa
ny
Age
(in
Year
s)
Educ
atio
nal Q
ualifi
catio
n
Wor
k Ex
peri
ence
pri
or to
jo
inin
g th
e C
ompa
ny
Invo
lved
in C
ompa
ny’s
busi
ness
act
iviti
es (Y
es/N
o)
Rol
e in
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Ajinkya Ajay Pathrikar
Son 22 B.E. Me-chanical (appear)
No Yes Manager [email protected]
9850194545
Company’s Initial Investment: 26 lacs
loan/Financial Assistance taken since the start of the company:Sr. No.
Bank Name / Govt. Assistance
Year Purpose Amount (Rs.) Status
1 State bank of Hyderabad 2011 Term loan 10 lacs 2 State bank of Hyderabad 2011 Cash credit 5 lacs
Production capacity of the Unit:Year Production capacity2013-2014 3600 (Proj. Sales Rs. 60.00 lacs)2013-2012 3000 (Sales Rs. 48.75 lacs)
297 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
2012-2011 1300 (Sales Rs. 25.40 lacs)2011-2010 N. A.2010-2009 N. A.
Types of Customer:
Type Total number of Customers
Names/List of Customers Products Manufactured
Household Appliances
150 Plastic Water Tank
Building Contractors, Traders and Hardware shops
200 • Building Construction contractor
• Abhimanyu traders• Govind traders• Arihant traders• Shrikrishna Hardware• Santosh traders• Padmavati
Plastic Water Tank
Total number and List of Vendors or Suppliers: All types of customers like contractor, traders, home user, etc.
Total number of Employees at the company: 7
Ajay Pathrikar (Proprietor)
Manager: 01
Shift in charge: 01
Operator: 03
Helper: 02
Types of Business: OEM
Area of the Unit:
Plot Area 5500 Sq. mtr.Total Built-up Area 3000 Sq. mtr.
Turnover of the Unit (in Rupees):
Year Annual Turnover Gross Profit Net Profit2011-2012 25.40 6.74 2.102012-2013 48.75 9.87 4.60 2013-2014 (expected) 60.00 12.80 5.50
Certifications: N. A.
Audit Reports: N. A.
Business Competitors:
Sr. No.
Competitor’s name
Competitor’s Product Speciali-zation
Type of Business (Exporter/OEM/Tier 1 Supplier/Tier 2 Supplier / Tier 3 Supplier
1 Sintex water tank Plastic Water tank Exporter2 Sarita water tank Plastic Water tank OEM3 laxmi water tank Plastic Water tank OEM4 Ganga Water tank Plastic Water tank OEM5 Vasundara Water
tankPlastic Water tank OEM
298 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Company Plant and Process FlowCompany’s Plant layout:
Manufacturing area
Finishedmaterialstorage
OpenSpace
Rawmaterial storage
Worker room
Toilet
StaffCabin
Stairs for 1st floor
Garden Space
M. I. D. C. Road
Temple Security
Information of Workers, Supervisors, Managers and Staff for cleaning
Sr. N
o.
Nam
e of
wor
ker
Age
(yrs
)
Gen
der (
M/F
)
Wor
kers
/ Su
perv
isor
/M
anag
er /
Staff
for
clea
ning
Qua
lifica
tion
Ope
ratio
n / F
unct
ion
Year
s of e
xper
ienc
e in
In
dust
ry
Wor
king
hou
rs /
day
1 Ajinkya Pathrikar
22 M Manager B.E. Mech.
Mgt. 2 yrs 4 hrs
2 Sagar Patil 26 M Accountant (Staff) M.com Accounting 6 yrs 4 hrs3 Balasaheb
Dhepale45 M Supervisor BA Shift incharge
/ supervisory 8 yrs 8 hrs
4 Parmeshwar Dehade
42 M Worker 9th Machine operator
5 yrs 8 hrs
5 Kashinath Tejankar
47 M Worker HSC Machine operator
5 yrs 8 hrs
6 Machindra Mhaske
40 M Helper SSC Helper 3 yrs 8 hrs
7 Tukaram Shinde
37 M Worker HSC Machine operator
4 yrs 8 hrs
Functions/Operations in the company:Function / Operation
Required Qualification of workers
Required number of workers
Shortfall of workers
Number of hours /shift
Number of shifts/day
Design & devel-opment of plastic products
DMEBE
03 03 8 hrs 1
299 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Business Process FlowPurchase raw material
Weighting of raw material required for mfg. process
Cooling process done, after completion of total mfg. process
Quality control / inspection done by supplier
Required raw material load in machinery (mould)
Screen printing on logo name
Dispatch material
Manufacturing Process FlowThe rotational moulding process for manufacturing water storage tank consists of the following major process steps.
loading of raw material in Dies / Mould
Cooling or curing
Unloading of finished part
Moulding of the part as per layer
Screen printing on logo name
Machine operations:Sr. No.
Machine name No. of labors required per machine
Time required for process
Idle time per shift of 8 hrs
Wastage %
1 Roto molding machine
4 55-60 min
Products manufactured at the Company:Sr. No.
Product Name Cost to Company
Price to Customers
Repeat Order
Supplied to
1 300 ltr Plastic water tank 900 1100 Yes All types of custom-ers in Aurangabad, Jalna, Jalgaon
2 500 ltr Plastic water tank 1300 1600 Yes3 750 ltr Plastic water tank 2100 2400 Yes4 1000 ltr Plastic water tank 2900 3200 Yes
Quality Control PlanProject Documentation: N. A.
Quality Control Procedure: (In house/ External agency)
N. A.
Testing of Raw Materials (Incoming - Quality Control Techniques)
Raw material quality control done by the suppliers
Name of Testing Labs for Raw Mate-rials (tie-ups for Raw Materials)
N. A.
Name of Testing Labs (tie-ups for Finished Products)
N. A.
Testing of Finished Products It is done in house
Design & DevelopmentDesign Process: Presently not done. Design process will be done in house by using technical & qualified employee.
Budget allocated for Research & Development (Annually in Rs.)
10 lacs
300 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
IT/CAD/Softwares/CAM used in the Com-pany
N. A.
Exhibition/trade shows visits:
Sr. N
o.
Exhi
bitio
n / S
how
Part
icip
ant /
V
isito
r
Last
atte
nded
(Y
ear)
Fees
(in
case
the
com
pany
par
tici-
pate
d)
Bene
fits
1 Advantage Maharash-tra Expo-2014
Ajay Pathrikar
2013 N. A. New design & development
Safety standards in the Company:Manufacturing Op-erations
Possible accidents / hazards
Safety measures in the company
Remedies / Medication
Moulding (Heating process)
Fire fire extinguisher First Aid Kit
Marketing and Branding:logo of company:
Effectiveness of the company logo Medium
Describe the Company’s Target Market: Export the product and develop new products in plastic industries. Special marketing not required for the products. Its easily sales in local market.
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
N. A.
Online services Yes
Company Label: N. A.
Company Packaging: N. A.
Finance & AccountsCostingCost Sheet: Part name - 1000 Ltr Plastic water tankCost of raw material Rs. 2160Processing cost Rs. 375labour cost (wages) Rs. 300Transport cost Rs. 65Total cost to company Rs. 2900Margin Rs. 300Selling cost Rs. 3200
Human Resource ManagementEmployment recruitment rules No any specific recruitment rules. Employee’s
selection on their skilled and work efficiency.
301 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Training Policy for the new recruits and already employed with the company:
For New Recruits For Already Employed
Machine Operator Work experience / trail run Work experience Supervisor Work experience Work experience Manager Work experience Work experience Helper/Cleaning Staff N. A. Work experience
leave Policies:Staff Leave PolicyMachine Operator 4 days in months and public holiday Supervisor 4 days in months and public holiday Manager 4 days in months and public holiday Helper/Cleaning Staff 4 days in months and public holiday
Overtime Policy: Payment according to overtime hours
Insurance/Medi-claim Policy: N. A. (proposed to start)
Wage Rate Policy:Staff Wage Rate PolicyMachine Operator On work experience or fixed on Rs.6000 - 7000 p.mSupervisor On work experience or fixed on Rs.9000 - 10000 p.mManager On work experience or fixed on Rs.10000 - 12000 p.mHelper/Cleaning Staff Helper / cleaning fixed Rs.3000 – 4000 p.m
Salary Structure:Staff For Fresher
(in Rs.)With experi-ence of 3 years (in Rupees)
Training required, if yes then please men-tion the training
Machine details if produced In house
Machine Operator
6000-7000 p.m.
7000- 8000 p.m
Practical work done -
Supervisor 9000-10000 p.m.
10000-12000 p.m.
HRM -
Manager 10000-12000 p.m.
11000-13000 p.m.
Business Management training
-
Helper/Cleaning Staff
4000-6000 p.m
6000-8000 p.m For staff - as per post training
-
Male & Female Employees:
Staff Number of staff
Profile (Ma-chine Operator / Supervisor / Manager / Helper / Clean-ing Staff)
Hometown (Aurang-abad/Outside Au-rangabad but within Maharashtra/Outside Maharashtra)
Years of experience in the Company
Machine details if produced In house
Male 02 Manager / staff Aurangabad 2 yrs – 3 yrs N. A.Female 01 Receptionist Aurangabad 1 yr N. A.
Covered under ESI/EPF/Gratuity: N. A. (Proposed to cover)
Contract Worker Policy: N. A.
Compensation Plan for workers in case of injury or accidents: (Proposed to cover)
Career Graph Plan for Employees: N. A.
Retention Policies and Welfare Schemes: N. A. Assistance by CIPET, Aurangabad: N. A.
Assistance by IGTR, Aurangabad: : N. A.
Assistance by ITI, Aurangabad: : N. A.
Assistance by MCED, Aurangabad: : N. A.
302 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
SWOT Analysis of the CompanySTRENGTHS• Good reputation among custom-
ers• Huge works orders in-hand• Use of pure raw material for pro-
duction
WEAKNESSES• Unskilled labour• Insufficient capital
THREATS• Competitor sale produce in lesser
amount• Recovery of credit sales
OPPORTUNITIES• Export the product• Design & develop new products
Future Plan of the CompanyTimelines Plan Assistance required by the
Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months Acquired certification from ISO
N. A. Develop material quality
1 year Design & development new products
Finance/Training/Design Assis-tance
Acquired new work orders
3 years Export sales Finance Export order 5 years N. A. N. A. N. A.
Product Design BriefDesign Brief
design & development of new plastic products and estimated cost for the same up to 10 lacs to 15 lacs
Plan of the Design ProjectProduct Design Brief specifications
Various types of Plastic products
Proposed Design Process N. A.Timeline 2 to 3 yearsBudget Rs. 10 lacsTeam members & Skills Required
Team includes 05 Members• Industrial Designer (two)• Technical Engineer (Two)• Marketing
Benefits for the Company It will create brand value and build business con-fidence and more profitability
303 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The owner of the unit is showcasing his innovating water tank with offset opening. This helps the uses to look into the tank easily.
304 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The gear box is seen damaged. Needs proper maintenance.
The inner wall of the remoulding machine chamber is covered with thick layer of burnt plastic. The inner wall needs proper maintenance to maintain the heat transfer efficiency of the machine.
The lid of the tank is sourced from vendors as a result there is mismatch between the tank and lid w.r.t. the colour. The lid is also seen fitted very loosely.
305 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The defect in the tank is very common because of the frequent disruption in the electricity supply.
The defect in the tank is very common because of the frequent disruption in the electricity supply.
The defect in the tank is very common because of the frequent disruption in the electricity supply.
The defect in the tank is very common because of the frequent disruption in the electricity supply.
306 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The nuts used in locking the tank is prone to wear and tear very easily. Need frequent change leading increase in operational cost.
The company’s logo needs to be printed more accurately.
307 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The stock of lids received from vendors generally does not match with the tank of the colour.
308 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The oil supply system is not proper. Needs urgent up-gradation.
The fire extinguisher is kept out of reach in case of accident and emergency. It is kept in the store room.
309 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
310 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations SatisfactoryWorkplace & Ergonomics Need to improvePlant layout Improvement Space arrangement is a concern as the plant area
remains un-utilised for most of the period.New Product Development No In-house product development process fol-
lowedPackaging Need to improveMarketing Market awareness is a problem. No effective
marketing for business growthHuman Resource Training initiatives for the workers need to im-
prove
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Need to developWebsite Need to improve
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space
allocation to provide for ease of movement of workers during daily and emer-gency situations.
There is lot of space remain un-utilised in the work place can be used more efficiently. For example granule grinding machine can be purchased to reduce the cost of raw material.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: Company is dependent on only one type of product, it should think about venturing into other products to reduce the business risk. The colour cap of the tank is always mismatch with the tank colour, effort should be put up to manu-facture the cap in-house.
Human Resource: Employee attrition rate is high so the salary levels need to be revised to attract better skilled manpower.
Marketing:• A website need to be up-graded on urgent basis so that the customer reach
can be extended.• It requires more publicity on retail level. A proper branding strategy should
be formalised to get maximum visibility in the market.• A logo needs to be more creative, to make a place in the customers percep-
tion.• Emphasis should be given on the putting the stall in the exhibitions to cre-
ate awareness among probable customers.• A company can tie-up with the trade bodies, which give funding for the
new product development, this will be very beneficial to speed up the de-velopment process.
