INDUSTRIAL VISIT -

REPORTSILVASSA & DADRA

AVADHOOT HINGE

PGDM DIV – B

ROLL NO – PG12101

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Acknowledgement

I have taken efforts in this review. However, it would not have been possible without the kind

support and help of many individuals and organizations. I would like to extend my sincere

thanks to all of them.

I would like to express my gratitude towards Prof. Vikas Naik for giving us this great

opportunity to visit the companies & understand its functioning. I would also like to thank my

Prof. Naik for his kind co-operation and encouragement which help me in completion of this

project.

I am highly indebted to Bombay Rayon Fashions Limited, Nilkamal Limited, Sterling

Generators Pvt. Ltd & Voltas Limited for their guidance and for providing necessary

information regarding the industry report & also for their support in completing the project. I

am obliged to staff members of these companies, for the valuable information provided by

them in their respective fields.

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Synopsis

Executive Summary: This review is based on the industrial visits that we made in Silvassa.

The visits were done to understand the day to day functioning of the organizations as well as

the factories. Through this review, we would be able to understand many aspects of

operations, marketing, accounting and human resource related procedures, processes and

hurdles. The main components of the visit includes but are not limited to –

Documentation of all processes inward/outward

Logistics of inward/outward

Stores operations, ledgers and interaction with accounts dept.

Manufacturing process, layouts, equipment for mall handling

HR Issues- records, union dealings etc.

Marketing info (may not be full but whatever can be obtained)

Management - mission etc.

Objective of the Study: The objective of the review is to understand how an organization &

a production plant functions. The main objective of the visit was the application of class room

study with the real working environment. The following companies were included in the

industrial visit:

o Bombay Rayon Fashions Ltd.

o Nilkamal Plastics Ltd.

o Sterling Generators Pvt. Ltd.

o Voltas Ltd.

Methodology: The Industrial Visit was broken into 2 days. Day 1 included 2 company visits

namely – Bombay Rayon Fashions Ltd. & Nilkamal Plastics Ltd. Day 2 included the other

companies, namely – Sterling Generators Pvt. Ltd. & Voltas Ltd. We were taken inside the

industry & were given information by the concerned person about how each and every

function performs. We were allowed to ask questions as & when required, anytime during

the visit. At Nilkamal Plastics, we were also shown the process of making chairs, trays & its

quality checks. A similar process of producing cloth & its variants was shown at Bombay

Rayon Fashions Ltd.

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Bombay Rayon Fashions Pvt. Ltd.

Company Profile: Bombay Rayon Fashions (BRFL) was incorporated in 1992 and is

engaged into manufacturing of fabrics and apparels. Presently, the company is the largest

shirt manufacturer in India. Currently, it has employee strength of 32000 people. Its fabric

division manufactures 55 million meters per annum. Its garment unit manufactures 35 million

pieces per annum. The company operates through 13 manufacturing facilities including one

sampling unit in Mumbai. They are located across Bangalore in Karnataka, Navi Mumbai

and Thane in Maharashtra and Silvassa; in Dadra and Nagar Haveli. They are having a

strong presence across the entire value chain of design, yarn dyeing, weaving, fabric

processing, garment manufacturing and retail. The company manufactures a wide variety of

fabrics and garments.

Company Mission: At BRFL, we aim to become exclusive and efficient with the newest

designs and consistent fabric quality. Our goal is to provide the shortest turn-around time in

production and supply. We strive towards better employee work culture, 100% customer

satisfaction and stronger supplier and stakeholder relations.

Company Vision: Our vision is to become an all-inclusive Global Fashion Apparel Brand,

catering to the ever- changing fashion industry of direct retail customers and create long

term associations with transparent business offerings.

Observations from the Industrial Visit: The first company that we visited was the Bombay

Rayon. It was the weaving department where we visited. Bombay Rayon has many other

plants and the biggest in Tarapur. The plant which we visited is the smallest plant of Bombay

Rayon as said by the manager over there. The plant basically does the weaving of the fabric.

The details of the plant and what we understood are as given below:

Location – Silvassa

Shifts – The factory works in 2 shifts of 12 hours each. According to the instructor,

the factory is open for a total of 363 days. There are only 2 day holiday – on Diwali &

on Holi. The shift timings are from 7 a.m. – 6 p.m. & 6 p.m. – 7 a.m.