311 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
31
2
23Tr
imur
tiPo
lymer
s
312 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Trimurty PolythenesAddress of the Company: Gut. No.48, Plot no.12, Opp. Siemens ltd., Near MIDC, Waluj, Aurangabad, Pin: 431 136, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9372005542, 9922245562Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: 2005
Type of Company: Proprietorship
Company’s Specialization/Product/Services• Manufacturer of poly sheet and bags•Affiliated units/sister concern/subsidiary: N. A.
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Misal Bhaskar Harinathr
52 Owner M. Com. DME ap-peared
Purchased of-ficer with Bajaj Auto, Waluj, from 1986 to 2002
9372005542
Trimurti PolymersMIDC, Waluj, Aurangabad
Company’s Initial Investment: 5 lacs
loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name /
Govt. AssistanceYear Purpose Amount (Rs.) Status (Active/
Closed)1 HDFC Bank 2007 Purchase of
machine11.40 lacs Still continue with
regular repayment
Production capacity of the Unit:Year Production capacity2013-2014 150 M Tones 2013-2012 125 MT2012-2011 113 MT2011-2010 102MT2010-2009 99 MT
Customer: (Automotive and Pharmaceutical) For Packing materials• Fiat India Automoboils ltd., Ranjangaon, Pune• Acey Engg P ltd., Bilimora Gujrat• Videocon Industries ltd., Aurangabad • lombardini India P ltd., Chikalthana, Aurangabad• Mac Engg Inds, Bilimora, Gujrat • Baxtor India lTd., Waluj, Auranbagad• J K Ansell ltd., Waluj, Aurangabad• Minda Industries ltd., Aurangabad• Shree Chemicals, Beed• Durga Polytherm p ltd., A’nagar
313 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
• Akar Tools ltd., Waluj, Aurangabad• Addon Engg P ltd., Faridabad• Jolly Board India ltd., Aurangabad• Varsa Plastic p ltd., Waluj, Aurangabad• Precision PlasticPltd.,Waluj, Aurangabad
Total number of Employees at the company: 6
Organization Chart:• Proprietor• Main Supervisor• Main Operator• Sub Supervisor• labour
Area of the Unit: 2000 sq feet rented
Types of Machines
Sr. N
o.
Nam
e of
M
achi
ne
Qua
ntity
Mak
e of
m
achi
ne
Pric
e of
the
Mac
hine
(R
s.)
Year
of
Purc
hase
Loan
/ by
Self
1. Extruder 3 Intec, India 19 lacs 2005, 2007 and 2013
HDFC bank loan
2. Cutting & Sealing 3 Vijay Platomech, India 4 lacs 2005, 2008 and 2012
Self
Types of ToolsSr. No. Name of Machine Quantity
1 Spanners 502 Hammers 53 Plier 54 Dial gauge 25 Scale 3
6 Measuring tape 37 Punches 28 Alley keys 25
Raw materialsSr. No.
Raw Material
Current Rate (Rs. Per Kg)
Specifi-cation
Supplier’s Name
Minimum quantity maintained in the company per month
1 HMDPE 112 basic Reliance Reliance 500kg2 lDPE 115 basic Reliance Reliance 1000 kg
3 llDPE 112 basic Reliance Reliance 1500kg
4 RE-cycle 90 basic local local 1000 kg5 Master
batches160 basic alok alok 200kg
Functions/Operations in the company:Function / Operation
Required Qualification of workers
Required number of workers
Shortfall of workers
Number of hours /shift
Number of shifts/day
Store Keeping & Accounting
Graduate 2 0 12 hrs/day 1
Quality Inspection Graduate 1 0 12 hrs/day 1Production Incharge Graduate 1 0 12 hrs/day 1Factory Inhouse Manager
Graduate 1 0 12 hrs/day 1
Quality Control PlanProject Documentation
Does the company maintain Documents for every Project? NoQuality Control Procedure: (In house/ External agency) In-house
Testing of Raw Materials (Incoming - Quality Control Techniques) In-houseName of Testing Labs for Raw Materials (tie-ups for Raw Materials) In-house
314 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of Testing Labs (tie-ups for Finished Products) NoTesting of Finished Products No
Quality Standard for Product:Sr. No. Product name Specification Strictly followed1 Pulsar Housing Free from Flash, Welding flow
marks, silver marks Yes
2 612 Holders Free from defect and flash Yes3 Automotive
castingFree from silver marks flash Yes
4 Dripper Free from flash Yes5 Bottles Free from damage and over
deflashingYes
6 Protective Sleeves
Free from flash Yes
Design & DevelopmentWhat is Design? “As per customer requirement”
Budget allocated for Research & Development (Annually in Rs.)
No
IT/CAD/Softwares/CAM used in the Company
Not required
Exhibition/trade shows visits:Sr. No. Exhibition / Show Participant / Visitor Last attended (Year)
1 Plastic exhibition visitor Mumbai, 20132 Plastic exhibition visitor New Delhi 2012
Marketing and Branding:logo of company:
Effectiveness of the company logo Medium
Brand Awareness in respective markets; whether B2B or B2C
low
Finance & AccountsPrice break upHM DHPE 56GF004 112.00Plus Excise duty 12.36% 13.40Plus power 9.00Plus labour 4.00plus wastage 1.00plus transport 1.00Plus profit 3.00Total rate 143.40Salex tax 5% 7.17
Grant total 150.57SAY 151
Human Resource ManagementShift Timings: 8 AM to 8 PM
Number of Shifts per day: 1 shift of 12 hours
315 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Overtime Policy: Payment according to overtime hours
Assistance required from Government in the following areas:• Burden of Excise duty and other taxes should be less• Procedure of various return to be cut down or to be simplify• Excise audit to be simplified to be as audit and not policing
Assistance by CIPET, Aurangabad: For making sample test report prompt in time and at low cost
Assistance by MCED, Aurangabad: Assistance required for new project and for recommendation for financial institutions.
SWOT Analysis of the CompanySTRENGTHS• Quality – satisfactory customers• Advanced technology• Experienced & trained staff• Development strategies and plans
WEAKNESSES• Financial crunch• No own factory land
THREATS• Development of the firm’s new
design & components by other competitors.
OPPORTUNITIES• Support from government &
other initiatives for development of the firm
Product Design Brief: N. A
316 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The granules is being readied for putting into the hopper. The method is completely manual.
Extrusion blow moulding process for making sheets
317 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Need urgent attention for the proper wiring to avoid fire or any kind of accident.
Tools are left unattended near the machine which may damage the sheet being manufactured
The space around the machine is not maintained which congests the work area.
318 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Complete process for making sheet using the extrusion blow moulding machine.
A lot of temporary arrangement using wood is seen while controlling diameter of the plastic sheet.
319 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The sheet rolling process
The sheet slitting process
The sheet sealing process
320 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Need urgent attention for the proper wiring to avoid fire or any kind of accident.
A lot of clutter is seen around the machine
321 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Wires are seen hanging loosely around the main switch board leading to a risk of accident and fire.
Tool box is not maintained properly. All tools are mixed up in a small crate.
The marking for the switches is not shown. It needs urgent attention and maintenance.
322 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
A lot of temporary arrangement using wood is seen while controlling diameter of the plastic sheet.
A lot of clutter is seen around the machine
Improper posture while packing the finished goods. Needs better packaging methods.
323 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
lot of clutter is seen around the working area. No space management is practised
Proper maintenance of the machine and the support systems is required
The entrance to the unit is very not welcoming
The entrance to the unit is very not welcoming
324 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement • Space arrangement is a concern as the
plant area is congested• No use of Natural light
New Product Development No in-house product development process followed
Packaging Need to improveMarketing • Market awareness is a problem. No
marketing for business growth• Good branding material available• Sample swatches are available
Human Resource • Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: Three major categories where the company focuses on are:i) Automobile, ii) Electrical and iii) luggage. In order to provide regular fund-ing, the company may be linked to the respective corporate houses as dedicat-ed vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to get into household products, it can also explore product diversification in the home decor and kitchen products.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• Branding exercise needs to be conducted on priority basis as the company
aspires to get into the household product segments. Trademark registration should be taken to protect equity and prevent litigation in future.
• There is a huge dependence on one customer which might harm the busi-ness in the long run. Increasing the customer base is mandatory for long term sustenance and growth.
• Assistance should be provided to the company to set up their stall in exhi-bitions to highlight their products to the retail and manufacturing partners.
• Re-structuring of the website to increase vendor accessibility.• As the company plans to get into retail consumer segments like plastic
buckets, jugs, mugs etc. it should develop its distribution channel to reach out to the right target market.
325 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
2
31
24Ulk
a Plas
ticIn
dustr
ies
326 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Ulka Plastic IndustriesAddress of the Company: Plot no. B-10, Add. MIDC, Jalna, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 98232984905, 9975656193Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: September, 1995
Type of Company: Proprietorship
Company’s Specialization/Product/Services: • Manufacturing Of Krushi Pipes• Manufacturing Of Polythylene Sheets Upto 12’wide• Manufacturing Of Jerry Cans,1lit, 2lit & 5 lit Capacity• Polythylene Bags• Reprocessed Granules
Affiliated units/sister concern/subsidiary: N. A.
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
Ulka Plastic IndustriesMIDC, Jalna, Aurangabad
1 Mr. Subhash Wamanrao Thete
63 Owner DME, BE-CIVIl
Exp. In Marathwada Sheti Sahayya Mandal
9823984905
Details of the Owner/Director Family members:
Sr. N
o.
Fam
ily M
embe
r
Rel
atio
n to
the
Ow
ner o
f th
e C
ompa
ny
Age
(in
Year
s)
Educ
atio
nal Q
ualifi
catio
n
Wor
k Ex
peri
ence
pri
or to
jo
inin
g th
e C
ompa
ny
Invo
lved
in C
ompa
ny’s
busi
ness
act
iviti
es (Y
es/N
o)
Rol
e in
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Ulka s thete
Wife 62 Bachlor of Arts
EDP Train-ing BY MCED
Yes Management
2 Sachin S. Thete
Son 36 DCE, Civil Enggineer
Civil Enggi-neering
Yes Production & Marketing
3 Pallavi S. Thete
Daughter in law
29 M. com Ac-countant
Yes Accounting / Finance
4 Dr. Swati S. Thete
Daughter 38 BHMS Consult-ant
Yes Medical Assis-tance
5 Swapnil S. Thete
Son 33 B-Arch Consult-ing
Yes Production & Supervision
327 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name /
Govt. AssistanceYear Purpose Amount (Rs.) Status (Ac-
tive/Closed)1 Maharashtra State
Finance Corpo-ration
1995 For land and Building
178750 Closed
2 State Bank of India
1996 C. C. 150000 Closed
Affiliated units/sister concern/subsidiary:Sr. No. Unit name Product / Service Address Contacts
1 Ulka Associates Architectural Consultancy B-Add. MIDC. Jalna 99756561932 U A D P P Architectural Consultancy B-Add. MIDC. Jalna 9823984905
Vendor Code Details:Vendor Code
Customer Issued in
Products Supplied Last Audit by Customer
1 Gujarat Oil Depot. Sillod - Krushi Pipe -2 Bhansali M/C Rahata - Krushi Pipe -
3 Ambika General Stores, Jalna
- Jerry Cans -
Production capacity of the Unit:Year Production capacity2013-2014 5 Mt / year2013-2012 50 Mt / year2012-2011 200 Mt / year2011-2010 5000 Mt / year2010-2009 600 Mt / year
Types of Customer:Type Total number of
CustomersNames/List of Customers Products
ManufacturedAgricultural / Irrigation
154 - -
Consumer Products
58 - -
Total number and List of Vendors or Suppliers: 25
Total number of Employees at the company: 28
Organization Chart:
Administrative Officer
Office Staff Skilled worker Unskilled worker
Manager Accountant Supervisor Marketing Officer
Proprietor
Types of Business: OEM
Area of the Unit:Plot Area 1000 Sq. mtr.Total Built-up Area 310 Sq. mtr.
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2009-2010 8 lacs 8 lacs 0.8 lacs2010-2011 9 lacs 2.5 lacs 1 lacs2011-2012 9 lacs 2.5 lacs 1 lacs2012-2013 7 lacs 1 lacs 0.5 lacs2013-2014 (expected) 2 lacs 0.5 lacs 0.25 lacs
328 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Company Plant and Process FlowCompany’s Plant layout:
Manufacturing Unit
Store
Office Waiting
area Office
Toilet
Block Store
FoodCourt
Garden
Parking
M. I. D. C. Road
Types of Machines
Sr. N
o.
Nam
e of
M
achi
ne
Qua
ntity
Mak
e of
m
achi
ne
Pric
e of
the
Mac
hine
(R
s.)
Year
of
Purc
hase
Loan
/ by
Self
1 Extruder 90 mm 01 Raj Machinery, India 2 lacs 2011 30% selfand 70% loan
2 Extruder 60 mm 01 Raj Machinery, India 1.5 lacs 2011
3 Extruder 40 mm 01 Raj Machinery, India 1 lacs 20114 Mixer 01 Raj Machinery, India 1 lacs 20115 Grinder 01 Raj Machinery, India 0.5 lacs6 Cutter 01 0.15 lacs7 Sealing & Cutting 01 Raj Machinery, India 0.80 lacs8 Air Compressor 01 0.15 lacs9 Generator 01 0.80 lacs10 Take up/Mould 01 1 lacs
Types of Hand Tools: Set of spanners, Set of Hammers and Chisels
Raw materials
Sr. N
o.
Raw
Mat
eria
l
Cur
rent
Rat
e (R
s. Pe
r K
g)
Spec
ifica
tion
Supp
lier’s
Nam
e
Min
imum
qua
ntity
m
aint
aine
d in
the
com
pany
per
mon
th
Prod
uct M
anu-
fact
ured
with
the
mat
eria
l
Prod
uct S
uppl
ied
to
(OEM
/Tie
r 1 su
pplie
r/Ti
er2
Supp
lier/
Tier
3
Supp
lier)
1 lDPE 126.23 20FS040 Distributors 50 MT 49 MT
2 llDPE 118.57 FIlM 71601D
Distributors 30 MT 25 MT
3 HDPE 117.25 HDBM B6401
Distributors 1 MT 0.80 MT
4 Master Batches
400.00 - Distributors 50 KG --
5 lDPE 90.00 - local Manu-facturers
5 MT 4.7 MT
329 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Warehouse/Storage of Raw material (Inventory Control Techniques)Order Quantity: As per Stock RegisterOrder Process: As per Stock RegisterQuality Control: As per Stock Register
Information of Workers, Supervisors, Managers and Staff for cleaning
Shift Timings: N. A.
Number of Shifts per day: N. A.
Sr. N
o.N
ame
of w
orke
r
Age
(yrs
)
Gen
der (
M/F
)
Wor
kers
/ Su
perv
isor
/M
anag
er /
Staff
fo
r cle
anin
g
Qua
lifica
tion
Ope
ratio
n /
Func
tion
Year
s of e
xper
i-en
ce in
Indu
stry
Wor
king
hou
rs
/ day
1 B. S. KHODKE 50 M Manager SSC Quality & Production
22 12
2 Vijay Reddy 47 M Operator M.com Operator 20 123 K. S. KHODKE 44 M Operator HSC Operator 18 124 KASIM SHAIKH 52 M Operator 9th Operator 12 125 ANKUSH SHINDE 35 M Helper HSC Helper 9 126 MANOJ GAIKE 25 M Helper SSC Helper 6 127 ANSHIRAM
KACHRE30 M Helper HSC Helper 4 12
Functions/Operations in the company:Function / Operation
Required Qualification of workers
Required number of workers
Shortfall of workers
Number of hours /shift
Number of shifts/day
OPERATOR TECH.QUAlI-FIED
03 03 12 2
HElPER MIN. S.S.C 03 -- 12 2ClEANING S.S.C 15 -- 12 2
Business Process FlowRaw Material
Purchase Production Transport Supply to Distributors
Manufacturing Process FlowThe rotational moulding process for manufacturing water storage tank consists of the following major process steps.
Heating the Extruder by
Heaters
De-moisturisa-tion of Granules
in Mixer
Feeding Gran-ules in Feeder Zone of Ex-
truder
Extrusion Process
Pass product through
Conveyor’s/Take-ups
Machine operations:
Sr. N
o.
Mac
hine
na
me
No.
of
labo
rs
requ
ired
pe
r ma-
chin
e
Tim
e re
quir
ed
for
proc
ess
Idle
tim
e pe
r shi
ft of
8 h
rs
Was
tage
%
1 EXTRUDER 90MM 3 2 HRS 1 HR 3
2 !EXTRUDER 60MM 3 1.5 HRS 1 HR 2 3 EXTRUDER 40MM 3 1.25 HRS 1 HR 2 4 MIXER 1 15 MIN -- 0 5 GRINDER 1 5 MIN -- 0 6 CUTTER 1 2 MIN -- 0 7 SEAlING & CUTTING 2 2 MIN -- 0 8 AIR COMPRESSOR 1 2 MIN - 0 9 GENERATOR 1 5 MIN --10 TAKE UPS 3NOS 3 5 MIN -- 0
Products manufactured at the Company:Sr. No.
Product Name Cost to Company
Price to Customers
Repeat Order
Supplied to
330 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
1 KRUSHI PIPES 139.23 RS/KG 144.23 RS/KG Yes All over Maharashtra2 JERRY CANS 1lIT,
2lIT, 5lIT95.8, 112.56, 211.0PER DOZEN
50.8, 80.56, 175.0PER DOZEN
Yes
3 POlYTHElENE SHEETS
142.75 RS/KG 150.23 RS/KG Yes
4 POlYTHElENE BAGS
125.23 RS/KG 134.23, RS/KG Yes
Quality Control PlanProject Documentation: No Document
Quality Control Procedure: (In house/ External agency)
AS PER REQUIREMENT OF CUSTOMER
Testing of Raw Materials (Incoming - Quality Control Techniques)
ONlY BY IDENTIFICATION, NO TECHNICAl TESTING
Budget allocated for Research & Development (Annually in Rs.)
No
IT/CAD/Softwares/CAM used in the Com-pany
Auto CAD 2012 USED
Exhibition/trade shows visits:
Sr. N
o.
Exhi
bitio
n / S
how
Part
icip
ant /
V
isito
r
Last
atte
nded
(Y
ear)
Fees
(in
case
the
com
pany
par
tici-
pate
d)
Bene
fits
1 Maha Expo 97 Participant 1997 Rs.7000/- Increase in sales
Safety standards in the Company:Manufacturing Op-erations
Possible accidents / hazards
Safety measures in the company
Remedies / Medication
EXTRUSION BlOW MOUlD OPERA-TION
BURNING FIRE EXTINGUISH-ER,SAND BUCK-ETS,WATER TAPS
FIRST AID BOXES/MEDICAl CONSUlTANT
Marketing and Branding:Describe the Company’s Target Market
Brand Awareness in respective markets SCREEN PRINTING - 5000 RS/-
Initiatives taken to promote the Brand and Respective expenses
N. A.
Online services No
Company Label: Sr. No. Labelling
typeLabel speci-fication
Material used
Vendor name/ In house
Machine details if produced In house
1 STICKERS UlKA KRUSHI PIPES
PAPER! -- --
Company Packaging: Sr. No.
Packaging type
Packaging specifica-tions
Material used
Vendor name/Inhouse
Machine details if produced Inhouse
331 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
1 BAGS -- POlY PROPE-lENE
-- --
Marketing and Branding:logo of company:
Effectiveness of the company logo Medium
Brand Awareness in respective markets; whether B2B or B2C
low
Finance & AccountsProcess of Pricing:
KRUSHI PIPES - 1. COST OF RAW MATERIAl- 126.23 RS/KG.2. ENERGY CONSUMPTION - 5.0 RS/KG.3. lABOUR CHARGES - 1.50 RS/KG.4. TRANSPORTATION - 1.00 RS/KG.5. COlOUR’S & ADDITIVES - 2.00 RS/KG.6 PACKAGES - 1.00 RS/KG.7. WASTAGES - 2.50 RS/KG.8. PROFIT - 5.00 RS/KG. ----------------- 144.23 RS/KG.
Human Resource Management
Training Policy for the new recruits and already employed with the compa-ny: No
Leave Policies: Depends upon need of employee
Overtime Policy: As per hour policy
Insurance/Medi-claim Policy: Medi-claim Policy
Wage Rate Policy: As per Govt. rules
Salary Structure: Rs. 12000 for machine operators, Rs. 15000 to 18000 for Supervisors and Rs. 18000-20000 for Manager.Male & Female Employees:
Staff Number of staff
Profile (Machine Operator / Supervisor / Manager / Helper / Cleaning Staff)
Years of experience in the Company
Machine details if produced In house
Male 22 Operator / Supervisor / Manager / Helper
5 to 20 No
Female 08 Cleaning raw material N. A. No
Assistance required from Government in the following areas: Yes
Assistance by CIPET, Aurangabad: Designing of Moulds etc.
Assistance by IGTR, Aurangabad: No
Assistance by ITI, Aurangabad: : Trained Worker’s
Assistance by MCED, Aurangabad: : Training
SWOT Analysis of the Company
332 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
STRENGTHS• Good market for Krushi pipe• Water supply availability• Supply of electricity for 24 hrs• No pollution.• Enough work space.• Availability of transportation.
WEAKNESSES• Energy consumption is more• low production by machines• labour problems• Mostly manual work• Rate fluctuations by raw material
supplier’s (reliance changes rates for every 15 days.
• low finance, no bank credits• No automation
THREATS• No threats
OPPORTUNITIES• Working for farmers
Future Plan of the CompanyTime-lines
Plan Assistance required by the Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months Designing of new products
Design assistance & Training for modification of ma-chines & moulds
Modification & Expansion of unit
1 year Modification & installa-tion of automated ma-chine and start for new product production
Finance min. 90 lacks Modification & Expansion of unit
3 years Production & marketing Cash credit for working Capital
Modification & Expansion of unit
5 years Adoption of latest tech-nology & research for innovation
Assistance for research Modification & Expansion of unit
Product Design Brief
Design Brief
To design, modify & converting old machinery to new latest tech-nology with Atomisation of following products-1. Drip irrigation pipe2.hdpe pipes3.pvc pipes4. Krushi pipes5. Poly sheets for Agriculture farm tank
Plan of the Design ProjectProduct Design Brief specifications
As per machine manufacturer and designer
Proposed Design Process Design of moulds, electric/ electronic panels, heaters, conveyors, take-ups & modify old m/c or purchase of new machine, etc.
Time-line Within 6 monthsBudget 90 lacksTeam members & Skills Required
10
Benefits for the Company Modification and expansion of Unit
333 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
334 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
335 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations SatisfactoryWorkplace & Ergonomics Need to improvePlant layout Improvement Space management is a concernNew Product Development No in-house product development process
followedPackaging Need to improveMarketing Market awareness is a problem. No effective
marketing for business growthHuman Resource Training initiatives for the workers need to
improve
Business DesignMarketing Needs to improvelogo Design Needs to developVisiting Card Needs to developBrochures & leaflets Need to developWebsite Need to develop
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear and thus the productivity of machines can be im-proved. Some research and development work to be done so that the depend-ence on the manual work can be reduced. Some part of profit has to be kept for such activities. Processes need to be streamlined to reduce the electricity
wastage.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations. Forward contracts can be done with the raw material supplier to reduce the variation in the price of raw material.
Financials: Three major categories where the company focuses on are:i) Automobile, ii) Electrical and iii) luggage. In order to provide regular fund-ing, the company may be linked to the respective corporate houses as dedicat-ed vendor through Government interventions involving agencies such as CII and FICCI.
Product: Product testing should be done at various levels and report can be prepared to increase customer confidence.
Human Resource: To reduce Employee attrition rate, the salary levels need to be revised to attract better skilled manpower.
Marketing:• A website need to be developed on urgent basis so that the customer reach
can be extended.• It requires more publicity on retail level. It urgently requires a logo so that
customers identity the product with the company. A proper branding strat-egy should be formalised to get maximum visibility in the market.
• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers.
• A company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the de-velopment process.
336 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
2
31
25V.
P. P
etPo
lymer
337 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: V. P. Pet PolymerAddress of the Company: Plot no. E-97, MIDC, Waluj, Aurangabad Maharashtra, Indialandline number: 0240 - 3264000Mobile Number: 9595699555, 9370146402Company e-mail id: [email protected]: www.vppetpolymers.com Company started in: 2007
Type of Company: Proprietorship
Company’s Specialization/Product/Services:• Pet Jar• Pet Bottle• HDPE Bottle and Jar• PP Bottle and Jar
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Mrs. Jayshree Navnath Somase
38 Owner 12th No [email protected]
9370146402
V. P. Pet PolymerMIDC, Waluj, Aurangabad
Details of the Owner/Director Family members:
Sr. N
o.Fa
mily
Mem
ber
Rel
atio
n to
the
Ow
ner o
f the
Com
-pa
ny
Age
(in
Year
s)
Educ
atio
nal Q
ualifi
-ca
tion
Wor
k Ex
peri
ence
pr
ior t
o jo
inin
g th
e C
ompa
ny
Invo
lved
in C
ompa
-ny
’s bu
sine
ss a
ctiv
i-tie
s (Ye
s/N
o)
Rol
e in
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Navnath K. Somase
Husband 46 10th 15 Yes Pro-duction Man-ager
9325108445
2 Vaibhav N. Somase
Son 22 12th 0 Yes Plant Head
9595699555
3 Pranjali N. Somase
Daughter 17 12th 0 No - - -
Company’s Initial Investment: 8 lacs
Loan/Financial Assistance taken since the start of the company:Sr. No.
Bank Name / Govt. Assistance
Year Purpose Amount (Rs.) Status (Active/Closed)
1 Dena Bank 2007 Machineries 25 lacs (20 lacs term loan and 5 lacs C/C)
Closed
Loan/Financial Assistance taken since the start of the company:Sr. No. Unit Name Product/services Address Contacts
1 lelashree Plastics PET Preform MIDC, Waluj Aurangabad 9595699555
338 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Production capacity of the Unit:Year Production capacity2013-2014 40 lac Bottles2013-2012 30 lac Bottles2012-2011 25 lac Bottles2011-2010 15 lac Bottles2010-2009 10 lac Bottles
Types of Customer:Type Total number
of CustomersNames/List of Customers Products
ManufacturedPharmaceutical N. A. Sydler Remedies Pvt., ltd. at M-190,
MIDC, AurangabadPet jar
FMCG N. A. Ravi Masale, MIDC, Chikalthana, Aurangabad
Pet jar
Total number and List of Vendors or Suppliers: 38 (Thirty Eight)
Total number of Employees at the company: 10 (permanent) and rest on contract as per the work load
Types of Business: OEM and Business Type Products Products supplied toAs a Tier 1 Supplier to OEMAs an OEM
Area of the Unit: Plot Area 10000 sqTotal Built-up Area 3200 sq
The factory plot is taken on rent for and amount of Rs. 21000.