Labours – Most of the labours working in the factory are on pay scale basis. There

are NO UNIONS. Hence there aren’t any labour issues as such faced by the

company

Process –

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o Initially the yarn, which is the basic raw material is acquired from Tarapur, is

put in a warping machine. The machine rolls out the yarn & separates the

threads

o The machine can separate around 2000-2500 meters of yarn every day if

operated for 2 hours. These machines need to be continuously monitored by

a labour. The machine stops if the thread breaks. The thread has to be

manually repaired in order for the machine to start working again.

o An important point to note is that 7,000 threads require 2 labours & 6 hours

of efforts.

o The output from warping machine is the input for the drawing machine. The

name of the machine is Picanol Machine where the final cloth is processed.

o The factory has a total of 120 picanol machines out of which 30-40 are

operational. The capacity of 1 machine to produce in 12 hours is 100

meters of cloth. 12 hours of daily production gives 2500 meters of output.

The capacity of the machine is 300 rpm. These machines require manual

attention. A card system of how much to produce is stored in each and every

machine for the labours.

o The factory also has more advanced machines similar to picanol machines

called the Somet Machines. These machines are similar to the picanol

machines; however, no manual attention is required in such machines.

o These machines are operated by computer, and the required output is stored

prior in the computer. However, manual attention would be required if a

thread breaks during the process.

o Somet machine’s power is 450 rpm. It can produce 130-140 meters in 12

hours. The average production of these machines daily is around 3500-4000

meters. The factory has a total of 60 such machines.

o The company has another machine called the Alpha Machine. It is a

combination of two similar Somet machines. It gives us double output.

o The final output is cut in a standard 100 meter length and rolls of it are sent to

Tarapur for dyeing process & final packaging..

Human Resource – There is a certain amount of human resource involvement

amongst the labours. The HRD ensures that the labours are paid monetary

incentives if they produce more output in less time, that is if there efficiency. The

HRD also takes care of the safety measures of its labourers by providing gloves &

ear plugs. Earplugs are provided as the machines make lot of noise. It was however

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observed that most of the labours DO NOT use these safety equipments as they

think that these equipments slow their working speed.

Nilkamal Plastics Ltd.

Company Profile: Promoted by the Parekh family, Nilkamal Plastics, incorporated in

Dec.'85 as Creamer Plastic a private limited company, was converted into a public limited

company in Jul.90. In Aug.'90, the name was changed to the present one. It is India's largest

manufacturer of material handling plastic crates and a leader in moulded furniture. It is one

of the companies to benefit from moulded plastic, which is fast replacing conventional

materials in the manufacture of innumerable products. Today, using state-of-the-art

machines and imported moulds from Europe, the company manufactures a range of

products -- material handling crates, moulded furniture, house ware, multi-layer packaging

films and custom mouldings. The Company has 7 large manufacturing plants in India:

North – Samba (Jammu & Kashmir) and Greater Noida (Uttar Pradesh)

East - Barjora (West Bengal)

West - Sinnar, Nashik (Maharashtra) and Silvassa

(Union Territory of Dadra & Nagar Haveli) (2 plants).

South – Pondicherry (Union Territory)

Company Mission: Become “Benchmark” Process unit

Company Vision: Attain “Leadership” in Operational Effectiveness

Observations from the Industrial Visit: The second company that we visited was the

Nilkamal Plastics Ltd. The company at Silvassa is spread in an area 26000 sq.mts and has 9

moulding machines, with an installed capacity of 5,000 metric ton. We came to know from

the instructor that the company has its own dedicated in-house R&D team. The details of the

plant and what we understood are as given below:

Location – Silvassa

Shifts – The factory works in 3 shifts of 8 hours each. According to the instructor, the

factory is open for 24 hours a day & the entire year except for religious holidays as

specified by the company.

Labours – There are NO UNIONS. Hence there aren’t any labour issues as such

faced by the company. The total labour strength is around 350 labours. There is a

very less attrition rate amongst the labours as stated by the instructor. Every labour

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has to undergo a 15 day induction period in which he is made familiar with the

process & functioning of the plant. The labour is provided with different manuals &

guidelines to study from & an on the job training is also given to the labour for quite a

sufficient period of time.

Process – The following is the process observed in the factory:

o There is a different process & different moulds used for the making of chairs

and trays. The processes are however mentioned & specified in each and

every case.

o The raw material used by them for the different plastic products are low

density polyethylene, high density polyethylene, polyethylene terephtalate,

polypropylene and polyvinyl chloride.

o The raw materials are ordered in bulk & stored at a centralised place. The raw

materials are procured 1 week prior of starting of the production to save the

lead time.

o A kanban system is observed in each process – chair & tray making. Kanban

system includes different colour cards at all the moulds. The colour card

green indicates the specified inputs or the flow of process, the red indicates

that there is some problem with the inputs or the process which brings about

a halt in the process & the yellow card indicates that there is a technical

problem with the machine; however the production is still in flow.

o The company also follows a six sigma process.

o Each & every product is assigned a unique design patent number while

making of that product. The final product also includes the place & the year of

manufacturing, which is usually found at the bottom of the chairs & trays.