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2009-2010 10658739 1711752 6192502010-2011 12674833 2064135 769046
2011-2012 16053226 3789195 752246
2012-2013 17900435 6105194 1032640
2013-2014 (expected) 43590230 10897557 3000000
Certifications:Certification Description of the Certification Year taken inISO 9001-2008 2012
Types of Machines
Sr. N
o.
Nam
e of
M
achi
ne
Qua
ntity
Mak
e of
m
achi
ne
Pric
e of
the
Mac
hine
(R
s.)
Year
of
Purc
hase
Loan
/ by
Self
1 Hot filling machine 1 Technopet 717806 2011-12 Nil
2 Blowing machine 1 Technopet 1035437 2011-12 Nil
3 Stretch Blowing machine 1 Technopet 978468 2011-12 Nil4 Injection moulding ma-
chine 1 Electronics plas-
tic machine1716130 2011-12 loan
5 Printing machine 1 Techno print 270000 2011-12 Nil6 5 ltr Double station Blow
moulding machine1 Jagmohan 2691525 2012-13 loan
Raw materials
Sr. N
o.
Raw
Mat
eria
l
Cur
rent
Rat
e (R
s. Pe
r Kg)
Supp
lier’s
N
ame
Prod
uct M
an-
ufac
ture
d w
ith
the
mat
eria
l
Prod
uct S
up-
plie
d to
(OEM
/Ti
er 1
supp
lier/
Tier
2 Su
pplie
r/Ti
er 3
Sup
plie
r)
1 Pet Preform 126 Novel Plast Jar, Bottle OEM
2 Granules 112 Polygram Industries
Preform OEM
339 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Company’s Plant layout
Injection Moulding machine
Grinder
Stretch blow Moulding
Stretch blow Moulding
Stretch blow Moulding
Finished Goods area
Office
Office
Stretch Moulding machine
labelling Glue ma-chine
Blow Moulding machine
Com
pres
sor 5
Com
pres
sor 4
Com
pres
sor 3
Com
pres
sor 2
Com
pres
sor 1
Store room
Parking area
Entrance
Main road
Cooling tower
Mould Area Assembly Table
Information of Workers, Supervisors, Managers and Staff for cleaning
Sr. N
o.
Nam
e of
wor
ker
Age
(yrs
)
Gen
der (
M/F
)
Wor
kers
/ Su
perv
isor
/M
anag
er /
Staff
for
clea
ning
Qua
lifica
tion
Ope
ratio
n / F
unct
ion
Year
s of e
xper
ienc
e in
In
dust
ry
Wor
king
hou
rs /
day
1. Vaibhav M. Somase
22 Male Plant Head 12th, Diploma
5 12
2. Krishna H. Mheisane
32 Male Manager B. Com 5 8
3. Navnath K. Somase
46 Male Production Manager
12th 15 12
4. Gopal Solanki 24 Male Supervisor 12th 5 125. Krishna
Solanki22 Male Worker 12th 3 12
6. Uday Divede 27 Male Operator 12th 5 127. Sandir 27 Male Operator 12th 5 128. Vikas Hevele 25 Male Operator 12th 5 129. Ravi
Bhalkhanch 25 Male Driver 12th 5 12
Functions/Operations in the company:Function / Operation
Required Qualification of workers
Required number of workers
Shortfall of workers
Number of hours /shift
Number of shifts/day
Production 12th 9 2 12 2
Manufacturing Process Flow
Raw material Heating Blowing Cooling Finished Goods
340 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Machine operations:Sr. No. Machine name No. of labors required per machine
1. Hot filling machine 22. Blowing machine 23. Stretch Blowing 24. Injection moulding Machine 15. Blow Moulding 3
Exhibition/trade shows visits:
Sr. N
o.
Exhi
bitio
n /
Show
Part
icip
ant /
V
isito
r
Last
atte
nded
(Y
ear)
Fees
(in
case
th
e co
mpa
ny
part
icip
ated
)
Bene
fits
1. Maharashtra Advantage Expo-2014
Participant 2014 37000 New business
Marketing and Branding:logo of company:
Effectiveness of the company logo High
Brand Awareness in respective markets; whether B2B or B2C
High
Initiatives taken to promote the Brand and Respective expenses
• Online marketing• Most Important satisfactory customer• Person to person marketing
Online services Yes
Company Packaging: Polypack and cardboard boxes
What is Design ‘‘Unique products for everyday problems. It should also be aesthetically appealing and market friendly’’
Process of PricingCost break up for Food Rite, IndiaPreform Cost 129Neck Size 96 mmPreform weight (+/- 2 gms) 70Preform rate 9.03Cap rate/piece 1.85Packing rate 0.08Transport rate 0.15Blowing rate 1.15Total 12.26Profit 13% [email protected]% 1.64Total 14.89VAT@5% 0.74FINAL RATE 15.63
Human Resource ManagementEmployment recruitment rules
New recruitment are made based on the qualities such as experience in the plastic industry leadership qualities good communication skills manpower management skills, etc.
341 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Training Policy for the new recruits and already employed with the company:For New Recruits For Already Employed
Machine Operator 2 2Supervisor 2 2Manager 1 1Helper/Cleaning Staff 1 1
leave Policies:Staff Leave PolicyMachine Operator Weekly OffSupervisor Weekly OffManager Weekly OffHelper/Cleaning Staff Weekly Off
Insurance/Medi-claim Policy: N. A.
Salary Structure:Staff For Fresher
(in Rs.)With experience of 3 years (in Rupees)
Training required, if yes then please mention the training
Machine Operator 6000 9000 N. A.Supervisor 8000 10000 N. A.Manager 10000 12000 N. A.Helper/Cleaning Staff 4000 6000 N. A.
Male & Female Employees:Staff Number
of staffProfile (Ma-chine Operator / Supervisor / Manager / Helper / Clean-ing Staff)
Hometown (Aurang-abad/Outside Au-rangabad but within Maharashtra/Outside Maharashtra)
Years of experience in the Company
Machine details if produced In house
Male 4 2 4 3 -Female - - - - -
SWOT Analysis of the CompanySTRENGTHS• Quality manufacturer of PET
bottles in Aurangabad
WEAKNESSES• The company is running on a rent-
ed factory space
THREATS• Too much dependency on big
companies• Increasing price constraints
leading to low profits
OPPORTUNITIES• Supply of PET and Blow-moulding
bottles to Pharmaceutical companies and liquor companies
Future Plan of the CompanyTime-lines Plan Assistance required by the Government
(Finance/Training/Design Assistance, etc.) Benefits for the Company
1 year Own factory space
Subsidies for machineries and land Benefits for the Company
Product Design BriefDesign Brief 1 Innovative Pet jars, Pet bottles, HDPE & P. P. Jars & Bottle.Design Brief 2 Innovative PET bottles for Fridge
Plan of the Design ProjectProduct Design Brief specifications
Various types of Plastic products
Proposed Design Process N. A.Timeline 1 yearBudget Rs. 10 lacsTeam members & Skills Required
• Industrial Designer• Technical Engineer
Benefits for the Company It will create brand value and build business con-fidence and more profitability
342 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The previous company’s name is still seen on the wall.
Special mention of the sponsoring bank.
The injection moulding machine. The area is clean and has sufficient space around it.
The box of PET Preform as received from the vendor.
343 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The stack of finished goods is well maintained.
The cartons are too close to the machine.
344 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Needs proper arrangement for moulds maintenance and should be ergonomically fit for the workers.
The packaging plastic quality is inferior.
345 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The blow moulding process.
The product inspection is in progress
The blow moulding process.
The PET jars are thrown which may damage the finished products.
346 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The machine needs proper arrangement w.r.t. it’s pipes
The flooring needs to be cleaned and maintained
The work area needs to be cleaned and maintained
347 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The entrance needs to be cleaned and maintained
The chiller area needs to be cleaned and maintained
The moulds needs to be arranged properly
The compressor area needs to be cleaned and maintained.
348 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The pipes are not arranged properly.
Improper approach for machine maintenance
The cartons are too close to the machine. The machine is hidden
349 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Blow moulding machines. The area is maintained clean
The samples of jars produced by the unit
Company’s branding on office vehicle.
Company’s branding on transport vehicle.
350 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Need to improveWorkplace & Ergonomics Need to improvePlant layout Improvement Space management is a concernNew Product Development no in-house product development process
followedPackaging Need to improveMarketing Market awareness is a problem. No effective
marketing for business growthHuman Resource Training initiatives for the workers need to
improve
Business DesignMarketing Needs to improvelogo Design Needs to developVisiting Card Needs to developBrochures & leaflets Need to developWebsite Need to improve
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear and thus the productivity of machines can be im-proved.
R&D budget to be planned to develop new products.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Product: Company currently producing only one type of product (pet jars), it should venture into other categories to reduce the business risk. Product testing should be done at various levels and report can be prepared to increase customer confidence.
Human Resource: To reduce Employee attrition rate, the salary levels need to be revised to attract better skilled manpower. Proper training should be formulised to improve the skill of the workers.
Marketing:• A website need to be up graded on urgent basis so that the customer reach
can be extended.• It requires more publicity on retail level. It urgently requires a modifica-
tion in a logo so that customers identity the product with the company. A proper branding strategy should be formulised to get maximum visibility in the market.
• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers. A company should participate in trade fairs related to plastics to attract new customers
• A company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the de-velopment process.
351 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
2
31
26Va
rroc P
olym
er(T
ech.
R&D)
352 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Varroc Polymers Pvt. ltd. (Technical Center: R & D)Address of the Company: M – 138/139, MIDC, Waluj, Aurangabad, Pin: 431136, Maharashtra, IndiaLandline number: 0240-6676196Mobile Number: 9673001490Company e-mail id: [email protected] No.: N. A.Website: www.varrocgroup.com Company started in: 2010
Type of Company: Private limited
Company’s Specialization/Product/Services• Body Parts: 2W/3W/4W• Mirror: 2W/3W• Seat: 2W/3W• Af: 2W
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Tarang Jain 48 Owner MBA 10 -- --
Varroc Polymer Pvt. Ltd. Tech. CentreMIDC, Waluj, Aurangabad
Company’s Initial Investment: 16 Crores
Loan/Financial Assistance taken since the start of the company: NA
Vendor Code Details: NA
Production capacity of the Unit: NA (No Production Plant)
Types of Customer:Type Total number of
CustomersNames/List of Customers Products
ManufacturedAutomotive - • Bajaj Auto
• Mahindra & Mahindra• Volkswagen & Skoda• General Motors• Honda• Yamaha• Harley Davidson• Volvo
Moulding, Painting, Assembly, PU Foam Moulding, etc.
Total number and List of Vendors or Suppliers: 10
Total number of Employees at the company: 84
Types of Business: Tier 1 supplier to OEMs
Area of the Unit:Plot Area 40000 Sq. feetTotal Built-up Area 32528 Sq. feet
353 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Organization Chart & Resources
354 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Certifications: Department of Scientific and Industrial Research (DSIR)
Business Competitors:Sr. No.
Competitor’s name Competitor’s Product Specialization
Type of Business (Exporter/OEM/Tier 1 Supplier/Tier 2 Sup-plier / Tier 3 Supplier
1 Motherson Automotive Product Tier 12 Mahalle Automotive Product Tier 13 Field Guard Automotive Product Tier 1
Company Plant and Process FlowTypes of Machines:Tool Room • 5 Axis Double column computer numerical control
M/c• High Speed Graphite Milling M/c• Deep Hole Drilling M/c• Drilling M/c• Injection Molding M/c• Die Spotting Press M/c• Double Column Electrical Discharge M/c• Continuous 5 Axis Horizontal M/c• Crane
Prototyping • Hot Melt Pleating Machine• Polyurethane Dispensing Machine• Air Filter Mould – Pneumatic Press
Testing • Air Filter Test Rig• Pore Size Meter• Particle Counter• Burst Strength tester• Vibration Meter• Weighing Balance• Crock Meter• Digital Torque Wrench• Shore Hardness Tester• Modular Fixture• Portable portable coordinate measuring M/c
Reverse Engineering • White light Scanner
Raw materials
Sr. N
o.
Raw
Mat
eria
l
Cur
rent
Rat
e (R
s. Pe
r Kg)
Spec
ifica
tion
Supp
lier’s
N
ame
Min
imum
qu
antit
y m
ain-
tain
ed in
the
com
pany
per
m
onth
Prod
uct M
an-
ufac
ture
d w
ith
the
mat
eria
l
Prod
uct
Supp
lied
to
(OEM
/Tie
r 1
supp
lier/
Tier
2 Su
pplie
r/Ti
er
3 Su
pplie
r)
1 Polypropylene (PP)
- - - - Seat, Af -
2 Polyethylene (PE)
- - - - - -
3 Polyurethane (PU)
- - - - Seat foam -
4 Nylon (NY) also known as Polyamide)
- - - - Radiator Tanks
-
5 Acrylonitrile Butadiene Sty-rene (ABS)
- - - - Body Parts -
Number of Shifts per day: One general shift
Products manufactured at the Company: NA
Quality Control PlanProject DocumentationDoes the company maintain Documents for every Project?
Yes
Quality Control Procedure: (In house/ External agency)
In house / ARAI
Testing of Raw Materials (Incoming - Quality Control Techniques)
In-house: C Q A lab
355 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of Testing Labs for Raw Materials (tie-ups for Raw Materials)
In-house: C Q A
Name of Testing Labs (tie-ups for Finished Products)
CQA
Testing of Finished Products In house as applicable
Quality Standard for Product: As per customer requirements
Design & DevelopmentDesign & Engineering Capabilities:• Bench Marking • Styling proposals• 3D Cad data Feasibility and drawing conversion• Reverse Engineering• Product Re-engineering• Styling (‘A’) surface to product Design• New product design• Rapid Proto typing• VA / VE / Poka Yoke• Design Optimization through CAE• Plastic flow simulation through mold flow• Structural analysis• CFD analysis• Jigs / Fixtures / SPM design
Project Organization:
Business Head
Project Manager
lead Engineer
Quality EngineerPlant NPD Team
Plant Head
MFG EngineerMFG Team
Sales
Supplier & VD
FeasibilityStudies Kick off
Production Part Approval Process
Execution &Validation Ramp Up
Budget allocated for Research & Development (Annually in Rs.)
1 crore
IT/CAD/Softwares/CAM used in the Company
Catia, Unigraphics
Safety standards in the Company:Possible accidents / hazards Safety measures in the company Remedies / MedicationZero Fire Extinguisher, Safety alarm,
Smoke detectors and Fire Hy-drant System
First Aid BoxAmbulance
356 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Marketing and Branding:logo of company: ogo of company:
Effectiveness of the company logo High
Brand Awareness in respective markets; whether B2B or B2C
Medium
Online services No
Finance & AccountsComponent_ Cost Break UPItem name Unit Bracket
RHD_MTC
Bracket RHD-Disel
Lever Clutch RHD
Pedal Pad MTC_RHD
Hous-ing
Drawing No. - 102P-J3084
102P-J3033 102P-J3086
102P-J3098
Item no. 1 2 3 4Mould Cost Assumption
RS 0 2000000 785000 415000 0
Delivery Period Weeks 10~12 weeks
10~12 weeks 10~12 weeks
8~10 weeks
Material As-sumption
- PP CP GF 20% BlACK SEB 200
PP CP GF 20% BlACK SEB 200
PP CP GF 20% BlACK SEB 200
PP CP GF 20% BlACK SEB 200
PP
Colour - Black Black Black Black BlackNet. Wt. gms 1337 1060 365 31.4 100Runner gms 100 80 12 7 6Shot wt. gms 1437 1140 377 69.8 106Cavity nos 1 1 1 2 1Recon. Wt. gms 1483.9 1177.0 392.9 35.8 109.8Raw matl. Cost Rs/kg 140.00 140.00 120.00 120.00 120.00Raw matl. Cost/piece
Rs/piece
207.7 164.8 47.1 4.3 13.2
Cycle time secs 90 90 80 60 60Prod. Per shift nos/
shift293 293 330 880 440
Production @ 90 % effeciency
nos/shift
264 264 297 793 396
M/c used Tonns 1800 1800 300 180 250M/c tariff Rs/shift 18000 18000 3000 1800 3000Moulding cost Rs/
piece68.2 68.2 10.1 2.3 7.6
Inspection and packing cost
Rs/piece
0.8 0.8 0.3 0.2 0.3
Subtotal Rs/piece
276.8 233.8 57.5 6.8 21.1
Rejections @ 5 %
Rs/piece
13.84 11.69 2.88 0.34 1.05
Profit +over-head @ 10 %
Rs/piece
27.68 23.38 5.75 0.68 2.11
Poly bag cost Rs/piece
0 0 0 0 0
Packing box cost
Rs/piece
1.0 1.5 0.9 0.6 0.2
Plating Cost Rs/piece
- - - - -
357 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Total Com-ponent Price
Rs/piece
319.26 270.36 67.08 8.38 24.41
Terms & Conditions:• Above price is basic price. Other taxes will be as applicable.• For making of moulds 60 % advance along with PO balance against first
trial.• For supply of components payment within 30 days after despatch from
our end.• Above rates are ex our works K-151, MIDC, Waluj.• Cost is subject to change if there will be any change in material ,product
design or raw material rate.• Packing cost of polybag is extra if needed.• Component wt. considered as per given by you.
Human Resource ManagementEmployment recruitment rules As per policy given by corporate. Recruitment is
done only through references.
Training Policy for the new recruits and already employed with the company:For New Recruits For Already Employed
Supervisor Technical Induction As per new IdentifiedManager Technical Induction As per new Identified
leave Policies:Staff Leave PoliciesMachine Operator NASupervisor As per policy (24 - Pl, 6 – Cl, 6 – Sl)Manager As per policy (30 - Pl, 6 – Cl, 6 – Sl)Helper/Cleaning Staff NA
Mediclaim Policy: Mediclaim Policy from Bajaj Alliance for managers.
Salary Structure: N. A.
Covered under ESI/EPF/Gratuity: EPF
Compensation Plan for workers in case of injury or accidents: Medical Policy
Career Graph Plan for Employees: Career plan as per policy
Retention Policies and Welfare Schemes: As per Policy
Assistance required from Government in the following areas:
Assistance by CIPET, Aurangabad: One year Trainee
SWOT Analysis of the CompanySTRENGTHS• Innovative• The Value Methodology: Value
Engineering (VE) & Value Anal-ysis (VA)
• Reverse Engineering• Benchmarking• Computer-Aided Designing &
Computer-Aided Engineering
WEAKNESSES• Workaholic employees• Work life balance• late staying
THREATS• Competition
OPPORTUNITIES• New business of AF / Seat & Body
parts• Tapping market for Four-wheeler
Dash board
358 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Future Plan of the CompanyTime-lines
Plan Assistance required by the Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
1 year Build In-house Design capability of seats
Design Assistance New Opportu-nity
Product Design BriefDesign Brief 1
300 seat Assembly to be Designed for auto Rickshaw segment. Help needed in market Survey, Market Potential competition analysis, feedback from OEMs.
Design Brief 2
Design calculation of concepts.
Design Brief 3
Product Design with simulation result.
Plan of the Design ProjectProduct Design Brief specifications To be discussed laterProposed Design Process To be decided laterTime-line To be decided laterBudget To be decided laterTeam members & Skills Required To be decided later
Benefits for the Company New Business opportunities
359 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Company’s product range on display
Company’s product range on display
Good management practices
360 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Company’s work area is clean and well maintained
Mould’s finishing process Mould’s finishing process
Company’s work area is clean and well maintained
361 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The worker’s wrong posture while working on the mould. The mould is kept on temporary arrangement.
The grinding process needs to be in a separate area.
The hanging crane bring used to shift heavy loads.
362 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
The grinding process The grinding process
The worker’s wrong posture while working on the mould.
363 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
No safety gears used while working on the machine.
The wrong posture of the workers will make them suffer from work-related diseases.
364 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement • Space arrangement is a concern as the
plant area is congested• No use of Natural light
New Product Development No in-house product development process followed
Packaging Need to improveMarketing • Market awareness is a problem. No
marketing for business growth• Good branding material available• Sample swatches are available
Human Resource • Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to get into household products, it can also explore product diversification in the home decor and kitchen products.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• Branding exercise needs to be conducted on priority basis as the company
aspires to get into the household product segments. Trademark registration should be taken to protect equity and prevent litigation in future.
• There is a huge dependence on one customer which might harm the busi-ness in the long run. Increasing the customer base is mandatory for long term sustenance and growth.
• Assistance should be provided to the company to set up their stall in exhi-bitions to highlight their products to the retail and manufacturing partners.
• Re-structuring of the website to increase vendor accessibility.• As the company plans to get into retail consumer segments like plastic
buckets, jugs, mugs etc. it should develop its distribution channel to reach out to the right target market.
365 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
2
31
27Yo
gesh
Plas
ticIn
dustr
ies
366 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Name of the Unit: Yogesh Plastic IndustriesAddress of the Company: Plot no. A-114/3, Five Shendra, MIDC, Aurangabad, Maharashtra, Indialandline number: 0240-2622422Mobile Number: 9403759542, 8087428329Company e-mail id: [email protected] Company started in: 2011
Type of Company: Partnership
Company’s Specialization/Product/Services: Agro Shade Net
Affiliated units/sister concern/subsidiary: N. A.
Details of the Owners / Partners:
Sr. N
o.
Nam
e of
Ow
n-er
/ Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wne
r / P
artn
er)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail
Id.
Phon
e nu
mbe
r
1 Yogesh Vrajlal Parmar
38 Partner SSC 10 Yrs [email protected]
9403759542 8087428329
2 Pradeep Vrajlal Parmar
45 Partner B. Com
10 Yrs 9421306083
3 Rajesh Vrajlal 40 Partner SSC 10 Yrs 9422712005
Company’s Initial Investment: 26.41 lacs
loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name / Govt.
AssistanceYear Purpose Amount (Rs.) Status (Ac-
tive/Closed)1 State bank of Hyderabad 2011 Term loan 37 lacs N. A.2 State bank of Hyderabad 2011 Cash Credit 25 lacs N. A.
Vendor Code Details: N. A.
Production capacity of the Unit:Year Production capacity2013-2014 80000 kgs p.a. (Proj. Sales Rs. 120.00 lacs)2013-2012 34691 kgs p.a. (Sales Rs. 50.30 lacs)2012-2011 11428 kgs p.a. (Sales Rs. 16.46 lacs)2011-2010 N. A.2010-2009 N. A.
Types of Customer:Type Total number of
CustomersNames/List of Cus-tomers
Products Manufac-tured
Agricultural/Irrigation
20 Farmers Agro shade net
Total number and list of Vendors or Suppliers:• Polygrain – from Pune• Perfect color and plastic – from Daman• Mihir processing – from Rajkot
Yogesh Plastic IndustriesMIDC, Shendra, Aurangabad
367 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
• A – top polychem – from Rajkot • Om polybland - from Daman
Total number of Employees at the company:• Partners : 03• Operators : 06• Helper : 04
Types of Business: OEM
Area of the Unit:Plot Area 1179 sq. mtr.Total Built-up Area 622 sq. mtr.
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2011-2012 16.46 l 5.80 l 0.09 l2012-2013 50.29 l 14.59 l 0.28 l2013-2014 (expected) 120.00 l 36.85 l 2.17 l
Certification/s (If any): N. A.
Audit Report/s (If any): N. A.
Business Competitors:Sr. No.
Competitor’s name
Competitor’s Prod-uct Specialization
Type of Business (Exporter/OEM/Tier 1 Supplier/Tier 2 Supplier / Tier 3 Supplier
1 Rushi Packers Agro shad net N. A.2 Krushi Net Agro shad net N. A.3 Mayura Agro Agro shad net N. A.4 Balaji Agro Agro shad net N. A.
Types of Machines:
Sr. N
o.
Nam
e of
M
achi
ne
Qua
ntity
Mak
e of
m
achi
ne
Spec
ifica
-tio
n
Pric
e of
the
Mac
hine
Year
of
Purc
hase
Loan
/ by
Self
1 Extruder 01 Renuka, India
75mm 8.00 2011 30% Self & 70% loan
2 Sletting machine
02 Rose Ind., India
58 inch 11.50 2011 2013
3 Net wraping machine
02 Rose Ind., India
3 mtr 31.00 2011 2013
4 Grinder Mixer 01 Rose Ind., India
30 kg 0.70 2011
5 Bale press ma-chine
01 Rose Ind., India
1.50 ton 1.00 2011 Self
6 Weight lifting 01 Rose Ind., India
1 ton 0.80 2011 Self
Types of Hand Tools:
Sr. N
o.
Nam
e of
To
ol
Qua
ntity
Mak
e of
m
achi
ne
Spec
ifica
-tio
n
Pric
e of
th
e To
olYe
ar o
f Pu
rcha
seLo
an/ b
y Se
lf
1 Hand grinder
01 Max India India
4 inch grinder 0.02 2011 Self
2 Hand drill 01 Max India India
5 mm drilling 0.02 2011 Self
3 Air blow 01 Prakash India
0.02 2011 Self
4 Weighing scale
04 Excel India
500 kgs, 300 kgs, 150 kgs, 30 kgs, 600 gram
1.20 2011 Self
368 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
5 Tools kit 01 Tapadiya India
8-24 Instruments 0.02 2011 Self
Raw materials
Sr. N
o.
Raw
Mat
eria
l
Curr
ent R
ate
(Rs.
Per K
g)
Spec
ifica
tion
Supp
lier’s
Nam
e
Min
imum
qua
ntity
mai
n-ta
ined
in th
e co
mpa
ny p
er
mon
th
Prod
uct M
anuf
actu
red
with
the
mat
eria
l
Prod
uct S
uppl
ied
to
(OEM
/Tie
r 1 su
pplie
r/Ti
er2
Supp
lier/
Tier
3
Supp
lier)
1 H. D. P. E. 127 per kgs
Natural, Virgin
Pol-ygrain, A-Top poly and Mihir process-ing
10 ton (12.70 lacs)
Agro Sheet net
Warehouse/Storage of Raw material (Inventory Control Techniques)
Order Quantity: N. A.Order Process: N. A.Quality Control: N. A.
Sr. N
o.