These codes help the company to track the location of manufacturing of the

products.

o Economical Order Quantity (EOQ) method is followed by this plant. According

to the instructor the EOQ for this plant is 200 units

o The time required to produce 1 tray is approximately 49 seconds. According

to the instructor, approximately 550 trays are produced by 1 mould in 1 shift

of 8 hours.

o The time required to produce 1 chair is 45 seconds. Approximately 650-700

chairs are produced by 1 machine in 1shift of 8 hours.

o These products have to undergo some rigorous mandatory & optional tests

given by the ISO standards. The mandatory tests are –

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Drop Test – The chair is dropped 100 times from a height of 2.5 meters to

check its durability

Static Load Test – A load of 125 kgs is kept on the chair for 24 hours to

check the strength of the legs. The tolerance level of the legs is 20 mm for

each leg.

Vibrator Test – A labour shakes the chair with the load on it for 1 min to

check the strength & durability of the chairs.

o 5-6 chairs in a lot undergo these tests & if they fail in these tests then the

entire lot is rejected.

o Optional tests includes –

Crate Drop Test

Seat Impact Test

Back Fatigue Test

Drop Test for Crates

Human Resource – Involvement of Human Resource is at a large level in this

organization. The HRD has to continuously keep on motivating its employees by

offering those rewards & bonus as many a times the work of the labourers gets

monotonous. The HRD has to also develop regular training programs, manuals &

guidelines in the interest of the labourers.

Other Information –

o There is an ANNUAL DEALER MEET organized by the company. In this

meeting, dealers are assigned their annual targets. The dealers who have

done exceptionally well are rewarded by monetary of non monetary gifts

by the company. The instructor mentioned that this year 2 dealers were

given a trip to Thailand as they achieved their given targets.

o The major buyers of trays & crates are PepsiCo & Coke.

o Major competitors are National Plastics, Supreme & Celo Plastics.

o The company produces 9-10 different models every year

o Most of the products are exported to Gulf countries, New Zealand, South

Africa, Australia etc.

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Sterling Generators Pvt. Ltd.

Company Profile: Sterling Generators Pvt. Ltd. (a Shapoorji Pallonji Company) is one of the

leading manufacturers of Diesel Generators, MV & LT Panels.

The engines used for the DG sets are imported from Sweden, Germany, UK. They have 18

offices in India and 78 dealers all over the country. Mr. Nagendra Singh is the company’s

President and the company has a Turnover of about Rs. 450 cr.

The major work done by Sterling Generators is at Lakshadweep Island. From the past 6

years they have been providing electricity to this island without any break down. This was

the major achievement gained by the company. The other successful project was of the

Delhi airport. Sterling has successfully installed their generators at Delhi Airport. The other

places where Sterling has installed their generators are at TCS, Infosys, HP, Cisco, Tata

Motors etc.

Sterling imports the Engine form Perkins (UK), Volvo Penta (Sweden), Maxforce (Mahindra).

The major work done by Sterling is of Fabrication and Assembly. They also make the

Control Panels. Sterling Generators have tied up with Siemens for HT Panel Manufacture.

Company Vision: Sterling Generators strives to be a world class manufacturing

organization for generators, electrical control panels and energy management solutions by

imbibing the best work practices and caring for its customers, employees, society and

environment.

Observations from the visit: This Company was visited on the second day of our Industrial

Visit.

Location: Silvassa

Shifts: The factory works in 3 shifts of 8 hours each. According to the instructor, the

factory is open for 24 hours a day & the entire year except for religious holidays as

specified by the company.

Labours: The labour strength in this company was about 300-400 workers along with

the management. This is one of the biggest manufacturing units in Silvassa.

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Process: The following process was observed at Sterling Generators:

o All sheet metal processing like cutting, bending, punching etc. are done on

world-class high accuracy CNC Machines. The sheet metals are carried to

the point of processing on wheeled trolleys from point of stacking.

o We source all sheet metals directly from the manufacturer so as to receive a

quality product.

o After completion of the fabrication work, the processed sheet is transferred to

the paint shop for further processes.

o Before going to the paint shop the sheet metal goes under a chemical

treatment. The various stages under which it goes is as follows –

Knockout Degreasing

a. Degreasing

b. Rinsing

c. De-rusting

d. Rinsing

e. Activation

f. Phosphating

g. Rinsing

h. Passivation

i. Dryer - 1

j. Dryer – 2

Human Resource: Like Nilkamal, HRD plays a major role at Sterling Generators Pvt.

Ltd. The HRD ensures that the labours are motivated during their working hours.

Appreciation, monetary benefits are given to those who achieve their targets on

timely manner. A highest level of safety is observed in this company. Helmets, gloves

& goggles are mandatory to the labours working with machines. Shoes iin the

premises are also a compulsion.