Nam
e of
wor
ker
Age
(yrs
)
Gen
der (
M/F
)
Wor
kers
/Sup
ervi
-so
r/M
anag
er/S
taff
for c
lean
ing
Qua
lifica
tion
Ope
ratio
n/
Func
tion
Year
s of e
xper
i-en
ce in
Indu
stry
Wor
king
hou
rs/
day
1 Munari Manji 28 M Supervisor SSC Supervi-sor
6 yrs 8hrs
2 Ramchandra Manji
20 M Operator SSC Machine Operator
3 yrs 8 hrs
3 Shikant Pawar 21 M Operator HSC Machine Operator
2yrs 8 hrs
4 Anil Rathod 19 M Operator 9th Machine Operator
3 yrs 8 hrs
5 Vijay Manji 23 M Operator 8th Machine Operator
3 yrs 8 hrs
6 Chotelal Prajapati
30 M Operator SSC Machine Operator
4 yrs 8 hrs
7 Rakesh Paswan
22 M Helper 9th Helper 2 yrs 8 hrs
8 Pankaj Singh 25 M Helper 11th Helper 2 yrs 8 hrs9 latabai 35 F Helper 5th Helper 2 yrs 8 hrs10 Rukhmanibai 35 F Helper 6th Helper 2 yrs 8 hrs
Functions/Operations in the company:Function / Operation Required
Qualifi-cation of workers
Required number of workers
Shortfall of workers
Number of hours /shift
Number of shifts/day
Design & Development of household & other plastic products
DME, BE 03 03 8 hrs 1
Flow chart of Business Process:
Purchase Raw Material > Raw Material With Master Batches & Extra life Chemicals > Heating Process > load in Extruder Ma-chine and Prepare Films > Films Roll loading in Sliting Machine > Weaving in Neting Machine > Folding and Prepare Bales on Press
369 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Machine > Weighing as per Customer Requirement
Flow chart of Manufacturing Process:• RM Mixing with master batch• Heating process• load in extruder• Film roll from extruder machine load in slitting machine• Weaving with neting machine• Folding and prepare bale for dispatch• Weighing
Machine operations:Sr. No.
Machine name No. of labors required per machine
Time required for process
Idle time per shift of 8 hrs
Wastage %
1 Extruder 01 1 hrs – 45 kgs production
350 kgs 2%
2 Slitting Machine 01 2 hrs – 15 kgs production
120 kgs 10%
3 Weaving Machine 01 2 hrs – 15 kgs production
120 kgs 0%
Products manufactured at the Company:Sr. No.
Product name
Cost to Company
Price to Customers
Repeat Order
Supplied to
1 Agro shade net
Yes Farmers, Building construction, Schools, Sport ground, etc. in and around the state of Maharashtra
Quality Control PlanProject Documentation:
Does the company maintain Documents for every Project?
No
Quality Control Procedure: (In house/ External agency)
In house
Testing of Raw Materials (Incoming - Quality Control Techniques)
Raw material quality control done by the suppliers
Name of Testing labs for Raw Mate-rials (tie-ups for Raw Materials)
N. A.
Name of Testing labs (tie-ups for Finished Products)
N. A.
Testing of Finished Products It is done in house by manually
Quality Standard for Product: N. A.
Design & DevelopmentWhat is Design? “Design is new Customers and New
Money earned”
Design Process of existing products (choose any top one product that is being manufactured at the company for a OEM or a Customer): N. A.
Design Process/Plan fora new Product innovation: Design process will be done in house by using technical & qualified employee, and we will developed new design in plastic Agricultural products, household & other products.
Budget allocated for Research & Development (Annually in Rs.)
Rs. 15,00,000/- (proposed plan for development)
IT/CAD/Softwares/CAM used in the Company
Tally
370 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Exhibition/trade shows visits:Sr
. No.
Exhi
bitio
n /
Show
Part
icip
ant /
V
isito
r
last
atte
nded
(Y
ear)
Fees
(in
case
th
e co
mpa
ny
part
icip
ated
)
Bene
fits
1 Advantage Mahar-ashtra Expo-2014
Yogesh Parmar
2014 N. A. New Design & Development
2 Plast Vision, Mumbai
Yogesh Parmar
2013 N. A. Information about New Agri-cultural products
Safety standards in the Company:Manufacturing Operations
Possible acci-dents / hazards
Safety measures in the company
Remedies / Med-ication
Slitting Machin-ing
Hand Injuries Sensor attached with machinery
N. A.
Marketing and Branding:logo of company:
Effectiveness of the company logo High
Brand Awareness in respective markets; whether B2B or B2C
Medium
Describe the Company’s Target Market: Export the product and develop new products in Agricultural & plastic Indus-tries.
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
N. A.
Online services No
Company label: N. A.
Company Product Samples: Yes. Swatch of the Agricultual Sheet net is presented with all the relevant information
Finance & AccountsWhat is the process of Pricing? Also attach a Cost Sheet of one of the product manufactured at your company.
Cost sheet for 1000 kgs Agro Shade netCost of raw material Rs. 1.00 lacsProcessing cost Rs. 0.40 lacslabour cost (wages) Rs. 0.05 lacs
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Total cost to company Rs. 1.45 lacsMargin Rs. 0.05 lacsSelling cost Rs. 1.50 lacs
Explain the Distribution Process. Backward linkages and Forward linkages (Supply Chain): Finished material dispatched to customer by transport or cus-tomers directly purchased from our factory premises.
Human Resource ManagementEmployment recruitment rules No any specific recruitment rules.
Employee’s selection on their skilled and work efficiency.
Money charged (in Rupees) by contractors for each worker/staff in case the workers/staff are recruited through Contractors
N. A.
Training Policy for the new recruits and already employed with the company:Staff For New Recruits For Already Employed
Machine Operator Work Experience / trail run Work ExperienceSupervisor Work Experience Work ExperienceManager Work Experience Work ExperienceHelper/Cleaning Staff N. A. N. A.
leave Policies:Staff Leave PolicyMachine Operator 4 days in months and public holidaySupervisor 4 days in months and public holidayManager 4 days in months and public holidayHelper/Cleaning Staff 4 days in months and public holiday
Overtime Policy:Staff Overtime PolicyMachine Operator Wages per hourSupervisor Wages per hourStaffManager Salary per hourHelper/Cleaning Staff N. A.
Insurance/Medi-claim Policy: N. A. (Proposed to begin for all staff)
Wage Rate Policy:Staff Wage Rate PolicyMachine Operator On work experience or fixed on Rs.6000 – 7000 p.m.Supervisor On work experience or fixed on Rs.9000 – 10000 p.m.Manager On work experience or fixed on Rs. 10000 – 12000 p.m.Helper/Cleaning Staff Helper / Cleaning fixed Rs. 3000 – 4000 p.m.
Salary Structure:Staff For Fresher (in
Rupees)With experience of 3 years (in Rupees)
Training required, if yes then please men-tion the training
Machine details if produced In house
Machine Operator
6000 – 7000 p.m. 7000 – 8000 p.m. Practical work done N. A.
Supervisor 9000 – 10000 p.m. 10000 – 12000 p.m. HRM N. A.Manager 10000 – 12000 p.m. 11000 – 13000 p.m. Business Management
TrainingN. A.
Helper/Cleaning Staff
4000 – 6000 p.m. 6000 – 8000 p.m. For staff – as per post training
N. A.
Male & Female Employees:Staff Number
of staffProfile (Machine Operator / Supervisor / Manager / Helper / Cleaning Staff)
Hometown (Aurangabad / Outside Aurangabad but within Maharashtra / Outside Maharashtra)
Years of experience in the Company
Machine details if produced In house
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Male 03 Supervisor / Manager / Staff
Aurangabad 2 yrs – 3 yrs
Female 01 Receptionist Aurangabad 1 yrs
Covered under ESI/EPF/Gratuity: N. A. (Proposed to begin for all staff)
Contract Worker Policy: N. A.
Compensation Plan for workers in case of injury or accidents: N. A.
Career Graph Plan for Employees: N. A.
Retention Policies and Welfare Schemes: N. A.
Future Plan of the Company
Timelines Plan Assistance required by the Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months Acquired certification from ISO
N. A. Develop material quality
1 year Design & development new products
Finance / Training / Design Assistance
Acquired new work orders
3 years Export sales Finance Export order5 years N. A. N. A. N. A.
Product Design Project BriefDesign Brief
Design & development of new plastic products and estimated cost for the same up to 10 lacs to 15 lacs
Plan of the Design Project
Product Design Brief specifications Various types of plastic productsProposed Design ProcessTimeline 2-3 yearsBudget Rs. 15,00,000Team members & Skills Required 05 (Ind. Designer, Engineer,
Researched, etc.)Benefits for the Company Develop new products and develop
new markets for the company
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Used blades are seen lying casually at the entrance. This needs to be properly disposed after its use.
The stock of Rolls and the tools need to be arranged properly and labelled.
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Need urgent attention for the proper wiring to avoid fire, electric shock or any kind of accident.
The raw material bags are seen lying in the aisle. These bags need to placed at proper distance from machine.
The scrap to be collected properly for the properly functioning of the machines.
The tools are lying unattended. The tools need to be removed after its use.
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Need urgent attention for the proper wiring to avoid fire, electric shock or any kind of accident.
The tools are lying unattended. The tools need to be removed and placed at its specified shelves after its use.
The scrap to be collected properly for the properly functioning of the machines.
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Improper approach for machine maintenance
The gap to move around the working area is too less. The stocks around seen around needs to be arranged properly.
Improper approach for machine maintenance
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The gears and the chain is seen open and exposed to material scrap. Need to keep the machine covered to avoid damage.
The machine parts is seen open which prone to accident. The wiring and the oil spillage needs to be maintained.
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The machine switches needs to be maintained and needs proper marking as per its function.
The production area is chaotic. The raw material is kept in haphazard manner and not enough space to seen to walk around the area.
The incomplete rolls are not stocked properly. Needs to be arranged neatly.
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FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Need to improveWorkplace & Ergonomics Need to improvePlant layout Improvement Space management is a concernNew Product Development No in-house product development process
followedPackaging Need to improveMarketing Market awareness is a problem. No effective
marketing for business growthHuman Resource Training initiatives for the workers need to
improve
Business DesignMarketing Needs to improvelogo Design Needs to developVisiting Card Needs to developBrochures & leaflets Need to developWebsite Need to develop
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear and thus the productivity of machines can be im-proved.
Some research and development work to be done so that the dependence on
the manual work can be reduced. Some part of profit has to be kept for such activities.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Wastage and spoilage of the material can be reduced to improve the through-put of material, thus reducing the cost of manufacturing.
Product: Company currently producing only one type of product, it should venture into other categories to reduce the business risk. Product testing should be done at various levels and report can be prepared to increase customer confidence.
Human Resource: To reduce Employee attrition rate, the salary levels need to be revised to attract better skilled manpower. Proper training should be formalised to improve the skill of the workers.
Marketing:• A website need to be developed on urgent basis so that the customer reach
can be extended.• It requires more publicity on retail level. It urgently requires a modifica-
tion in a logo so that customers identity the product with the company. A proper branding strategy should be formalised to get maximum visibility in the market.
• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers.
• A company should participate in trade fairs and exhibition related to plas-tics to attract new customers
• A company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the de-velopment process.
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FInishing the woven plastic mat’s rough edge at Siddhi Polyweave, MIDC, Waluj, Aurangabad
SWOT - Plastic Clusterstrengthsweaknessesopportunities & threats
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STRENGTHS:
• First Generation Entrepreneurs• Eagerness to take challenges and risks• Predisposition to scaling up the scope of business and modify prod-
uct offerings as per changing market demands• Efficient production capabilities for Product Designs & Specifications
provided by customers Easy availability of Raw Materials in desired quality & quantity
• A good dealer network• low Real Estate prices and easy availability of land / Industrial Plots• Government policies supporting the access to by entrepreneurs• Government Incentives for investment and credit availability
WEAKNESS:
• Increased competition in same type of manufacturing• The cluster operates on very low margins with some companies oper-
ating on margins as low as 3%• Dependence on single / two companiesw• No own Products. No investment in IPR• lack of funds for R&D • lack of trained manpower and no structured plan for skill up-grada-
tion• No standard practice of visiting Trade Fairs which results in lack of
Market Awareness• First Generation Entrepreneurs hence limited risk absorbing capacity• No structured growth plan in place• low awareness levels for Government schemes and policies
SWOT - Plastic cluster• Inadequate water and power supply• Infrastructure is not upgraded to meet the changing industry require-
ments• Focus only on making basic products• Reliance on customer to provide all design inputs• Absence of product benchmarking as basic Quality control process is
followed• Moderate to high wastage• Slow Technology Up gradation and basic to minimum use of software
which lengthens lead time• Ergonomics and Medical facilities
OPPORTUNITIES:
• MIDC has planned to develop Additional MIDC’s in the region which creates good opportunities for industries.
• Cluster development programme of Central Govt. boost for creation of jobs /skilled & unskilled man power.
• Expansion project of CIPET is playing vital role for plastics manufac-turing in the region.
• Government initiatives like DMIC Project, Shendra-Bidkin Industri-al Park, Revised Seed Money Scheme, Prime Minister Employment Generation Programme etc.
• Development of retail sector.• Growth possibilities through mutual cooperation.• Government incentives for Infrastructure and Technology Up-grada-
tion.• Awareness regarding importance of training. • Positive attitude towards product diversification.
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• With the growth in the size of the cluster, there will be greater availability of cheaper raw materials due to industry forces.
THREATS
• Skill up-gradation is crucial for keeping pace with changing technological needs.• Increasing pace of competition while the customers remain limited.• limited product innovation might make the companies redundant in future.• No safeguards for reducing environmental waste which might result in problems in future.• Slow pace of market expansion by targeting new customers.• The export market has not been tapped.• No testing labs which might lead to issues while dealing with international companies with stringent quality norms.• No plans for making the business self-sustaining.
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Findings
Survey work in progress at Mould Technology, MIDC, Waluj, Aurangabad
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The survey presents the findings focussing on the lack of MSMEs’ exposure to new markets as most of the units is catering to OEM based job work wherein each and every detail is specified by the client not leaving any scope of design intervention in terms of product design and development.
Si. No. Current Status Impact on Business1 Most of the units in the
cluster are focussed on making component parts for the OEM market.
The job work kind of business identity prohibits any kind of product development as the product designs are provided by the customers and the units are just supposed to execute the same.
2 No substantial efforts at attending Trade Shows.
The units lack market awareness about the cur-rent product requirements of the industry.
3 No substantial marketing or branding efforts.
It increases dependence on a smaller customer base which increases the business risk.
4 lack of commitment for Research & Develop-ment.
The units continue to make similar products which prohibits innovation and product diver-sification which might result in weakness in the face of increasing competition.
5 Extremely small margins in the product because of the units making basic products and competing of rates.
Generation of moderate to minimum profits which cannot be ploughed back in business. Hence, the units cannot become self-sufficient.
Some of the Unit owners have ideas about the products they want to diversi-fy with, but the problem is the market awareness. There is an urgent need to create an awareness about the opportunities at common business platform for the entire cluster where people can share there strength and weakness, come up with a cumulative solution wherein everybody gets benefited w.r.t. the focussed design research, processes, emerging technologies, new target market, etc.
The cluster may contribute towards developing a common market place in their area where all the manufacturers can individually showcase and market
Findings - Highlight observations at cluster leveltheir products and processes continuously.
Technology:Most of the units uses conventional machines such as semi-automatic ma-chines. Also, due to the high cost of new machines the units generally uses the second hand machines which leads to high energy consumption and decreased productivity. Investment in technical up-gradation is low. The units hardly use IT technology. There is no any tie up with technical and R&D institutions.
Infrastructure: limited growth scope in basic infrastructure. The units are not able to main-tain delivery schedules due to logistics bottlenecks in region due to bad roads and connectivity. The social infrastructures are also inadequate at Aurangabad region. There is an alarming gap between supply & potential demand for the infrastructure required for high growth.
Raw Material:The frequent increase in raw material prices is adding up to the input costs of the production. The easily procurement is also a big problem faced by the small units in the cluster.
Design Process and Product Development:Most of the companies depends on the design and specifications which are provided by their clients. The production is done as per the job work. As a result the units do not get opportunity to implement design processes required to come up with better designs and increasing the intellectual capability of the units. Barely any units have product innovation facility and most of the cluster units do not have their own products as they are manufacturing on job work for bigger units.
Target Market:Most of the target market is local clients except a few units who manufacture products sold directly in retail markets through dealers. Due to increasing
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competition the units and are always under pressure to keep prices low in spite of rising input costs. The units have enough critical mass to promote their common brand subject to form the marketing consortia.
Production Capacity:Due to fewer and low capacity machines the units have low productivity. Most of the units uses second hand machines which requires frequent maintenance and effects the productivity. Also, the production is tightly defined by the cli-ents and their requirements.
Logistic, Packaging & Transportation:Most of the production being manufactured for the local clients the products are packed in polythene bags and corrugated boxes.
Plant Layout:In most of the units the layout is not according to the process flow of raw ma-terials and the manufactured items. When a item moves haphazardly during processes it leads to increased time periods and overall efficiency of the work-ers and the unit itself. The travel distance increases and also its material han-dling or transportation cost increases. layout shall be reviewed in the light of process flow to reduce the travel-distance of the items in the unit.
Ergonomics:In most of the units finishing, assembly and packing and final packaging op-erations are being done by persons sitting on floor or against a wall. This puts more strain on work , thereby reducing the productivity. The wrong posture of the workers will make them suffer from work-related diseases, which are further complicated by social, psychological and physiological issues. Overall this will further affect the productivity of the unit. Arrangements should be made to make work stations in such a way that workers work while standing. For workers working on machines gravity chutes etc. may be used.
Material Handling:Most of the units the raw material and finished goods are moved by manually. Only in a bigger units material handling trolleys are being used which are used manually. Use of Fork lifters, Pallet lifters and hoists or cranes is used by a
very few units. There is a need to identify and start using mechanized material handing system.
Skills & Training:The skill of the workers in most of the units have deficit in the area of Produc-tion techniques, Machine know-how, 5S, Information technology, Machining & Programming, design & testing of financial Management. Workers are most-ly focusses on one type of skill and are not multi talented. Higher attrition rate of the skilled employees due to lack of career planning and promotion avenues.
Entrepreneurs & Enterprise:Majority of the units are family owned. Barely any fresh talents are recruited from outside which restricts the sense of innovative w.r.t. to products or busi-ness. There is very low level exposure and awaress among the workers and staff about the technological development around the world. There is also very little awareness about the training programmes and promotional schemes of the state and central government. The risk taking capacity is least seen among the smaller units. There is also a poor co-ordination and trust level between cluster units. Majority of the entrepreneurs in the cluster are with artisan background and have attitudinal constraints and not open to the changes in new technolo-gy and modern management practices.
Finance and Credits:The financial planning, control & accounting system is not properly main-tained by most of units get these important work done by external agents such as local Chartered Accountants due to lack of adequate resources and exposureDue to lack of financial management skills the return on investment in low as planned by them. The relationship between the cluster units and borrower & financial institutions seems to be weak.
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Recommendations
Turning Process at Mould Technology, MIDC, Waluj, Aurangabad
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WAY FORWARD
Business Processes:Currently the manufactures in the plastic cluster are working on the various types of products catering to automobile to the household industry. While interacting with the participants under this survey, they opened up with their problems of supply chain, managing the capital, labour issues and majorly the marketing aspects. Here we will try to focus on the some of them:
Profit Margin:It is clear from the information given by the respondents of this survey that profit margin is very tight in this sector. This is because competitors from man-ufacturers of other industrial area are producing the goods with same specifica-tion at very reasonable rate. Major reasons that the respondents said are: • Higherelectricitycharges• Highertransportationcosts• Fluctuationsintherawmaterialprices• NosubsidyfromGovernmentinanyform• Noinitiativeontheexpansionofthemarket
Higher raw material costs:The major component of the total cost is raw material; which is around 85%. The raw material required for most of the units in the cluster is of similar nature and as per respondents the issue that the prices are changing every 15 days. This issue can be sorted out by placing a combined order from all manu-facturers. This will reduce the raw material cost by economies of scale and buyer can also negotiate with the supplier for trade discount.Alternate source of raw material can be found out to reduce dependency on one supplier.
Research and development:Very few companies are engaged in the new product development process, either because of they don’t have skilled manpower to do that or they lack the
funds required for it. Also no company is taking benefit of the synergy and developing the new product. A platform should be provided to the manufactures so that they can share the ideas, resolve the issues or problems and come up with the strategy to solve the major concerns of the cluster. Cash rich big companies can also fund the development activities of the small units facing financial problems.
Transportation:The overall infrastructure specially the condition of roads is not in such a good condition. This hampers the growth of the business by increasing the lead-time. A better and efficient logistics means faster movement of the raw materi-al and finished goods, thus reduces the business cycle for a company.It is also evident that the market for most of the manufacturers is common and very nearby. To reduce the overall cost of transportation, the products from all the supplier going to the same market place can be combined together thus reducing the transportation cost per unit. A delivery schedule can be planned as per the market place and variety of goods produced by different manufactures are transported in the same vehicle on a particular date. As per the demand the transportation frequency can be increased.
Power:Currently a plastic cluster at Aurangabad is facing problems in supply of electricity. The fluctuations in the power supply hamper the efficiency of the machines as well as the defects in the products. A smooth and regular power supply is the need of the hour as it will increase the throughput and reduce the wastage and spoilage.
Starting of Common Facility Center (CFC):A common facility center can be formed to sort out following issues:• Acombinedbulkpurchaseorderofrawmaterialforallthemanufac-turers to get trade discount,• AcommonR&Dunitforalltheparticipants,• Managementofcommontransportationfacility• Stringenttrainingscheduletoconverttheunskilledlabourtoskilledworkers
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• Formulationofcareerpathtoattractmoreworkforceinthisindustry• Financialhelpinvisitingandexhibitinginthetradeshow
Porter’s view:There are three approaches to run an organization are referred to as “generic strategies”, because they can be applied to products or services in all industries, and to organizations of all sizes. They were first set out by Michael Porter in 1985 in his book Competitive Advantage: Creating and Sustaining Superior Performance. Porter called them Generic Strategies.
Porter’s generic strategies are ways of gaining competitive advantage – in other words, developing the “edge” that gets the sale and takes it away from the com-petitors.
“Cost leadership” (no frills): it involves being the leader in terms of cost in the industry or market.
“Differentiation” (creating uniquely desirable products and services): making products or services different from and more attractive those of competitors. And
“Focus” (offering a specialized service in a niche market): concentrate on particular niche markets and, by understanding the dynamics of that market
and the unique needs of customers within it, develop uniquely low cost or well-specified products for the market. He then subdivided the Focus strate-gy into two parts: “Cost Focus” and “Differentiation Focus”. The terms “Cost Focus” and “Differentiation Focus” can be a little confusing, as they could be interpreted as meaning “A focus on cost” or “A focus on differentiation”. Cost Focus means emphasizing cost-minimization within a focused market, and Differentiation Focus means pursuing strategic differentiation within a focused market.
How to choose which generic strategy to adopt?STEP 1: The units need to conduct a SWOT analysis of their individual units or discuss with the experts to take an outsider view of their unit.
STEP 2: This should be followed by a Porter’s Five Forces Analysis of the clus-ter.
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STEP 3: This will enable the units to identify which Generic Strategy will suit them the best on the basis of their vision for the company.
Collaborations & Exhibitions:
The unit owners in the cluster should collaborate to organize an exhibition every six months to showcase their new product developments to the industry. This exhibition can be promoted with the help of Government agencies.
The unit which exhibits most unique product development or process improve-ment may also be rewarded by signing up deals or contracts with the business houses.
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5 Day Workshop
Work in progress at Varroc Polymers, MIDC, Waluj, Aurangabad
About the WorkshopSchedule of the WorkshopDay 1Day 2Day 3Day 4Day 5Design Briefs
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Design clinic workshop held for the Plastic Cluster was a combination of pres-entation and interactive sessions on interactive design study and need assess-ment, design seminar and design clinic activity. The design expert/s presented the opportunities identified from need assessment. The design seminar pres-entation from design expert/s and guest design speakers focussed on design topics and case studies relevant to the plastic cluster and participants. During the design clinic, design expert/s diagnosed solutions for existing design prob-lem/opportunity and suggested on the spot remedial steps, during the work-shop. The workshop helped the participants to get quick remedies on identified opportunities for design intervention from existing problems taken up from their respective work areas.
Objective: Objective of Design Clinic Workshop was to create a platform where partic-ipants were able generate the holistic perspective for their scenario with the help of design expert/s guidance. The design expert helped participants in identifying opportunity areas in their respective units and cluster with the help of interactive design study insights. The expert also helped in providing on the spot design solutions to problems taken up by participants from their respec-tive backgrounds of products, process, communication and design strategy.