Other Information –

o The diesel generators manufactured by Sterling Generators are from 250-

3000 KVA. They also make custom built generators for special purpose.

o The generators are marketed under the name of Sterling-Wilson Power

Generation Pvt Ltd.

o They provide with an annual maintenance contract for their generators and a

after sales service till the life of the generator that to free of cost.

o They also have international customers. Their 50% of orders are from abroad.

o They also have offices in Nigeria, Sudan and Dubai.

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Voltas Limited

Company Profile: Voltas is one of the world's premier engineering solutions providers and

project specialists. Founded in India in 1954, Voltas Limited offers engineering solutions for

a wide spectrum of industries in areas such as heating, ventilation and air conditioning,

refrigeration, electro-mechanical projects, textile machinery, mining and construction

equipment, materials handling equipment, water management & treatment, cold chain

solutions, building management systems, and indoor air quality.

The Company's strengths lie principally in

management and execution of electro-mechanical projects, including air conditioning

and refrigeration

the design and manufacture of industrial equipment, cooling appliances and

materials handling equipment

sourcing, installation and servicing of diverse technology-based systems serving

Indian industry through representation of global technology leaders

Nationwide & global network

Head office in Mumbai

Zonal HQ in Mumbai, Delhi, Chennai and Kolkata

Branch/area offices in Ahmadabad, Baroda, Bangalore, Calicut, Coimbatore,

Chandigarh, Delhi, Ghaziabad, Indore, Jaipur, Jamshedpur, Kochi, Kolhapur,

Lucknow, Ludhiana, Madurai, Panjim, Pune, Secunderabad, Surat, Tirupati, Tirupur,

Vijayawada and Visakhapatnam

Overseas offices in UAE (Abu Dhabi, Dubai), Bahrain, Qatar (Doha), Kingdom of

Saudi Arabia (Jeddah) and Singapore

Factories: Thane (Maharashtra), Dadra (Union Territory) and Pantnagar

(Uttaranchal)

Company Mission: VOLTAS and its people source and develop the most advanced and

suitable technologies, helping countries and companies to create a positive energy

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balance by using sustainable resources and enabling people to live in comfort and

harmony with their environment.

Observations from the visit: This was the last and the largest of the companies which we

visited during our industrial visit. At the plant we visited Voltas was manufacturing air

conditioning equipment for central plant projects. We saw how the copper tubes were cut

and how they were tested so as the cooling system works properly.

Location – Dadra

Shifts – Like most other companies, Voltas has 3 shift systems, each shift consisting

of 8 hours each.

Labours – The manufacturing plant of Voltas at Dadra is one of the largest it has.

The Labour strength in the manufacturing plant consists of 800 workers including

management employees.

Process – The following manufacturing process is followed in Voltas:

o The basic raw material used for the conditioners are the copper tubes which

are cut in a equal lengths to test the functioning of the cooling systems.

o The copper tubes are basically used and as told by the manager at Voltas,

Copper tube is widely used in air conditioning and refrigeration systems due

to its high thermal conductivity which is about 8 times more than that from

Aluminium tube.

o The refrigeration cycle was explained at Voltas. We were made aware of the

compressor, condenser, evaporator and the expansion valve. The

refrigeration cycle was explained as follows:

a. For an air conditioning system to operate with economy, the

refrigerant must be used repeatedly.

b. For this reason, all air conditioners use the same cycle of

compression, condensation, expansion, and evaporation in a closed

circuit.

c. The same refrigerant is used to move the heat from one area, to cool

this area, and to expel this heat in another area.

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d. The refrigerant comes into the compressor as a low-pressure gas, it is

compressed and then moves out of the compressor as a high-

pressure gas.

e. The gas then flows to the condenser. Here the gas condenses to a

liquid, and gives off its heat to the outside air.

f. The liquid then moves to the expansion valve under high pressure.

This valve restricts the flow of the fluid, and lowers its pressure as it

leaves the expansion valve.

g. The low-pressure liquid then moves to the evaporator, where heat

from the inside air is absorbed and changes it from a liquid to a gas.

h. As a hot low-pressure gas, the refrigerant moves to the compressor

where the entire cycle is repeated.

Human Resource: Because of the employee strength, Voltas has a dedicated team

of HRD which deals into day to day issues faced by its employees. The HRD in

Voltas looks after the policies, procedures and continuous upgradation of training &

development. The HRD is also responsible in recognizing & appreciating their

employees as and when required by giving them monetary & non monetary benefits.

The HRD maintains softwares to keep the track of their employees absence or leave

or any other issues.

Other Information:

o The company keeps a track of their inward & outward goods at the entrance

gate. There is a separate register maintained by the company which includes

the product name, vehicle number, driver name, destination where the goods

need to be delivered etc.

o They cater to many industries such as textiles, mining, water cooling systems

and deep freezers for pharmaceutical companies.

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