The major activities of design clinic workshop was as following:
• Discussion of opportunity areas identified from interactive design research • Design presentations by guest design speaker/s • Provide remedies to design problems taken up by the participants
Guest Speakers/Experts: Mr. S G Rajput, GM, DIC AurangabadMr. T R Sharma, Dy Dir. MSME AurangabadMr. S K Thote, Regional Officer, MCED Aurangabad
Mr. Thaware D U, Project officer, MCED AurangabaadMs. Bharti Sose, Project Officer, MCED AurangabadMr. Sanjay Bondekar, Dy General Manager, NSIC AurangabadMr. Anidya Pal, Dy General Manager, SIDBI AurangabadMr. Pravin Bachhav, Sr. Technical Office, CIPET AurangabadMr. Vinayak Garkhedkar, Project Consultant, AurangabadMr. Tanmay Kandekar, andMs. lipi Choudhury
About the Workshop
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Date Day Time Session Speakers8th March, 2014 1 10 AM – 10:30 AM Registration Process
Inauguration
Welcome Address
MCED teamMr. S G Rajput, GM, DIC AurangabadMr. T R Sharma, Dy Dir., MSME AurangabadMr. S K Thote, Regional Officer, MCED AurangabadMr. Thaware, D U, Project officer, MCED AurangabaadMs. Bharti Sose, Project Officer, MCED AurangabadMr. Saurabh Kumar, NIFT MumbaiMr. Tanmay KandekarMs. lipi Choudhury
10:30 Am to 12:30PM Introduction to DCS Workshop Mr. Saurabh Kumar12:30 PM to 12 :45 PM Tea Break12:45 PM to 2:00 PM Trends in New Products Innovation Ms. lipi Choudhury2:00 PM – 2:30 PM lunch2:30 PM – 3:30 PM Personal discussion with participants Mr. Saurabh Kumar, NIFT Mumbai
9th March, 2014 2 10:00 AM to 11:00 AM Schemes for MSMEs Mr. T R Sharma , Dy Dir MSME Aurangabad 11:00 AM to 11:30 AM DIC Schemes for MSMEs Mr. S G Rajput , GM, DIC Aurangabad11:30 AM - 12.00 PM Design & Trademark Protection & Issues Mr. Tanmay Kandekar 12:00 Noon – 1:30 PM Design Process & Design Case Studies Mr. Saurabh Kumar1:30 PM to 2:00 PM lunch2:00 PM – 3:30 PM Personal discussion with participants Mr. Saurabh Kumar, NIFT Mumbai
10th March, 2014 3 10 AM – 1:30 PM live Clinic: Personal Interaction with Twelve MSMEs - Brainstorming for Design Innovation/Product Ex-ploration/Product Diversification
Mr. Saurabh Kumar & Mr. Tanmay Kandekar
1.30 PM – 2:00 PM lunch2:00 PM – 5:30 PM live Clinic: Personal Interaction with Six MSMEs
- Brainstorming for Design Innovation/Product Ex-ploration/Product Diversification
Mr. Saurabh Kumar & Mr. Tanmay Kandekar
Schedule of the WorkshopACTION PlAN - 5 DAY workshop (5DW) for PlASTIC Cluster, AurangabadMarch 8th - March 12th, 2014, Co-ordinator: Saurabh Kumar (NIFT Mumbai) & MCED team
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10th March, 2014 4 10 AM – 1:30 PM live Clinic: Personal Interaction with Nine MSMEs - Brainstorming for Design Innovation/Product Ex-ploration/Product Diversification
Mr. Saurabh Kumar & Mr. Tanmay Kandekar
1.30 PM – 2:00 PM lunch2:00 PM – 5:30 PM live Clinic: Personal Interaction with Six MSMEs
- Brainstorming for Design Innovation/Product Ex-ploration/Product Diversification
Mr. Saurabh Kumar & Mr. Tanmay Kandekar
12th March, 2014 5 9:30 AM – 10:00 PM live Clinic: Personal Interaction with One MSMEs - Brainstorming for Design Innovation/Product Ex-ploration/Product Diversification
Mr. Saurabh Kumar & Mr. Tanmay Kandekar
10:00 AM – 11:00 AM Schemes of NSIC for MSMEs Mr. Sanjay Bondekar, Dy General Manager, NSIC Aurangabad11:00 AM – 11:30 AM Schemes of SIDBI for MSMEs Mr. Anidya Pal, Dy General Manager, SIDBI Aurangabad11:30 AM – 12:30 PM Support Schemes of CIPET for MSMEs Mr. Pravin Bachhav, Sr. Technical Office, CIPET Aurangabad12:30 PM– 1:30 PM Design Process & Design Case Studies Mr. Saurabh Kumar1:30 PM – 1:45 PM Project Proposal for Bankable loan for MSMEs Mr. Vinayak Garkhedkar, Project Consultant, Aurangabad1:45 PM - 2.15 PM lunch 2:15 PM – 2:45 PM live Clinic: Personal Interaction with One MSMEs
- Brainstorming for Design Innovation/Product Ex-ploration/Product Diversification
Mr. Saurabh Kumar & Mr. Tanmay Kandekar
2:45 PM – 3:30 PM Closing Ceremony MCED teamMr. S K Thote, Regional Officer, MCED AurangabadMr. Thaware, D U, Project officer, MCED AurangabaadMs. Bharti Sose, Project officer, MCED AurangabadMr. Saurabh Kumar, NIFT MumbaiMr. Tanmay Kandelar, NIFT MumbaiMr. Vinayak Garkhedkar, Project Consultant, Aurangabad
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The workshop was inaugurated by the esteemed guests. Mr. T. R Sharma Dy Dir. MSME Aurangabad congratulated MCED on this initiative to streamline and bring structured design thinking to the Plastic Cluster. The esteemed panel of guests were facilitated by the MCED representatives.
The event was attended by the key stakeholders of the Plastic Cluster at Aurangabad like Electroplast, Yogesh Plastic, Darshan Plastic, Snehal Plas-tic, V. P. Pet Polymers, Mitali Industries, etc.
The inaugural session was followed by a session on developments in the Plastic cluster with Ms. lipi Choudhury. The session was interactive in nature with design ideas being shared and discussed by everyone present.
Presentation by Ms. Lipi Choudhury on ‘New Product Development’
The session concluded with a question and answer session moderated by Mr. Tanmay Kandekar. The Cluster representatives and the entrepreneurs discussed about various bottlenecks in terms of finances, awareness about schemes for MSMEs, teamwork and capacity building.
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The day started with presentation on Policy Initiatives & Schemes of Govt. of India for Development of MSMEs by Mr. T. R. Sharma Dy. Dir. MSME, Aurangabad. He informed the present MSME units about the Schemes & Programmes such as Credit linked Subsidy Scheme (ClCSS) for Technology Upgradation of MSEs, Cluster Development Programme, CFC & its funding pattern, Credit Guarantee Fund Trust for Micro Small Enterprises, ISO Reimbursement Scheme, Schemes for Capacity Building, Credit Rating Scheme of NSIC, National Manufacturing Competitiveness Programme - components. later the presentation by Mr. S G Rajput , GM, DIC Aurangabad further informed the units about the Cluster Develop-ment Programme.
Presentation by Mr. T. R. Sharma on ‘Policy Initiatives & Schemes of Govt. of India for Development of MSMEs’
During the second phase of presentations Mr. Tanmay Kandekar interact-ed with MSME Units about the Design & Trademark Protection & Issues. He emphasised on the importance of Design protection for creating sus-tainability and long-term growth prospects for the business.
As the day progressed Mr. Saurabh Kumar presented design case studies relevant to the plastic cluster and participants. During the workshop he discussed the diagnostic solutions for existing design problem/opportu-nity and suggested on the spot remedial steps, during the workshop to the MSME units.
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Day 3 was dedicated to live Clinic for MSME units. During this session one to one interactions were carried out with twelve MSME units in order to brainstorm for Design Innovation, Product Exploration and Product Diversification. The workshop helped the participants to get quick reme-dies on identified opportunities for design intervention from their Unit’s existing problems taken up from their respective work areas. The list of twelve MSME units is as follows:• APM Plast• AR Polymers• Electroplast• Mitali Enterprises• Moraz Plastic
Live Clinic on Day 3 with Mr. Yogesh Parmar of Yogesh Plastics
• Rupesh Enterprises• Siddhi Polyweave• Snehal Plastic• Tirumala Industries
Trimurty Polythenes• Ulka Plastics• Yogesh Plastics
The expert also helped the MSME units in providing on the spot design solutions to problems taken up by participants from their respective back-grounds of products, process, communication and design strategy.
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live Clinic continued on Day 4 with the next set of nine MSME units for exploring possible product diversification and new product development opportunities. The list of nine MSME units is as follows:• Cool Engineering• Concept Engineering• Darshan Plastic• Jyoti Industries• Mould Tech• Plast Tech• Sunrise Auto Pack• Sushma Industries• Suyog Plastic
Live Clinic on Day 3 with Mr. Ashok Joshi of Swagat Polymers and MSME unit
The expert helped the MSME units in providing on the spot design solu-tions to problems taken up by participants from their respective back-grounds of products, process, communication and design strategy.
The Design expert along with the MSME unit members discussed oppor-tunities for New Product Development. The Design briefs were generated for the MSME Units to go ahead to the third phase of the DCS i.e. the Professional Design Projects .
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On the final day of the workshop representatives from NSIC and SIDBI were invited to give inputs about loan and financial schemes. Mr. Pravin Bachhav, Sr. Technical Office, CIPET Aurangabad was invited for creating awareness about the various technical programmes run by CIPET. He also discussed the various facilities than can be availed by the MSMEs like raw material and product testing, prototyping, pilot production by associating with CIPET.
live Clinic was conducted for V. P. Pet Polymer for exploring possible product diversification and new product development opportunities.
Mr. Vinayak Garkhedkar, Project Consultant, Aurangabad discussed and
Mr. Shaukat Syed of Electro Plast Industry addressing the Closing ceremony and giving the vote of thanks to all the participating members.
presented the process involved in creating Bankable Project Proposals for loans.
Mr. Saurabh Kumar presented Design, Prototyping and Communication case studies to the MSME unit members. The session was made interactive involving the unit members to raise their concerns and together discuss-ing the solutions for the same. The Unit members also took opportunity to express their enthusiasm and willingness to work further with the DCS and the MCED team for Professional Design Projects.
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Design Briefs - by MSME Units of Plastic Cluster, Aurangabad
The Design Briefs generated during the 5-Day Workshop is given below:
Design BriefsSr. no. Name of Unit Name of Proprietor/
OwnerProducts Design brief
1 Annu Industries Vishal Panjabi Automotive Parts. N. A.
2 APM Plast Ajinkya Nandkumar Kawathekar
Engineering Plastic Products Design of a new Mobile cover case which can carry cards and documents
3 AR Polymers Rohit S. Deshpande Injection moulded products Design of a new Key case for storing multiple keys4 Blue Star Engineers Rajesh K. Sanghavi Plastics M. V. & Home Appli-
ances Parts.N. A.
5 Concept Auto Pack-aging
Rahul S. Neele Fully Auto on line Care Pack-ers.
N. A.
6 Cool Engineering S. P. Kale Water Chillers, Industrial Re-frigerators
N. A.
7 Darshan Plastic Ashok B. Thorat Plastic Injection moulded Com-ponents.
Design & Development of lighting Solutions for Household, Automobiles and Two wheelers.
8 Electro Plast Industry Syed Shaukat Abdul Rauf
Inter Storage Tank • Design of a new Water Tank for household and industrial use. • Design of new lid for Water Tanks.• Design of new Pet Bottles
9 Jayshree Enterprises Shailendra Prataprao Baviskar
Plastic Injection Products New Plastic Injection Moulded Component
10 Jyoti Industries Atmajyoti Bapu Na-gare
Drip Irrigation. N. A.
11 Mitali Industries Pramila Kanha Kashide
Auto Components. Design of motorcycle accessories such as Helmet case, Mud cover and Wind-shield.
12 Moraz Plastics Vilas More In Process Design of New Safety Shaving Razor (Patent Pending as on December 2014)
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13 Mould Technology Bhalchandra Dhond-pant Bhandrao
Plastic Moulds & moulding Products.
Design & Development of Poultry Farm Equipments. The products to be manufactured using Injection molding, blow molding and extrusion molding technology.
14 Plast Tech laxman Irana Man-dkar
Appliances spare parts N. A.
15 Rupesh Enterprises Godavari Dattrao Narwade
Plastic Mould & Dies Design of a new mould for household products/toys
16 Sejal Plastics Santosh Vajantrao Joshi
P. P. Mats N. A.
17 Siddhi Polyweave Shashikant Nagnath-rao Ernale
P. P. Mats Design & development of Plastic Mats using Floral patterns, Geometric pat-terns, Promotional branding, etc.
18 Snehal Plastic Indus-tries.
Bharat Hariba Shindi-kumate
Caster Wheel Design of Plastic Castor Wheels for application in multiple products/Mul-ti-purpose
19 Sunrise Auto Pack Raju Suresh Neele Flyash Bricks. N. A.20 Sushma Industries Parvati Mahadeo
PhundePVC Pipe N. A.
21 Suyog Plastic. Vinay Walandikar Agriculture , Electrical, Auto-mobile.
Design & Development of Drip Irrigation Equipment.
22 Swagat Polymers Ashok R. Joshi Packaging Products Design and Development of Food-grade Food Wrap Film with dispenser and Wall Mounting System. The product may dispense Film, Foil and Paper Nap-kin.
23 Tirumala Industries Ajay Annasaheb Patharikar
Plastic Water Tank Design of new Water Storage Tank for Household, Farming and industrial use
24 Trimurty Polythenes Misal Bhaskar Hariha-ranrao
Poly Bags & Sheets For India. Design & development of a new Garbage Bag for Household, Hospitals, Hotels, etc.
25 Ulka Plastic Industries Sachin S. Thete Krishi Pipe, polymers Sheets Design of a new Drip Irrigation Pipe system26 V. P. Pet polymer Jayshree N. Somase Pet jars , pet bottles N. A.27 Varroc Polymer Pvt.
ltd. Tech. Centre Ritesh Solanke Seat Assembly, Air Filter, Body
Parts & Mirrors.N. A.
28 Yogesh Plastic Indus-tries
Yogesh Vrajlal Parmar Plastic Shed net. • Design a range of Agricultural nets using different patterns, e.g. floral, geometric, branding, etc.
• Marking at Fixed length in the net.
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• Database of District Industries Centre regarding MSME, large enterprises• Database of Directorate of Industries regarding Mega Projects, SEZs• MIDC office information regarding existing and proposed MIDC• Infrastructure and DMIC Employment Self Employment data from Assistant Director employment and self employment• Maharashtra Economic survey 2009-10• Sales tax information from Assistant Commissioner Sales tax• Suggestions from committee members, industrialist, experts
References
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Notes
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404 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai
Need Assessment Survey ReportPlastic Cluster, AurangabadSurvey byNIFT Mumbai
Supported byMCED Aurangabad, NID Ahmedabad,& Design Clinic Schemeby Ministry of MSMEsGovt. of India
2014 www.designclinicsmsme.org